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7013 - Lake Lewisville Water Treatment Plant Phase II Improvements, 3.Specifications- Volume 2 PROJECT MANUAL FOR THE CONSTRUCTION OF Lake Lewisville Water Treatment Plant Phase II Improvements IFB 7013 Engineering Project No. 6305 Chris Watts Todd Hileman Mayor City Manager Todd Estes, P.E. City Engineer Frank Pugsley, P.E. Deputy Director, Water and Wastewater Prepared for The City of Denton 2019 Volume 2 4055 International Plaza, @200 Fort Worth, TX 76109 Phone – (817) 735-7300 12400 Coit Road Dallas, TX 75251 Phone – (972) 934-3711 Adopted September 2018 City of Denton Standard Construction Specification Documents 00 00 00 - 1 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 1 of 6 CITY OF DENTON IFB 7013 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Lake Lewisville Water Treatment Plant PH 2 Improvements Revised September 20, 2018 SECTION 00 00 00 TABLE OF CONTENTS VOLUME 1 Division 00 - General Conditions 00 05 15 Addenda [Insert] 00 11 13 Invitation to Bidders 00 21 13 Instructions to Bidders 00 35 13 Conflict of Interest Affidavit 00 41 00 Bid Form 00 43 13 Bid Bond 00 43 36 Proposed Subcontractors Form 00 43 37 Vendor Compliance to State Law Nonresident Bidder 00 45 13 Bidder’s Minimum Qualification Statement 00 45 26 Contractor Compliance with Workers' Compensation Law 00 52 43 Agreement 00 61 13 Performance Bond 00 61 14 Payment Bond 00 61 19 Maintenance Bond 00 61 25 Certificate of Insurance [Insert] 00 72 00 General Conditions 00 73 00 Supplementary Conditions 00 73 73 Form 1295 – Certificate of Interested Parties [Insert] Division 01 - General Requirements 01 11 00 Summary of Work 01 25 00 Substitution Procedures 01 26 00 Change Management 01 29 00 Application for Payment Procedures 01 29 01 Measurement and Basis for Payment 01 31 00 Project Management and Coordination 01 31 19 Preconstruction Meeting 01 31 20 Project Meetings 01 32 16 Construction Progress Schedule 01 32 33 Preconstruction Video 01 33 00 Submittals 01 33 06 Graphic Documentation 01 35 00 Special Procedures 01 35 13 Special Project Procedures 01 45 23 Testing and Inspection Services 01 50 00 Temporary Facilities and Controls 01 57 13 Storm Water Pollution Prevention Plan 01 58 13 Temporary Project Signage 01 60 00 Product Requirements 01 64 00 Owner-Furnished Goods and Special Services 01 66 00 Product Storage and Handling Requirements 01 70 00 Mobilization and Remobilization 01 71 23 Construction Staking and Survey 01 74 23 Cleaning 00 00 00 - 2 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 2 of 6 CITY OF DENTON IFB 7013 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Lake Lewisville Water Treatment Plant PH 2 Improvements Revised September 20, 2018 01 75 00 Starting and Adjusting 01 77 19 Closeout Requirements 01 78 23 Operation and Maintenance Data 01 78 39 Project Record Documents 01 79 00 Training of Operation and Maintenance Personnel TECHNICAL SPECIFICATIONS Contractor shall refer to the following documents for Technical Specifications, unless otherwise noted in the contract documents: North Central Texas Council of Governments Standard Specifications for Public Works Construction – Fourth Edition, Divisions 200-800 (incorporated by reference) North Central Texas Council of Governments Standard Specifications for Public Works Construction – Fourth Edition, Divisions 200-800 – Amendments DIVISION 3 CONCRETE 03 11 00 Concrete Forming 03 21 00 Reinforcing Steel 03 30 00 Cast-In-Place Concrete 03 45 00 Architectural Precast Concrete DIVISION 4 MASONRY 04 05 05 Unit Masonry Construction 04 05 11 Masonry Mortaring and Grouting 04 05 19 Masonry Anchorage and Reinforcing 04 21 13 Brick Masonry 04 22 00 Concrete Unit Masonry DIVISION 5 METALS 05 05 13 Galvanizing 05 12 00 Structural Steel Framing 05 50 13 Miscellaneous Metal Fabrications 05 51 00 Metal Stairs 05 52 15 Aluminum Handrails and Railings DIVISION 6 WOODS, PLASTICS, AND COMPOSITES 06 10 53 Miscellaneous Rough Carpentry 06 40 23 Interior Architectural Woodwork 06 82 23 Fiberglass Reinforced Plastic Handrails and Railings DIVISION 7 THERMAL AND MOISTURE PROTECTION 07 11 13 Bituminous Dampproofing 07 19 16 Silate Water Repellants 07 21 05 Building Insulation 07 22 16 Roof Board Insulation 07 41 13 Metal Roof Panels 07 53 00 Coal-Tar Elastomeric Roofing System 07 62 00 Sheet Metal Flashing and Trim 00 00 00 - 3 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 3 of 6 CITY OF DENTON IFB 7013 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Lake Lewisville Water Treatment Plant PH 2 Improvements Revised September 20, 2018 07 71 00 Roof Specialties 07 72 33 Roof Hatches 07 73 00 Manufactured Roof Curbs 07 92 00 Joint Sealants DIVISION 8 OPENINGS 08 11 13 Hollow Metal Doors and Frames 08 11 16 Aluminum Doors and Frames 08 14 00 Wood Doors 08 16 13 Fiberglass Reinforced Plastic Doors and Frames 08 31 00 Access Doors and Panels 08 33 23 Overhead Coiling Doors 08 41 13 Aluminum Storefronts 08 51 13 Aluminum Windows 08 71 00 Door Hardware 08 71 13 Automatic Door Operators 08 81 00 Glass Glazing 08 90 00 Louvers and Vents DIVISION 9 FINISHES 09 21 16 Gypsum Board Assemblies 09 22 16 Non-Structural Metal Framing 09 30 13 Ceramic Tile 09 51 13 Acoustical Panel Ceilings 09 61 53 Concrete Hardener 09 65 05 Resilient Flooring 09 67 23 Resinous Flooring 09 91 00 Painting VOLUME 2 DIVISION 10 SPECIALTIES 10 11 00 Visual Display Surfaces 10 14 00 Signage 10 21 13 Toilet Compartments 10 28 05 Toilet and Bath Accessories 10 44 00 Fire Protection Specialties 10 51 00 Lockers DIVISION 12 FURNISHINGS 12 21 00 Window Blinds DIVISION 21 FIRE SUPPRESSION 21 11 00 Facility Fire-Suppression Water-Service Piping 21 11 16 Facility Fire Hydrants 21 13 13 Wet-Pipe Sprinkler Systems DIVISION 22 PLUMBING 22 00 01 Plumbing Systems 00 00 00 - 4 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 4 of 6 CITY OF DENTON IFB 7013 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Lake Lewisville Water Treatment Plant PH 2 Improvements Revised September 20, 2018 22 13 14 Packaged Sewage Lift Station DIVISION 23 HVAC MECHANICAL 23 00 00 Heating, Ventilating, and Air Conditioning 23 05 13 Common Motor Requirements for HVAC Equipment 23 05 29 Hangers and Supports for HVAC Piping and Equipment 23 05 53 Identification for HVAC Piping and Equipment 23 05 93 Testing, Adjusting, and Balancing for HVAC 23 07 13 Duct Insulation 23 07 19 HVAC Piping Insulation 23 23 00 Refrigerant Piping 23 31 13 Metal Ducts 23 33 00 Air Duct Accessories 23 34 23 HVAC Power Ventilators 23 37 00 Air Outlets and Inlets 23 37 13 Diffusers, Registers, and Grilles 23 38 13 Commercial-Kitchen Hoods 23 74 09 Rooftop Air Conditioners 23 74 33 Make-up Air Systems 23 81 13 Wall Mount Air Conditioners 23 81 29 Variable Refrigerant Flow HVAC Systems 23 82 39.16 Propeller Unit Heaters DIVISION 26 ELECTRICAL 26 01 26 Testing of Electrical Systems 26 05 00 Common Work Results for Electrical 26 05 10 Electrical Demolition 26 05 13 Medium Voltage Cables 26 05 19 Low Voltage Electrical Conductors & Cables 26 05 26 Grounding and Bonding for Electrical Systems 26 05 29 Hangers and Supports for Electrical Systems 26 05 33.01 Conduits 26 05 33.02 Wireways 26 05 33.03 Outlet Boxes 26 05 33.04 Pull and Junction Boxes for Electrical Systems 24 05 36 Cable Trays for Electrical Systems 26 05 43.01 Manholes and Concrete Pull Boxes for Electrical Systems 26 05 53 Identification for Electrical Systems 26 12 01 Medium Voltage Pad-Mounted Switch 26 12 19 Pad-Mounted, Liquid Filled, Medium Voltage Transformers 26 13 00 Medium Voltage Metal Clad Switchgear 26 13 23 Medium Voltage Motor Control Center 26 22 13 Low Voltage Distribution Transformers 26 24 13 600 Volt Switchboards 26 24 16.02 Lighting and Branch Panelboards 26 27 26 Wiring Devices 26 28 13 Fuses 26 28 16 Enclosed Switches and Circuit Breakers 26 29 13 Enclosed Controllers 00 00 00 - 5 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 5 of 6 CITY OF DENTON IFB 7013 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Lake Lewisville Water Treatment Plant PH 2 Improvements Revised September 20, 2018 26 29 87 Electrical Control Panels 26 36 23 Automatic Transfer Switches 26 41 13 Lightning Protection for Structures 26 50 00 Lighting DIVISION 27 COMMUNICATIONS 27 15 23.01 Fiber Optic Data Network DIVISION 31 EARTHWORK 31 05 13 Soils for Earthwork 31 05 16 Aggregates for Earthwork 31 11 00 Clearing and Grubbing 31 23 10 Structural Excavation and Backfill 31 23 23.34 Flowable Fill 31 23 33.14 Trench Safety 31 23 33.19 Trenching and Backfill 31 25 13.13 Seeding for Erosion Control 31 63 29 Drilled Concrete Piers and Shafts DIVISION 32 EXTERIOR IMPROVEMENTS 32 11 23 Aggregate Base Courses 32 13 13 Concrete Paving 32 31 13.53 High-Security Chain Link Fences and Gates 32 91 13 Soil Preparation 32 91 19.13 Topsoil Placement and Grading 32 92 13 Hydro-Mulching DIVISION 33 UTILITIES 33 05 01.02 Ductile Iron Pipe and Fittings 33 05 01.09 Polyvinyl Chloride (PVC) Pipe and Fittings 33 05 01.13 PVC Sanitary Sewer Pipe 33 10 13 Disinfecting of Water Utility Distribution 33 39 13 Sanitary Utility Sewage Manholes, Frames and Covers DIVISION 40 PROCESS INTEGRATION 40 05 23.23 Stainless Steel Process Pipe for Liquid Service 40 05 43 Miscellaneous Valves 40 05 53 Identification for Process Piping and Equipment 40 05 61 Gate Valves 40 05 62 Eccentric Plug Valves 40 05 64 Butterfly Valves 40 05 65.23 Swing Check Valves 40 05 78 Air Release and Air and Vacuum Valves 40 80 00 Commissioning of Process Systems 40 90 00 Instrumentation and Control for Process Systems 40 90 01 Instrumentation 40 90 02 Supervisory Control and Data Acquisition (SCADA) System 40 92 13.13 Electrically Operated Primary Control Valves DIVISION 41 MATERIAL PROCESSING & HANDLING EQUIPMENT 41 22 13.13 Bridge Crane Rehabilitation 00 00 00 - 6 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 6 of 6 CITY OF DENTON IFB 7013 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Lake Lewisville Water Treatment Plant PH 2 Improvements Revised September 20, 2018 DIVISION 43 PROCESS GAS & LIQUID HANDLING 43 21 13.16 Centrifugal Magnetic Drive Sealless End Suction Pumps DIVISION 46 WATER & WASTEWATER EQUIPMENT 46 33 44 Skid Mounted Peristaltic Metering Pumps 46 35 11 Copper Ion Solution Generator 46 36 11.16 Liquid Polymer Feed System Appendix GC-4.02 Subsurface and Physical Conditions GC-6.09 Permits and Utilities GR-01 64 00 Owner Furnished Goods and Special Services A. Valves and Related Materials B. Electrical Transformers END OF SECTION TECHNICAL SPECIFICATIONS PREPARED BY DAVID SLOAN, P.E. SECTION TITLE 01 11 00 Summary of Work 01 25 00 Substitution Procedures 01 26 00 Change Management 01 29 00 Application for Payment Procedures 01 29 01 Measurement and Basis for Payment 01 31 00 Project Management and Coordination 01 31 19 Preconstruction Meeting 01 31 20 Project Meetings 01 32 16 Construction Progress Schedule 01 32 33 Preconstruction Video 01 33 00 Submittals 01 33 06 Graphic Documentation 01 35 00 Special Procedures 01 35 13 Special Project Procedures 01 45 23 Testing and Inspection Services 01 50 00 Temporary Facilities and Controls 01 57 13 Storm Water Pollution Prevention Plan 01 58 13 Temporary Project Signage 01 60 00 Product Requirements 01 64 00 Owner-Furnished Goods and Special Services 01 70 00 Mobilization and Remobilization 01 71 23 Construction Staking and Survey 01 74 23 Cleaning 01 75 00 Starting and Adjusting 01 77 19 Closeout Requirements 01 78 23 Operation and Maintenance Data 01 78 39 Project Record Documents 01 79 00 Training of Operation and Maintenance Personnel 22 13 14 Packaged Sewage Lift Station 32 31 13.53 High-Security Chain Link Fences and Gates 33 05 01.02 Ductile Iron Pipe and Fittings 33 05 01.09 Polyvinyl Chloride (PVC) Pipe and Fittings 33 05 01.13 PVC Sanitary Sewer Pipe 33 10 13 Disinfecting of Water Utility Distribution 4-15-2019 33 39 13 Sanitary Utility Sewage Manholes, Frames and Covers 40 05 43 Miscellaneous Valves 40 05 53 Identification for Process Piping and Equipment 40 05 61 Gate Valves 40 05 62 Eccentric Plug Valves 40 05 64 Butterfly Valves 40 05 65.23 Swing Check Valves 40 05 78 Air Release and Air and Vacuum Valves 41 22 13.13 Bridge Crane Rehabilitation 46 36 11.16 Liquid Polymer Feed System TECHNICAL SPECIFICATIONS PREPARED BY PRABIN KC, P.E. SECTION TITLE 03 11 00 Concrete Forming 03 21 00 Reinforcing Steel 03 30 00 Cast-In-Place Concrete 03 45 00 Architectural Precast Concrete 05 05 13 Galvanizing 05 12 00 Structural Steel Framing 05 51 00 Metal Stairs 31 23 10 Structural Excavation and Backfill 31 23 23.34 Flowable Fill 31 63 29 Drilled Concrete Piers and Shafts 3/20/2019 TECHNICAL SPECIFICATIONS PREPARED BY VAN CASHEN, P.E., LEED AP BD+C, ENV SP SECTION TITLE 21 11 00 Facility Fire-Suppression Water-Service Piping 21 11 16 Facility Fire Hydrants 21 13 13 Wet-Pipe Sprinkler Systems 22 00 01 Plumbing Systems 23 00 00 Heating, Ventilating, and Air Conditioning 23 05 13 Common Motor Requirements for HVAC Equipment 23 05 29 Hangers and Supports for HVAC Piping and Equipment 23 05 53 Identification for HVAC Piping and Equipment 23 05 93 Testing, Adjusting, and Balancing for HVAC 23 07 13 Duct Insulation 23 07 19 HVAC Piping Insulation 23 23 00 Refrigerant Piping 23 31 13 Metal Ducts 23 33 00 Air Duct Accessories 23 34 23 HVAC Power Ventilators 23 37 00 Air Outlets and Inlets 23 37 13 Diffusers, Registers, and Grilles 23 38 13 Commercial-Kitchen Hoods 23 74 09 Rooftop Air Conditioners 23 74 33 Make-up Air Systems 23 81 13 Wall Mount Air Conditioners 23 81 29 Variable Refrigerant Flow HVAC Systems 23 82 39.16 Propeller Unit Heaters 03/20/2019 TECHNICAL SPECIFICATIONS PREPARED BY ERROL DAWKINS, AIA SECTION TITLE 03 45 00 Architectural Precast Concrete 04 05 05 Unit Masonry Construction 04 05 11 Masonry Mortaring and Grouting 04 05 19 Masonry Anchorage and Reinforcing 04 21 13 Brick Masonry 04 22 00 Concrete Unit Masonry 05 50 13 Miscellaneous Metal Fabrications 05 52 15 Aluminum Handrails and Railings 06 10 53 Miscellaneous Rough Carpentry 06 40 23 Interior Architectural Woodwork 06 82 23 Fiberglass Reinforced Plastic Handrails and Railings 07 11 13 Bituminous Dampproofing 07 19 16 Silate Water Repellants 07 21 05 Building Insulation 07 22 16 Roof Board Insulation 07 41 13 Metal Roof Panels 07 53 00 Coal-Tar Elastomeric Roofing System 07 62 00 Sheet Metal Flashing and Trim 07 71 00 Roof Specialties 07 72 33 Roof Hatches 07 73 00 Manufactured Roof Curbs 07 92 00 Joint Sealants 08 11 13 Hollow Metal Doors and Frames 08 11 16 Aluminum Doors and Frames 08 14 00 Wood Doors 08 16 13 Fiberglass Reinforced Plastic Doors and Frames 08 31 00 Access Doors and Panels 08 33 23 Overhead Coiling Doors 08 41 13 Aluminum Storefronts 08 51 13 Aluminum Windows 08 71 00 Door Hardware 08 71 13 Automatic Door Operators 08 81 00 Glass Glazing 08 90 00 Louvers and Vents 09 21 16 Gypsum Board Assemblies 09 22 16 Non-Structural Metal Framing 09 30 13 Ceramic Tile 09 51 13 Acoustical Panel Ceilings 09 61 53 Concrete Hardener 09 65 05 Resilient Flooring 09 67 23 Resinous Flooring 09 91 00 Painting 10 11 00 Visual Display Surfaces 10 14 00 Signage 10 21 13 Toilet Compartments 10 28 05 Toilet and Bath Accessories 10 44 00 Fire Protection Specialties 10 51 00 Lockers 12 21 00 Window Blinds TECHNICAL SPECIFICATIONS PREPARED BY JEFF HENSLEY, P.E. SECTION TITLE 26 01 26 Testing of Electrical Systems 26 05 00 Common Work Results for Electrical 26 05 10 Electrical Demolition 26 05 13 Medium Voltage Cables 26 05 19 Low Voltage Electrical Conductors & Cables 26 05 26 Grounding and Bonding for Electrical Systems 26 05 29 Hangers and Supports for Electrical Systems 26 05 33.01 Conduits 26 05 33.02 Wireways 26 05 33.03 Outlet Boxes 26 05 33.04 Pull and Junction Boxes for Electrical Systems 24 05 36 Cable Trays for Electrical Systems 26 05 43.01 Manholes and Concrete Pull Boxes for Electrical Systems 26 05 53 Identification for Electrical Systems 26 12 01 Medium Voltage Pad-Mounted Switch 26 12 19 Pad-Mounted, Liquid Filled, Medium Voltage Transformers 26 13 00 Medium Voltage Metal Clad Switchgear 26 13 23 Medium Voltage Motor Control Center 26 22 13 Low Voltage Distribution Transformers 26 24 13 600 Volt Switchboards 26 24 16.02 Lighting and Branch Panelboards 26 27 26 Wiring Devices 26 28 13 Fuses 26 28 16 Enclosed Switches and Circuit Breakers 26 29 13 Enclosed Controllers 26 29 87 Electrical Control Panels 26 36 23 Automatic Transfer Switches 26 41 13 Lightning Protection for Structures 26 50 00 Lighting 27 15 23.01 Fiber Optic Data Network 40 80 00 Commissioning of Process Systems 40 90 00 Instrumentation and Control for Process Systems 40 90 01 Instrumentation 40 90 02 Supervisory Control and Data Acquisition (SCADA) System 40 92 13.13 Electrically Operated Primary Control Valves 3/25/2019 Visual Display Surfaces 10 11 00 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 10 11 00 VISUAL DISPLAY SURFACES 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. Contractor shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish and install visual display surfaces. 2. The type of products required includes the following: a. Dry marker-board. b. Set of dry markers. c. Trim and attachments. B. Related Sections: 1. Section 04 05 19, Masonry Anchorage and Reinforcing. 2. Section 09 21 16, Gypsum Board Assemblies. 3. Section 09 91 00, Painting. 1.02 REFERENCES A. Standards referenced in this Section are listed below: 1. American Architectural Manufacturers Association, (AAMA). a. AAMA 611, Voluntary Standards for Anodized Architectural Aluminum. b. AAMA 2603, Voluntary Specification, Performance Requirements and Test Procedures for Pigmented Organic Coating on Aluminum Extrusions and Panels. 2. American National Standards Institute, (ANSI). a. ANSI A117.1, Guidelines for Accessible and Useable Buildings and Facilities - Providing Accessibility and Usability for Physically Handicapped People (ICC/ANSI A117.1-1998). 3. American Society for Testing Materials, (ASTM). a. ASTM E 84, Standard Test Method for Surface Burning Characteristics of Building Materials. 4. International Building Code. 5. National Association of Architectural Metal Manufacturers, (NAAMM). a. NAAMM - Metal Finishes Manual for Architectural and Metal Products. 1.03 QUALITY ASSURANCE A. Component Supply and Compatibility: 1. Furnish all visual display surfaces from one manufacturer for the entire project. In addition to the requirements of this Section, comply with manufacturer’s instructions and recommendations for all phases of the Work, including preparation of substrate, installation of grounds and anchors, and application of materials. B. Requirements of Regulatory Agencies: 1. Codes: Comply with applicable provisions of the following: a. ANSI A117.1 and Americans with Disabilities Act of 1990 Title II ADAAG. 2. Fire-Test-Response Characteristics: Provide vinyl-coated tackboards with the following surface-burning characteristics as determined by testing assembled materials composed of facings and backings identical to those required in this Section in accordance with the Visual Display Surfaces 10 11 00 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements requirements of ASTM E 84 by a testing and inspecting agency acceptable to authorities having jurisdiction. Identify vinyl-coated tackboards with appropriate markings of applicable testing and inspecting agency. a. Flame Spread: 25 or less. b. Smoke Developed: 10 or less. 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Shop Drawings: a. Drawings for each type of visual display surface unit. Include full-scale sections of typical trim members and dimensioned elevations. Show anchors, grounds, reinforcement, accessories and installation details. 2. Product Data: a. Submit for approval manufacturer's technical data and installation instructions for each material and component part. Include methods of installation for each type of substrate to receive units. Transmit copy of each instruction to the installer. 3. Samples: a. Samples for each type and color of visual display surface, trim and accessories are required. Provide 4-inch square samples of sheet materials and 4-inch lengths of trim members. Engineer'S review of samples will be for color, pattern and texture only. Compliance with all other requirements is the exclusive responsibility of Contractor. B. Closeout Submittals: Submit the following: 1. Warranty Documentation: Manufacturer's warranty. 1.05 WARRANTY A. Porcelain-Enamel Marker-board Warranty: Submit a written warranty executed by manufacturer agreeing to replace porcelain enamel markerboards that do not retain their original writing and erasing qualities or become slick and shiny, or exhibit crazing, cracking, or flaking within the specified warranty period, provided the manufacturer's written instructions for handling, installation, protection, and maintenance have been followed. 1. Warranty Period: Life of the facility. 2.00 PRODUCTS 2.01 MATERIALS A. Porcelain-On-Metal Markerboards: Balanced, high-pressure laminated, 3-ply construction, with facing sheet, core and backing. 1. Porcelain Finish: Porcelain enamel over ground coat on writing surface with seal coat on reverse side. Furnish standard colors and special projection surface. 2. Face Sheet: Enameling steel, 24 gage. 3. Core: Plywood or hardboard, 3/8-inch thick. 4. Backing Sheet: Manufacturer's standard 0.015-inch aluminum sheet. 5. Color: Manufacturer's standard colors. 6. Products and Manufacturers: Provide one of the following: a. 500 Series p3 Markerboard by PolyVision Corporation. Visual Display Surfaces 10 11 00 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements b. Series 185 LCS Markerboard by Claridge Products and Equipment, Incorporated. c. Or equal. B. Plastic Impregnated Cork Tackboards: 1. Seamless sheet, 1/8-inch thick with washable vinyl finish, of ground natural cork compressed with resinous binder and integral color throughout entire thickness and laminated to burlap backing. Furnish rigid panels by factory-laminating under pressure to 3/8-inch thick plywood or hardwood backing. 2. Color: Manufacturer's standard colors. 3. Products and Manufacturers: Provide one of the following: a. Vinyl Plus Tackboard by PolyVision Corporation. b. No. 380A Tackboard by Claridge Products and Equipment, Incorporated. c. Or equal. C. Markers: Manufacturer's standard set of 12 assorted colors specifically made for use with specified markerboard. Provide one set for each markerboard. D. Combination Markerboard and Tackboard: 1. Same materials specified above. 2. Mounted as one unit. 3. Products and Manufacturers: Provide one of the following: a. 500 Series p3 Markerboard and Tackboard, Type B by PolyVision, Corporation. b. Type BR Markerboard/Tackboard by Claridge Products and Equipment, Incorporated. c. Or equal. E. Trim and Accessories: 1. General: Fabricate frames and trim of not less than 0.062-inch thick aluminum alloy. Size and shape as specified, to suit type of installation. Provide straight, single-length units wherever possible and keep joints to a minimum. Miter corners to a neat, hairline closure. a. Provide manufacturer's standard wide trim units, approximately 1-1/2-inch wide, slip-on type. b. When structural support accessories are required for markerboards and tackboards, in addition to normal trim, provide the required additional support or modify trim to provide the necessary support. 2. Markertrough: Finish continuous aluminum markertroughs for each markerboard, using box type, with slanted front and cast aluminum end closures. 3. Finishes: a. General: Comply with NAAMM's “Metal Finishes Manual for Architectural and Metal Products” for recommendations relative to applying and designating finishes. b. Class II, Clear Anodic Finish: AA-M12C22A31 (Mechanical Finish: non-specular as fabricated; Chemical Finish: etched, medium matte; Anodic Coating: Architectural Class II, clear coating 0.010-mm or thicker) complying with AAMA 607.1. c. Class II, Color Anodic Finish: AA-M12C22A32/A34 (Mechanical Finish: non-specular as fabricated; Chemical Finish: etched, medium matte; Anodic Coating: Architectural Class II, integrally colored or electrolytically deposited color coating 0.010-mm or thicker). 1). Color: Light bronze. F. Fabrication: 1. Assembly: Provide factory-assembled markerboards, tackboards and combination markerboard and tackboard units. Visual Display Surfaces 10 11 00 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements a. Make joints only between markerboard and tackboard. b. Provide mullion trim at joints between markerboard and tackboard. 2. Sizes: a. Markerboards: As Shown. 3.00 TACKBOARDS:AS SHOWN EXECUTION 3.01 INSPECTION A. Contractor and his installer shall examine substrate and conditions under which the visual display surfaces Work is to be performed and notify Engineer, in writing, of unsatisfactory conditions. Do not proceed with the Work until unsatisfactory conditions have been corrected in a manner acceptable to Engineer. B. Preparation: Backprime backing panels where installed on (--1--) before erection. 3.02 INSTALLATION A. Install display surfaces in locations and mounting heights as directed by Engineer and in accordance with the manufacturer's instructions. Provide all grounds, clips, backing materials, brackets and anchors, trim, and accessories for a complete installation. B. Install display surfaces in locations and mounting heights in accordance with accessibility codes where shown. C. Deliver factory-built vinyl display surfaces completely assembled in one piece without joints, whenever possible. Where dimensions exceed panel size, provide two or more pieces of equal length, as acceptable to Engineer. When overall dimensions require delivery in separate units, prefit at the factory, disassemble for delivery, and make final joint at a Site. Use splines at joints to maintain surface alignment and smooth joints. D. Install units with concealed hangers plumb and level, in accordance with the manufacturer's printed instructions. E. Coordinate job-assembled units with grounds, trim and accessories. Join all parts with neat, precision fit. END OF SECTION Signage 10 14 00 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 10 14 00 SIGNAGE 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, tools, equipment, and incidentals as shown, specified, and required to furnish and install signage. a. CONTRACTOR shall be responsible for all signage furnished under this Section for the entire Project in accordance with the Contract Documents. B. Under this Section, each prime contractor shall provide signage for their own Contract, in accordance with the Contract Documents. 1. Extent of signage is shown and specified. C. Coordination: 1. Coordinate adhesives and fasteners with mounting surfaces. Review other Sections to ensure compatibility of signage mounting accessories with various surfaces on which signage will be installed. 2. Review installation procedures under this and other Sections and coordinate installation of items to be installed with or before signage Work. D. Related Sections: 1. Section 03 30 00, Cast-In-Place Concrete. 2. Section 09 91 00, Painting. 1.02 REFERENCES A. Standards referenced in this Section are: 1. AA DSA-45, Designation System for Aluminum Finishes. 2. ASME A13.1 Scheme for the Identification of Piping Systems. 3. ANSI/ICC A117.1, Accessible and Usable Buildings and Facilities. 4. ANSI Z535.1, Marking Physical Hazards Safety Color Code. 5. ANSI Z535.2, Environmental and Facility Safety Signs. 6. ANSI Z535.3, Criteria for Safety Symbols. 7. ASTM B26/B26M, Specification for Aluminum-Alloy Sand Castings. 8. ASTM B584, Specification for Copper Alloy Sand Castings for General Applications. 9. ASTM E527, Practice for Numbering Metals and Alloys in the Unified Numbering System (UNS). 10. CDA, Properties of Cast Copper Alloys. 11. NFPA 704, System for the Identification of the Hazards of Materials for Emergency Response. 12. UL 924, Safety of Emergency Lighting and Power Equipment. 13. USGBC LEED-NC, LEED Reference Guide For New Construction and Major Renovation. 1.03 QUALITY ASSURANCE A. Qualifications: 1. Signage Manufacturers: a. Engage firms specializing in producing types of products specified, in compliance with the Contract Documents, with documented record of successful in-service Signage 10 14 00 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements performance, and that possess sufficient production capacity to avoid delaying the Work. b. Submit to ENGINEER name and experience record of manufacturers. B. Component Supply and Compatibility: 1. Obtain each separate type of signage from a single Supplier and from a single manufacturer. C. Regulatory Requirements: Comply with applicable requirements of the following: 1. OSHA, 29 CFR Part 1910.1200, Hazard Communication Standard. 2. OSHA, 29 CFR Part 1910, Subpart Z, Toxic and Hazardous Substances. 3. OSHA, 29 CFR Part 1910.144, Safety Color Code for Marking Physical Hazards. 4. OSHA, 29 CFR Part 1910. 145, Specification for Accident Prevention Signs and Tags. 5. United States Access Board, Americans with Disabilities Act (ADA) and Architectural Barriers Act (ABA) Accessibility Guidelines. 6. Americans with Disabilities Act (ADA), Public Law 101-36, 28 CFR Part 36, Appendix A, Accessibility Guidelines for Buildings and Facilities (ADAAG), relative to characters and symbols contrast only. 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Shop Drawings: a. Schedule of all signage required for the Work, indicating signage type location, and other information to demonstrate compliance with the Contract Documents. b. Fabrication and erection information for each type of signage c. Valve schedule for small-diameter valves, in accordance with this Section. d. Complete, camera-ready, color graphic layouts of custom- designed signs based on specified requirements and manufacturer recommendations. e. Complete selection of each specified manufacturer's standard and custom graphic layouts and pictograms, colors, and alphabetic/text styles. f. Full-size graphic layout drawings for plaques, individual dimensional letters and numbers, and other items where final graphic appearance is necessary prior to signage fabrication, incorporating all required graphic features specified or shown. g. Mounting and Installation Data: 1). Drawings of and information on anchorages and accessory items. 2). Submit location template drawings for items supported or anchored to permanent construction. 3). Coordinate mounting position, method, and proposed mounting accessories and fasteners with actual Project conditions. Indicate required mounting accessories on plan drawings showing locations of required exit signs based on measurements taken at the Site. Show final location and identify type of mounting surface for each exit sign. Coordinate location of exit signs for non-interference with other Work and as required by authorities having jurisdiction. 2. Product Data: a. Copies of manufacturer’s technical data, including catalog information and specifications, for each product specified. 3. Samples: a. Each color and finish of exposed materials and accessories required for signage. Signage 10 14 00 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements b. Sample Signage: 1). Full-size Sample of each type of permanent room and space identification sign, and informational and directional sign incorporating all features specified. 2). Full-sized Sample of each type (such has snap-on, strap-on, and adhesive) of pipe marker proposed for use with mounting accessories. 3). Full-sized Sample equipment nameplate, valve tag, pipe tag, and accessories. Stamp valve tag with information shown on valve schedules. When not indicated in the Contract Documents, information on the type of coding system will be furnished to CONTRACTOR by ENGINEER. 4). Full-sized Sample right-to-know signs, labels and tags. 5). Full-size representative sample of each individual-type letter and number specified, demonstrating alphabetic style/text type, material, color and finish specified. 6). ENGINEER's review of Samples will be for color and texture only. Compliance with other requirements is CONTRACTOR's responsibility. B. Informational Submittals: Submit the following: 1. Manufacturer's Instructions: a. Templates for anchorages to be installed in concrete or masonry. b. Manufacturer's instructions and recommendations for support and foundations of signs installed outdoors. 2. Sustainable Design Submittals: a. Product data for LEED-NC Credits MR 2.1 and 2.2, Construction Waste Management, including printed statement of costs for each recycled material. Refer to Section 01 74 19, Construction Waste Management and Disposal. b. USGBC LEED-NC Credits MR 4.1 and MR 4.2 require defined percentages of building materials to incorporate recycled content and requires documentation indicating the weight of material recycled. c. USGBC LEED-NC Credits MR 5.1 and MR 5.2 require defined percentages of building materials to be extracted and manufactured in the region and requires documentation indicating the cost of material. d. Product data for USGBC LEED-NC Credit EQ 4.1and 4.2: For adhesives, including printed statement of VOC content. C. Closeout Submittals: Submit the following: 1. Warranty Documentation: a. General and special warranties required under this Section. D. Maintenance Material Submittals: Submit the following: 1. Extra Stock Materials: a. Furnish extra stock materials from the same manufactured lot as the materials installed. b. Submit documentation of actual quantities of signage installed for the Project and calculations indicating the required quantity of extra stock materials. c. Furnish the following spare parts and accessories: 1). For every 20 of each type (snap-on, strap-on, adhesive type) of pipe markers installed: a). One complete mounting assembly. 2). For every 20 equipment nameplates installed: a). One complete nameplate mounting assembly. 3). For every 20 valve tags and pipe tags installed: Signage 10 14 00 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements a). One stainless steel cable and splice. 1.05 WARRANTY A. General Warranty: The special warranty specified for each type of sign in this Article shall not deprive OWNER of other rights or remedies OWNER may otherwise have under the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by CONTRACTOR under the Contract Documents. The obligations of CONTRACTOR under the Contract Documents shall not be limited in any way by the provisions of the specified special warranty. B. Special Warranty on Products: 1. Provide each signage manufacturer’s written warranty, running to the benefit of OWNER, agreeing to correct, or at option of OWNER, remove or replace materials specified in this Section found to be defective during a period of five years after the date of Substantial Completion. 2. Special warranty shall cover defective Work that includes, but is not limited to, the following: a. Deterioration of metal and polymer finishes beyond normal weathering. b. Deterioration of embedded graphic image colors and sign lamination. 2.00 PRODUCTS 2.01 SYSTEM PERFORMANCE A. General: 1. Details shown or indicated for signage, such as alpha-numeric and text type representation, letter spacing, designs of borders, and other graphic features, are generic and intended only to establish text, general positions, and symbols. 2. Colors shall be brilliant, distinctive shades, matching the safety colors specified in ANSI Z535.1 and OSHA 1910.144. 3. Permanent rooms and spaces, and directional and informational signage where specified as accessible to people with disabilities, shall comply with ANSI/ICC A117.1 and ADA-ABA Accessibility Guidelines. 4. Accident prevention signs and tags shall comply with OSHA 1910.145. 5. Health, safety, and warning signs shall comply with ANSI Z535.1, ANSI Z535.2, ANSI Z535.3, OSHA 1910.144, and 1910.145, unless otherwise shown or indicated. Colors shall be as indicated in Table 1 of ANSI Z535.1. In addition to text, safety symbol pictograms shall be incorporated into each sign. 2.02 PANEL SIGNS – ROOM IDENTIFICATION, INFORMATION, ENTRY, AND DIRECTIONAL A. Products and Manufacturers: Provide one of the following: 1. Graphic Blast MP and FG ADA System and Custom Design ADA Series, by Best Sign Systems, Inc. 2. Blast Etched Fiberglass and Blast Etched Melamine Signs, by Visigraph Corporation. 3. Or equal. B. Panel Signs – Room Identification, Information, Entry, and Directional: 1. Product Description: Provide unframed signs, surface-etched, 1/32-inch raised tactile lettering and pictograms, sandblasted on an opaque sheet. Signage 10 14 00 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2. Materials: a. Interior Signs: Three-ply, self-extinguishing melamine plastic. b. Exterior Signs: One-piece fiberglass. 3. Size and Thickness: 0.125-inch thick; eight inches by eight inches with 1/2-inch radiused corners. 4. Graphics and Text: White, Standard Helvetica Medium characters and matching arrow type-face; upper and lower case letters, one-inch high capitals and, in addition, Grade 2 Braille alphabet for room designation, directional, entry, and information signs. 5. Colors and Contrast: Background of signs shall be eggshell, matte, or other non-glare finish. Characters and symbols shall contrast by at least 70 percent with their background as determined by ADA formula in ADAAG Appendix A4.30.5. 2.03 PANEL SIGNS – HEALTH, SAFETY, WARNING, FLOOR LOADING, AND FIRE EXTINGUISHER LOCATION A. Product Description: Provide rigid fiberglass reinforced plastic signs with fade-resistant embedded graphics. B. Products and Manufacturers: Provide one of the following: 1. Graphic Blast Word and Picture Series, by Best Sign Systems, Inc. 2. Blast Etched Fiberglass Signs, by Visigraph Corporation. 3. Or equal. C. General: 1. Size and Thickness: 0.125-inch thick; 10 inches by 14 inches, unless otherwise shown or indicated. 2. Graphics and Text: Standard Helvetica Medium characters and matching arrow type- face; upper and lower case, one-inch high capitals and, in addition, Grade 2 Braille alphabet message designations and other text. 3. Exposure: As recommended by sign manufacturer for both indoor and outdoor use and with an upper service temperature limit of 190degrees F. Average durability for outdoor use shall be 15 years. D. Safety Instruction Signs: Standard color of sign background shall be white; panel shall be green with white letters and numbers. Letters and numbers used against white background shall be black. E. Caution Signs: Standard color of sign background shall be yellow; panel shall be black with yellow letters and numbers. F. Danger Signs: Standard color of sign background shall be white; panel shall be black with red insert with white letters and numbers. Letters and numbers used against white background shall be black. G. Warning Signs: Standard color of sign background shall be orange; panel shall be black with orange insert with black letters and numbers. Letters and numbers used against orange background shall be black. H. No Smoking Signs: Standard color of sign background shall be white. Letters and numbers used against white background shall be red. I. Biohazard Signs: Standard color of sign background shall be white; panel shall be black with white letters. Sign shall include red international biohazard pictogram on white background. J. Floor Loading Signs: Standard color of sign background shall be white; panel shall be blue with white letters and numbers. Letters and numbers used against white background shall be black. Signage 10 14 00 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements K. Fire Extinguisher Location Signs (surface-mounted units only): Standard color of sign background shall be red with white letters and numbers. Each sign shall include international fire extinguisher pictogram and directional arrow indicating location of fire extinguisher. L. Auxiliary Products: 1. Mounting Brackets: Provide sign manufacturer’s standard mounting brackets for installing projected or double-sided signs. 2.04 PIPE MARKERS A. Description: 1. Provide pipe markers for each pipeline provided under the Contract, and for other piping indicated to receive pipe markers. B. Products and Manufacturers: Provide one of the following: 1. Custom High Performance Pipe Markers (B-689), and SnapOn and StrapOn Pipe Markers (B-915), by Brady Worldwide, Inc., Signmark Division. 2. Custom Ultra-Mark High Performance Pipe Markers, by Seton Identification Products, a Tricor Direct Company. 3. Or equal. C. Pipe Markers: 1. Lettering of Titles/Legend and Color Field Size: a. Letter size and color field length shall be as indicated in Table 10 14 00-A of this Section: TABLE 10 14 00-A, PIPE MARKERS: SIZE OF TEXT AND COLOR FIELD Outside Diameter of Pipeline or Covering* (inches) Size of Text (Legend Characters) Minimum Length of Color Field** 3/4 to 1.25 1/2-inch 8 inches 1.5 to 1-7/8 3/4-inch 8 inches 2 to 5-7/8 1.25-inch 12 inches 6 to 9-7/8 2.5-inch 24 inches 10 and Larger 3.5-inch 32 inches *Outside diameter includes pipe diameter plus insulation and jacketing. **Length of sign and color field shall be as required to accommodate required legend, and shall not be less than minimum length indicated unless required otherwise by space constraints. b. Text and symbols shall be Standard Helvetica Medium, all upper case. Pipe markers shall include text with separate arrow signs indicating direction of flow of pipeline contents. Pipe markers with arrows shall be located as specified in Part 3 of this Section. c. Pipe markers indicating pipeline contents shall identify pipeline contents by complete name, as indicated in Table 10 14 00-B of this Section. Obtain from ENGINEER interpretation of required pipe marker text for pipelines provided under the Project that are not listed in Table 10 14 00-B of this Section. 2. Pipe Marker Materials: a. General: The following are applicable to all types of pipe markers furnished under this Section: Signage 10 14 00 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1). Provide pipe markers with ultraviolet light-resistant, sealed, subsurface color graphics, recommended by sign manufacturer, suitable for both indoor and outdoor use. 2). Pipe markers shall be resistant to abrasion, chemical reagents, and physical agitation such as washdowns and wind. 3). Provide manufacturer’s full selection of standard and custom sizes and graphics. 4). Where manufacturer has established minimum order quantities for custom units provide minimum order quantities at no additional cost to OWNER. b. Materials: Provide the following at CONTRACTOR’s option, suitable for outside diameter of the associated pipe and pipe covering: 1). Adhesive, Wrap-Around Pipe Markers: Adhesive pipe markers shall be coiled construction, 0.006-inch total thickness, PVF over laminated polyester, with peel-off backing. Suitable for for service temperature ranging from -40 degrees F to 230 degrees F. 2). Snap-on Pipe Markers: Snap-on pipe markers shall be cylindrically coiled, printed plastic sheets. Pipe marker total thickness for pipe and pipe covering from 3/4-inch to 2-3/8-inch outside diameter shall be not less than 0.020-inch. Pipe marker total thickness for pipe and pipe covering from 2.5-inch through six- inch ourside diameter shall be not less than 0.030-inch. Suitable for service temperature ranging from -40 degrees F to 180 degrees F. 3). Strap-on Pipe Markers: Provide strap-on pipe markers where pipe diameter is large enough to preclude overlap of pipe marker material around the circumference of the pipe. Strap-on pipe markers shall be flat, printed plastic sheets, not less than 0.020-inch total thickness, constructed to be attached to the pipe with bands. Suitable for service temperature ranging from -40 degrees F to 180 degrees F. Provide each pipe marker with two 1/4-inch wide band straps of nylon, plastic, or stainless steel, lengths as required by circumference of pipe and pipe covering. Provide manufacturer’s recommended banding tools for banding. THE FOLLOWING COLORS ARE FROM ASME A13.1: PIPELINE SERVICE LETTER COLOR BACKGROUND COLOR EXAMPLE Fire-quenching fluids White Safety Red LETTERS Toxic and corrosive fluids Black Safety orange LETTERS Flammable fluids Black Safety yellow LETTERS Combustible fluids White Safety brown LETTERS Potable, cooling, boiler feed, and other water White Safety green LETTERS Compressed air White Safety blue LETTERS IN ADDITION TO THE COLORS INDICATED ABOVE, ASME A13.1 FURTHER DEFINES SEVERAL COLOR COMBINATIONS THAT MAY BE USER-DEFINED. THE FOLLOWING ASME A13.1 COLOR COMBINATIONS ARE DEFINED HEREIN FOR USE ON THE FIRM'S PROJECTS: Signage 10 14 00 - 8 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements PIPELINE SERVICE LETTER COLOR BACKGROUND COLOR EXAMPLE Gases (non flammable, non-combustible) White Safety purple LETTERS Steam Black Safety white LETTERS Contaminated water (non-corrosive, non-toxic) White Safety gray LETTERS User-defined White Safety black LETTERS 3. Legend for Pipe Markers: Pipe markers shall have the text or abbreviations in the color combinations indicated in Table 10 14 00-B of this Section to identify the pipeline service hazard. Pipe marker colors shall comply with ASME A13.1, unless otherewise indicated. TABLE 10 14 00-B, SCHEDULE OF PIPE MARKERS* Pipeline Legend Lettering/Text Color Background Color WATER Air Conditioning Water White Green Chilled Water Return White Green Chilled Water Supply White Green City Water WhiteWhite GreenGreen Cold Water WhiteWhiteWhite GreenGreenGreen City Water WhiteWhiteWhite GreenGreenGreen Domestic Hot Water BlackWhiteWhite YellowGreenGreen Drinking Water WhiteWhiteWhite GreenGreenGreen Fire Water WhiteWhiteWhite RedGreenGreen Hot Water Return WhiteWhiteWhite GreenGreenRed Hot Water Supply WhiteWhiteWhite GreenGreenGreen Non-Potable WhiteWhiteWhite GreenGreenGreen Non-Potable WhiteWhiteWhite GreenGreenGreen Non-Potable WhiteWhiteWhite GreenGreenGreen Non-Potable WhiteWhiteWhite GreenGreenGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Sprinkler Water WhiteWhiteWhite RedGrayGreen Signage 10 14 00 - 9 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements TABLE 10 14 00-B, SCHEDULE OF PIPE MARKERS* Pipeline Legend Lettering/Text Color Background Color AIR AND GAS City Gas WhiteBlackWhite BrownOrangePurple CHEMICALS PROCESS Signage 10 14 00 - 10 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements TABLE 10 14 00-B, SCHEDULE OF PIPE MARKERS* Pipeline Legend Lettering/Text Color Background Color Signage 10 14 00 - 11 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements TABLE 10 14 00-B, SCHEDULE OF PIPE MARKERS* Pipeline Legend Lettering/Text Color Background Color Signage 10 14 00 - 12 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements TABLE 10 14 00-B, SCHEDULE OF PIPE MARKERS* Pipeline Legend Lettering/Text Color Background Color 2.05 EQUIPMENT NAMEPLATES A. Description: 1. Provide equipment nameplate for each equipment item furnished under the Contract, and for other equipment items indicated to receive nameplates. Equipment nameplates specified in this Article are in addition to equipment manufacturer’s standard nameplate with manufacturer name, model number, serial number, and similar information. 2. Install equipment nameplates as indicated in Part 3 of this Section. Mechanically fasten equipment nameplates to the associated equipment item. B. Products and Manufacturers: Provide one of the following: 1. Stainless Steel (HEET) Tags (B-748) custom engraved, by Brady Worldwide, Inc. 2. Custom Engraved Stainless Steel Nameplates, by Seton Identification Products, a Tricor Direct Company 3. Or equal. C. Products and Manufacturers: Provide one of the following: 1. Brady-Etch Stainless Steel ID Tags (B-748) custom engraved, by Brady Worldwide, Inc., 2. Custom Screenprinted Nameplates – Stainless Steel, by Seton Identification Products, a Tricor Direct Company 3. Or equal. D. Products and Manufacturers: Provide one of the following: 1. Engraved Plastic Tags (B-1), by Brady Worldwide, Inc. 2. Custom Engraved Plastic Nameplates, by Seton Identification Products, a Tricor Direct Company 3. Or equal. Signage 10 14 00 - 13 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements E. Equipment Nameplates: 1. Material: Type 304 or Type 316 stainless steel, 26-gage, with rounded corners. Suitable for temperatures ranging from -40 to 89 degrees C. 2. Material: Type 304 or Type 316 stainless steel with 0.0015-inch thick black enamel background or black screenprinted background, 26-gage thick with rounded corners. Provide nameplates with screenprinted background installed outdoors with acrylic overcoat. Suitable for temperatures ranging from -40 to 89 degrees C. 3. Material: 1/16-inch thick satin-surfaced acrylic nameplates with beveled edges, front- engraved. Suitable for indoor and outdoor use. Suitable for temperatures ranging from -40 to 90 degrees C. 4. Provide each equipment nameplate with not less than two holes, each approximately 3/16-inch diameter, for mechanically fastening nameplate to the associated equipment. Provide appropriate stainless steel fasteners. 5. Nameplate Size: a. Size shall be as required for required text, and shall be not less than one-inch by four inches. 6. Text Engraved on Nameplates: a. Text Size: Equipment nameplate titles shall have text as large as possible to fit on nameplate; text shall be not less than 1/2-inch high. All text on a given nameplate shall be one size. b. Text and symbols shall be Standard Helvetica Medium, all upper-case. c. Left-justify multiple lines of text d. Where more than one item of the same type of equipment is furnished, consecutively number each associated equipment nameplates as shown or indicated; for example “Pump No. 1”, “Pump No. 2”, “Pump No. 3”, and so on. F. Operating Stands for Valves and Gates: 1. Nameplate material, size, and text requirements are the same as indicated above for other equipment nameplates. 2. Operating stands for valves and gates shall carry the respective legends “V. No. ___” or “S.G. No. ___,” with the appropriate equipment number to be indicated by ENGINEER. 3. Background and text color of nameplates for valve and gate operators shall be the same colors specified above for other equipment nameplates. 4. Background and text color of nameplates for valves and gates shall be the same as for the associated pipe markers. 2.06 VALVE AND PIPELINE TAGS A. Products and Manufacturers: Provide one of the following: 1. Custom Engraved Stainless Steel Valve Tags, by Brady Worldwide, Inc. 2. Custom Stainless Steel Valve Tags, by Seton Identification Products, a Tricor Direct Company 3. Or equal. B. Metal Tags: 1. For each valve and for pipelines smaller than 3/4-inch outside diameter, provide permanently-legible, round metal tags, each two-inch diameter, Type 304 or Type 316 stainless steel, with engraved lettering filled with black enamel. Provide tags with 3/16- inch diameter hole located that does not interfere with legend. 2. Legend for Valve Tags: Signage 10 14 00 - 14 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements a. Based on information provided on the Drawings, submit to ENGINEER not less than 7 days before system startup, a valve schedule indicating all required valves. b. For each valve, the valve schedule shall indicate: location, valve type, valve number, words to identify valve's function, type of operator, and normal operating position. c. Information presented in the valve schedules shall be coded on tags in a system provided by or acceptable to OWNER. Each valve shall be coded and identified by ENGINEER utilizing a combination of up to twelve letters and numbers. 3. Legend for Small Pipeline Tags: Comply with requirements for pipe markers relative to legend. Where legend is not indicated, obtain interpretation from ENGINEER. 4. Miscellaneous Valve and Small Pipeline Tag Accessories: a. Stainless Steel Wire: Nylon-coated; 0.048-inch outside diameter. b. Clamps: Brass. c. Lead Seals: Monel; four ply, 0.014-inch by 10 inches long; for attaching tags. d. Hand Sealing Press: As recommended by tag manufacturer for crimping lead seals. 2.07 PANEL SIGNS – RIGHT-TO-KNOW LABELS, SIGNS, AND TAGS A. Products and Manufacturers: Provide one of the following: 1. Custom B-302 Pressure Sensitive Polyester Right-To-Know Labels, B-120 Fiberglass Chemical Tank Signs, Front No. 1/Back No. 1 B-851 Right-To-Know Accident Prevention Tags and Right-To-Know Pictograms, by Brady Worldwide, Inc. 2. Right-to-Know & HazCom Signs, Labels, and Tags, by Seton Identification Products, a Tricor Direct Company. 3. Or equal. B. General: 1. Right-to-know signs, labels, and tags shall use NFPA 704 “diamond” hazard identification systems and shall comply with OSHA 1910.1200 and OSHA Subpart Z. C. Tank Signs: 1. Provide quantity of signs shown or indicated, identifying the chemical stored in the tank, chemical's hazards, required protective equipment in text and pictograms, first-aid for eyes, skin, ingestion and inhalation, information on confined space entry and NFPA 704- required hazard rating system information. 2. Right-to-know fiberglass signs for storage tanks shall have pressure-sensitive adhesive backs and be provided with subsurface numbers, symbols, text, and legends. Labels shall indicate chemical name and chemical abstracts service number, fire and health hazard potential, reactivity, personal protection and target organ legends in compliance with NFPA 704 format and OSHA 1910.1200. D. Labels: Provide right-to-know polyester labels for each hazardous chemical container. Provide labels seven inches by ten inches with information pre-printed by manufacturer. Provide labels with two-mil polyester overlaminate and with a complete line of all standard and custom pictograms. E. Tags: Provide 15-mil right-to-know vinyl tags with self-adhering clear polyester overlaminate. Tags shall be laminated plastic and provided with nylon tie fasteners. Provide tags three inches by 5.75 inches with two chamfered corners with reinforced 3/16- inch diameter grommeted hole. 2.08 CAST METAL DEDICATION PLAQUES Signage 10 14 00 - 15 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. Provide cast metal plaques free from pits, scale, sand holes or other defects. Provide hand- tooled and buffed borders with raised copy to produce plaque manufacturer’s standard satin polished finishes. B. Products and Manufacturers: Provide one of the following: 1. Cast Aluminum Dedication Plaque, by Show and Tell Products. 2. Cast Aluminum Dedication Plaque, by the Southwell Company. 3. Or equal. C. Cast aluminum alloy UNSA03280, as designated by ASTM E527, or of alloy recommended by aluminum manufacturer complying with ASTM B26/B26M, to provide casting and finish requirements, two feet wide by 2.5 feet high with AA-M31C21A31 clear anodic finish, as designated by AA DSA-45. D. In general, four sizes of letters shall be used to provide a symmetrical, well-spaced tablet. Letter sizes shall be generally as follows: 1. Municipality and Date: 7/8-inch. 2. Site or Facility Name: 1/2-inch. 3. Individual Names and Companies: 7/16-inch. 4. Title and Cities: 5/16-inch. E. Layout: General arrangement for cast metal dedication plaque is indicated below. In plaque layout submittal and plaques provided for the Project, replace bracketed text below with the required names and information. Signage 10 14 00 - 16 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements DENTON, TEXAS MUNICIPAL WATER PURIFICATION PLANT CITY COUNCIL [Name], VICE-MAYOR [Name] [Name] [Name] [Name] [Name] DIRECTOR OF PUBLIC UTILITIES [Name] ASSISTANT DIRECTOR OF PUBLIC UTILITIES [Name] CONSULTING ENGINEER MALCOLM PIRNIE, INC. ENVIRONMENTAL ENGINEERS, SCIENTISTS & CONSULTANTS CONTRACTOR [Contractor Name] [City] [Year of Dedication] F. Mechanical Finish and Design: Provide plaque with raised, flat borders with fine, satin directionally-textured finish. Field background shall be uniform stipple finish. G. Mounting and Fasteners: Plaque shall be flush-mounted; with stainless steel threaded studs set in epoxy adhesive. H. Protective Coating: Provide with two coats of manufacturer’s clear, methyl methacrylate monomer air-dried protective coating system with dry film thickness of not less than 1.0 mil. 2.09 INDIVIDUAL DIMENSIONAL CAST CHARACTERS A. Provide individual cast metal letters and numbers with smooth, flat faces, sharp corners, true lines, and accurate profiles. B. Products and Manufacturers: Provide one of the following: 1. Cast Aluminum Individual Letters and Numbers, by Gemini, Inc. 2. Cast Aluminum Individual Letters and Numbers, by Visigraph Corporation. 3. Or equal. C. Material: 1. Bronze, Copper Development Association Designation Alloy, UNSC83450; 88 percent copper, 2.5 percent tin, two percent lead, 6.5 percent zinc and one percent nickel, in accordance with ASTM E527; with dark statuary bronze oxidized CDA-M31C5506x finish produced using aqueous sulfide conversion chemical. 2. Provide letters and numbers with both faces and edges with satin finish. 3. Provide integral cast lugs in the back of letters and numbers and tap to receive threaded mounting studs. D. Style and Height: Provide 8-inch high letters, 1/2 inch thick, optima (semi bold), all capitals . Signage 10 14 00 - 17 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements E. Mounting: Provide each letter and number with not less than two 4-inch long by 1/8-inch diameter threaded bronze studs. F. Provide the following individual dimensional cast letters and numbers located where shown or indicated: 1. Administration Building. 2. High Service Electrical Building. 2.10 AUXILIARY MATERIALS A. Very-High-Bond High-Performance Bonding Tape: 1. Provide all surface-mounted signage with very-high-bond foam tape backing except where specified as requiring mechanical fasteners. 2. Products and Manufacturers: Provide one of the following: a. Scotch Brand (Very-High-Bond) 4942 VHB Double Coated Acrylic Foam Tape and No. 94 Acrylic Primer, by 3M Industrial Tape and Specialties Division. b. Or equal. 3. Provide a very-high-bonding pressure sensitive joining system consisting of double- coated conformable acrylic foam tape and release liners. 4. Thickness: 0.045-inch. 5. Tape Width: 1.5 inches. 6. Color: Dark gray. 7. Bonding Adhesive: Acrylic; very-high-bond, solvent and shear resistance. 8. Primer: High-performance tape manufacturers recommended acrylic primer. B. Fasteners: Provide fasteners of non-magnetic stainless steel of size and type required and recommended by the associated individual signage manufacturer. C. Anchors and Inserts: Provide nonferrous metal or hot-dipped galvanized anchors and inserts. Provide toothed stainless steel or lead expansion bolts for drilled-in-place anchors. D. Mounting Brackets: 1. Provide manufacturer’s standard mounting brackets for each of the following sign types: hanging, projected, double-sided. 2. Provide inserts, and mechanical and adhesive anchoring devices as specified in this Article for installation of signage. 2.11 FABRICATION A. Shop Assembly: 1. Fabricate and preassemble items in the shop to the greatest extent possible. 2. Disassemble units only to extent necessary for shipping and handling limitations. 3. Clearly mark units for reassembly and coordinated installation. 2.12 SOURCE QUALITY CONTROL A. Fabrication Tolerances: 1. Produce smooth, even, level sign panel surfaces, constructed to remain flat under installed conditions within tolerance of plus or minus 1/16-inch measured diagonally across each sign. 3.00 EXECUTION 3.01 INSPECTION Signage 10 14 00 - 18 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. Examine substrates and conditions under which signage will be installed and notify ENGINEER in writing of conditions detrimental to the proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions are corrected. 3.02 INSTALLATION A. General: 1. Location: a. Install signage and appurtenances at the locations shown or indicated. When locations are not shown or indicated, install signage at locations directed by ENGINEER. b. Provide exit signs at locations shown or indicated. Surface-mount signs above each point of egress, unless otherwise shown or indicated. c. Lightly mark and locate position of each sign. Obtain ENGINEER’s acceptance of marked locations before mounting. 2. Installation – General: a. Install signs level, plumb, and at proper height. b. Signage shall be securely mounted with concealed, very-high-bond acrylic foam tape, specified adhesives, or mechanical fasteners where specified. Attach signs to surfaces in accordance with sign manufacturer's instructions, unless otherwise shown or indicated. c. Provide very-high-bond acrylic foam tape on back of signage using a full perimeter of specified tape. Leave no gaps in tape perimeter at back of signage; peel off second release liner and press onto surfaces. 3. Repair or replace damaged units. B. Panel Signs – Room Identification, Directional, and Information Signs: 1. Where permanent identification is provided for rooms and spaces, install signs on the wall adjacent to the latch side of the door. 2. Where there is no wall space on the latch side of the door, including at double leaf doors, install signs on the nearest adjacent wall. 3. Mounting height shall be in accordance with ADA-ABA Accessibility Guidelines in areas accessible to disabled people. For other areas install signs with five feethes from the finished floor to centerline of sign. Mount such signage so that a person may approach within three inches of the sign without encountering protruding objects or, when reading sign, be forced to stand within the swing of a door. C. Pipe Markers, Equipment Nameplates, and Pipe and Valve Tags: 1. Location of Pipe Markers and Pipe Tags: a. Provide pipe markers with text (pipeline contents or service) and adjacent arrow indicating the direction of flow of pipeline contents on each piping system provided under the Project and other piping systems shown or indicated as to receive pipe markers. b. Locations: Provide pipe markers at each of the following locations: 1). At intervals of not more than 30 linear feet apart 2). Directly adjacent to each side of each penetration by the pipeline of the following: wall, floor, ceiling, roof. 3). Adjacent to each change in flow direction. 4). On each branch where pipes connect together including but not limited to tees, wyes, and crosses. Signage 10 14 00 - 19 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 5). Adjacent to each side of each valve (including but not limited to check valves, isolation valves, control valves, and other valves), strainer cleanouts, and each equipment item along the pipeline. 6). Comply with ASME A13.1. c. Provide flow-direction arrows at intervals not greater than 15 linear feet. Where flow may be bi-directional, provide arrows adjacent to each other to indicate both directions. d. Pipe marker locations will be determined by ENGINEER, but in general place pipe markers where personnel view of label is unobstructed. When pipeline is overhead, install label on the two lower quarters of the pipe or pipe covering. Pipe markers shall be clearly visible from personnel operating positions, especially operating positions adjacent to valves and equipment. e. Provide pipe tags, where specified, at locations as specified for pipe markers. 2. Location of Valve Tags and Valve Nameplates: a. Valve nampeplates and valve signs for large valves shall be located on or adjacent to the valve. b. For smaller valves, attach tags to valve bonnet or valve flange bolts. c. For valves to receive equipment nameplates, as specified in this Section, install nameplate as requied for other equipment nameplates. d. Do not attach tags, nameplates, or signs to valve handwheels or other valve actuators. 3. Equipment Nameplates: a. Locate nameplates on equipment bases and on structures at readily-visible elevation in such positions relative to the equipment and structures as to prevent damage to nameplate. b. Position nameplace for ease of reading by operations and maintenance personnel. D. Panel Signs – Right-To-Know Signs, Labels, and Tags: 1. Locate tags at intervals of not more than 20 feet center-to-center along chemical pipelines and fill pipelines and on each side of locations where pipelines emerge from penetrations with other materials. 2. Install tank signs on each tank shown or indicated to receive signage at quarter-points on tank circumference, five feet above finished floor. E. Panel Signs – Site Entry, Directional, and Information Signs: 1. Install posts to concrete footings in accordance with sign manufacturer’s written instructions. Refer to Sections 03 30 00, Cast-in-Place Concrete, and Section 31 23 05, Excavation and Fill. 2. Attach sign panels to posts in accordance with sign manufacturer’s written instructions. F. Cast Metal Dedication Plaques: 1. Install plaques using standard fastening methods to comply with plaque manufacturer's instructions for type of wall surface on which plaque will be installed. 2. Concealed Mounting: Install plaques by inserting threaded studs into tapped lugs on back of plaque. Set in pre-drilled holes filled with quick-setting cement. 3. Face Mounting: Install plaques using exposed fasteners as specified in Part 2 of this Section attached through face of plaque into wall surface. G. Individual Dimensional Characters: 1. Install characters using standard fastening methods to comply with manufacturer's written instructions for character form, type of mounting, wall construction, and Signage 10 14 00 - 20 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements condition of exposure indicated. Provide heavy paper template to establish character spacing and to locate holes for fasteners. 2. Flush Mounting: Install characters with backs in contact with wall surface. H. Projected Mounting: Install characters at projection distance from wall surface indicated. 3.03 PROTECTION AND CLEANING A. After installation, clean soiled signage surfaces in accordance with manufacturer’s written instructions. B. Protect signage from damage until completion of the Work. END OF SECTION Toilet Compartments 10 21 13 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 10 21 13 TOILET COMPARTMENTS 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, tools, equipment, and incidentals as shown, specified, and required to furnish and install toilet compartments. 2. Extent of the toilet compartments is shown and specified. 3. Types of products include the following: a. Floor-supported and wall-braced, solid, high-density polyethylene plastic, pilasters and urinal panels. b. Vanity top, skirt, sidesplash, backsplash and support assemblies fabricated of solid, high-density polyethylene plastic. c. ADAAG-compliant, heavy-duty, stainless steel hardware and other custom hardware. d. Auxiliary items including stainless steel ceiling brackets, tamper-proof fasteners, heavy-duty pilaster mounting system, custom engraved identification graphics, supports, anchors and accessories. 4. In some cases, minor incidental accessories necessary to proper functioning of the materials furnished under this Section may not be mentioned in the Contract Documents. CONTRACTOR shall follow the recommendations of the manufacturer of the item required and provide the Work with all required incidental accessories necessary to proper functioning of the item, at no additional cost to OWNER. Provide materials matching the adjacent materials and similar items specified. B. Coordination: 1. Provide inserts and anchoring devices to be built into masonry and drywall for installation of toilet compartments and related Work. Provide setting drawings, templates, instructions, and directions for installing anchorage devices. Coordinate delivery with other work to avoid delay. 2. Refer to concrete, masonry, tile, and gypsum wallboard Sections of the Specifications for requirements on installing inserts and anchorage devices. 3. Review installation procedures under this and other Sections and coordinate installation of items to be installed with or before toilet compartments Work. 1.02 REFERENCES A. Standards referenced in this Section are: 1. ANSI/ICC A117.1, Accessible and Usable Buildings and Facilities. 2. ANSI/BHMA A156, Master Keying Systems. 3. ASTM A153/A153M, Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. 4. ASTM A666, Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar. 5. ASTM A890/A890M, Specification for Castings, Iron-Chromium-Nickel-Molybdenum Corrosion-Resistant, Duplex (Austenitic/Ferritic) for General Application. 6. ASTM D638, Test Method for Tensile Properties of Plastics. 7. ASTM D1505, Test Method for Density of Plastics by the Density-Gradient Technique. 8. ASTM D2240, Test Method for Determining Rubber Property - Durometer Hardness. Toilet Compartments 10 21 13 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 9. ASTM E84, Test Method for Surface Burning Characteristics of Building Materials. 10. NAAMM AMP 503, Finishes for Stainless Steel. 11. UL 94, Test for Flammability of Plastic Materials for Parts in Devices and Appliances. 1.03 QUALITY ASSURANCE A. Qualifications: 1. Installer: a. Engage a single installer regularly performing installation of toilet compartment partitions with documented skill and successful experience in installing types of materials require. Installer shall to employee only workers who are trained, skilled, and have successful experience with installing the types of materials required. b. Submit name and qualifications to ENGINEER with the following information for not less than three successful, completed projects: 1). Names and telephone numbers of owners and architect or engineer responsible for each project. 2). Approximate contract value of toilet compartments work. 3). Quantity (area) of toilet compartments installed. B. Component Supply and Compatibility: 1. Obtain materials included in this Section, regardless of component manufacturer, from one toilet compartment manufacturer. 2. Toilet compartment manufacturer shall review and approve, or shall prepare, all Shop Drawings and other submittals for components furnished under this Section. 3. Materials and components shall be integrated into overall toilet compartment system by toilet compartment manufacturer. C. Regulatory Requirements: 1. Comply with the following: a. Building code specified in Section 01 42 00, References. b. Requirements of authorities having jurisdiction c. ANSI/ICC A117.1 d. Americans with Disabilities Act of 1990 (Public Law 101-336), Appendix A, to 28 CFR Part 36 - Americans with Disabilities Act Accessibility Guidelines for Buildings and Facilities (ADAAG). 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Shop Drawings a. Installation drawings showing toilet compartment partition assemblies, vanities, urinal screens, and sight screens. Include plans and elevations drawn at scale of not less than one inch equal to one foot. Include all dimensions and clearances establishing sight line tolerances for the Work and the location of other work to interface with toilet compartment assemblies. b. Coordinated drawings showing location, size of cutouts and supports for toilet accessories, plumbing, and other Work to interface with vanities. c. Anchorage, leveling, and accessory items, location of each finish color, and all items of hardware and support. d. Location and layout of all custom graphics. 2. Product Data: Toilet Compartments 10 21 13 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements a. Manufacturer’s material specifications, fabrication specifications, and b. catalog cuts of each item of hardware, anchor, and fastenings. 3. Samples: a. Color samples for selection by ENGINEER. b. Submit six-inch by six-inch by one-inch thick pieces of actual panel material proposed for use showing actual color selections. One panel shall include an engraved representation of the international symbol of accessibility logogram at full size, as logoram will appear on the actual toilet compartment operable panel. Not less than two panels shall be welded together and demonstrate method and workmanship for assembling vanity countertops, skirts, and backsplash. Not less than one panel shall have aluminum heat-sink adhered continuously to one edge. c. All accessories, brackets, hardware, and fasteners, both standard and custom, including mounting and leveling devices mounted on frames and panels indicating proposed actual installation conditions. d. Samples will be reviewed by ENGINEER for color, texture, and surface uniformity only. Compliance with all other requirements is responsibility of CONTRACTOR. B. Informational Submittals: Submit the following: 1. Manufacturer Instructions: a. Storage, handling, and installation instructions. b. Location template drawings for bolt locations in supporting members. 2. Qualifications Statements. a. Installer, when requested by ENGINEER. C. Closeout Submittals: Submit the following: 1. Operations and Maintenance Data: Submit manufacturer's instructions for recommended maintenance practices for polymer resin toilet compartment panels, in accordance with Section 01 78 23, Operation and Maintenance Data. 2. Warranty Documentation: General and special warranties in accordance with this Section. 1.05 DELIVERY, STORAGE AND HANDLING A. Packing, Shipping, Handling and Unloading: 1. Clearly identify manufacturer, brand name, contents, color stock number, and order number on each package. 2. Handle materials in manner that avoids damaging materials and their finishes. B. Storage and Protection: 1. Store in original packaging. 2. Stack containers in accordance with manufacturer's approved written recommenda- tions. 1.06 SCHEDULING A. Include the effects on cost and impacts to Project Schedule of manufacturer’s minimum quantity ordering requirements and custom features such as custom colors, patterns, fire- resistant material, custom graphics, and use of custom hardware. 1.07 WARRANTY Toilet Compartments 10 21 13 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. General Warranty: The special warranty specified in this Article shall not deprive OWNER of other rights or remedies OWNER may otherwise have under the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by CONTRACTOR under the Contract Documents. B. Special Warranty: 1. Toilet Compartment Warranty: Provide written warranty, signed by the manufacturer and running to benefit of OWNER, agreeing to replace, for a period of fifteen years from the date of Substantial Completion, toilet compartments that show delamination, corrosion or breakage caused by manufacturing imperfections. 2.00 PRODUCTS 2.01 SYSTEM PERFORMANCE A. Performance Criteria: 1. Provide material complying with ASTM E84, Class A, with flame spread index of 25 maximum, and smoke developed index of 20, maximum. 2. Provide material that contains flame-retardants throughout its thickness providing total flaming combustion time not exceeding 50 seconds, and glowing combustion time that does not persist for more than 30 seconds after removal of test flame, when tested in accordance with UL 94. 3. Fire-Test-Response Characteristics: Where flame spread or smoke development classification is shown or specified for toilet compartment partitions (Class A or Class B), provide components complying with applicable requirements for materials and installation established by ASTM, and authorities having jurisdiction. 2.02 MATERIALS A. Doors, Panels, Vanity Components, and Pilasters: 1. Solid, one-inch thick, high-density polyethylene compression-molded, seamless panels, with eased edges and homogenous color throughout 2. Physical Properties: Provide materials complying with the following: a. Density, ASTM D1505: 0.96, minimum. b. Tensile Yield, ASTM D638: 4400 psi, minimum. c. Hardness, ASTM D2240: 68 Shore D. d. Elongation, ASTM D638: 600 percent, maximum. e. Self-Ignition: 700 degrees F. 3. Provide all panels and doors with continuous extruded aluminum heat-sink strip fastened to bottom of all edges. 4. Colors and Patterns: a. Full range of manufacturer's standard and custom colors and patterns for selection by ENGINEER. b. ENGINEER will select a maximum of 4 colors and patterns, including door panels and fixed partitions that differ in color and pattern from pilasters. 5. Exposed high-density polyethylene surfaces that exhibit pitting, seam marks, stains, discoloration, or other surface imperfections on the finished materials are unacceptable. B. Heavy-Duty Pilaster Anchor and Leveling Assemblies: 1. Provide manufacturer’s floor-mounted assembly consisting of two 1/2-inch by one-inch galvanized steel bars with square steel partition lifters complying with ASTM Toilet Compartments 10 21 13 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A153/A153M, Type B-3, and four 3/8-inch by six-inch steel studs, corrosion-resistant locking and leveling nuts and expansion anchors. C. Custom Hardware: 1. Heavy-Duty Vault Hinges: a. Provide cast alloy top and bottom pivot hinges, designed for solid polymer resin toilet compartments, with 3/4-inch diameter stainless steel gravity acting cams and wrap-around flanges. 2. Combination Latch, Striker and Keeper: a. Recessed stainless steel strike units, with combination rubber-faced door striker and slotted keeper. Provide latch units that have capabilities for emergency access. 3. Coat Hooks: a. Provide cast stainless steel hooks and hook/bumper combination units as required by swing of door and adjacency to obstructions. 4. Door Pulls: a. Provide cast stainless steel, three-inch high ADAAG-compliant pulls. 5. Door Stop: a. Stainless steel stop, 1-7/8-inch long. 6. Push Plates: a. Provide 0.125-inch thick stainless steel plate with No. 4 finish. b. Size: eight inches by 16 inches with beveled edges. c. ANSI/BHMA A156.6, J304; B3E. D. Auxilary Components: 1. Pilaster Shoes and Pilaster Sleeves: a. Provide double-hemmed, four-piece pilaster shoes and sleeves; ASTM A666, Type 302/304 stainless steel. b. Height: Three inches. c. Thickness: 20-gage (0.0312-inch), minimum. d. Finish: NAAMM AMP 503, No. 4 finish. 2. Brackets: a. Provide complete selection of specified manufacturer’s cast stainless steel one-ear, two-eared, U-shaped and angle brackets as required to assemble the Work. Provide cast stainless steel brackets complying with ASTM A890/A890M and as follows: b. For attaching urinal panels to walls provide urinal screen brackets with 3.5-inch extension legs with two fastener holes for fasteners extending through urinal screens. c. Provide panel brackets with 3.5-inch extra-long extension legs with one fastener hole for fastener extending through partition screens. E. Accessories: Manufacturer's standard and custom design, heavy-duty accessories, as follows: 1. Fasteners: Provide manufacturer's standard exposed stainless steel fasteners, with finish to match hardware. Use tamper-proof, one-way type heads and nuts for exposed anchorages. 2. For concealed anchors use hot-dip galvanized steel items. 2.03 FABRICATION A. Shop Assembly: 1. Preassemble items in the shop to the greatest extent possible. Toilet Compartments 10 21 13 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2. Disassemble units only to the extent necessary for shipping and handling. Clearly mark units for reassembly and coordinated installation. B. Panels and Doors: 1. Not less than one-inch thick panels with edges rounded to 1/4-inch radius. Provide exposed surfaces free of saw marks. 2. Fabricate panels in maximum sizes to avoid joints and splices, as shown. 3. Provide two-foot wide swing-in doors, unless otherwise shown or specified. 4. In water closet compartments accessible to people with physical disabilities, comply with ADAAG and ANSI/ICC A117.1. Provide swing-out doors 34 inches wide. 5. Provide operable compartment doors 58 inches high, mounted 12 inches above finished floor. 6. Custom Door Hardware: a. Inswing Doors: Top and bottom vault hinges; combination latch, striker and keeper; door bumper; and coat hook. b. Outswing Doors: Top and bottom vault hinges; combination latch striker and keeper; door bumper/coat hook combination, pull handle, international symbol of accessibility logogram. C. Floor-Supported and Wall-Hung Urinal Screens: 1. Products and Manufacturers: Provide one of the following: a. Floor/Wall Braced Urinal Screens by Comtec Industries Division of Compression Polymers Group. b. Floor/Wall Braced Urinal Screens by Accurate Partitions Corp., an ASI Group Company. c. Or Equal. 2. Not less than one-inch thick panels and pilaster units with heavy-duty pilaster anchor and leveling assembly for each pilaster with stainless steel shoes to match compartment units. 3. Panels: 58 inches tall by two feet wide, mounted 12 inches above finished floor and of same construction and finish as toilet compartment panels and pilasters. 4. Pilasters: 70 inches high and five inches wide. 5. Brackets: Not less than three stainless steel wall brackets. D. Sight Screens: Provide units of the same type, construction and finish, supports and anchorages, and hardware and fasteners to match compartment units. Provide door pulls, keepers, and push plates and other hardware as required for toilet compartments. E. Vanities: 1. Shop-fabricate vanity units of same material as toilet compartments, and in compliance with approved Shop Drawings and submittals, using aluminum angles, brackets and tamper-resistant stainless steel fasteners as required to support of the Work. Space intermediate support panels not more than three feet on centers. 2. Tops: One-inch thick and two feet wide; lengths required to minimize joints. 3. Provide four-inch wide skirt and six-inch high backsplash and sidesplash. 4. Provide heavy-duty pilaster anchor and leveling assembly for each support extending to floor, with stainless steel pilaster shoes, as required for toilet compartments. 3.00 EXECUTION 3.01 INSPECTION Toilet Compartments 10 21 13 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. Examine the areas and conditions under which toilet compartment partitions and related items will be installed. Notify ENGINEER in writing of conditions detrimental to proper and timely completion on the Work. Do not proceed with the Work until unsatisfactory conditions are corrected. 3.02 INSTALLATION A. General: 1. Install doors, panels, and pilasters rigid, straight, plumb and level, with panels laid out as shown on approved Shop Drawings. Secure units to supporting walls in accordance with Article 2.2 of this Section, and shown on approved Shop Drawings. 2. Allowable Tolerances: Clearance at vertical edges of panels shall be uniform top to bottom and shall not exceed 1/4-inch between panels. B. Wall-Braced Panels and Screens: 1. Secure panels to walls with not less than three wall brackets of the type required to accommodate wall configurations and as shown on approved Shop Drawings. 2. Attach with heavy-duty concealed anchoring devices, to suit the supporting wall construction. Set units in accordance with manufacturer's written instructions to provide support for the units and to resist lateral impact. C. Vanity Assemblies: 1. Level units and install pilaster shoes. 2. Secure assemblies to walls using continuous aluminum angles and stainless steel tamper-resistant fasteners. 3.03 ADJUSTMENT, PROTECTION AND CLEANING A. Protect units after installation so that there will be no indication of use or damage at Substantial Completion. B. Perform all final adjustments to pilaster leveling devices, door hardware, and other operating parts of toilet compartment assemblies just prior to Substantial Completion. Clean exposed surfaces of partitions, hardware, fittings and accessories, and touch up minor scratches and other finish imperfections using materials and methods recommended by toilet compartment assemblies manufacturer. C. Hardware Adjustments: Adjust and lubricate hardware for proper operation after installation. 1. Set hinges on inswing doors to hold doors open approximately 30 degrees from closed position when unlatched. 2. Set hinges on outswing doors and sight screen swing doors, if any, to return to fully- closed position. END OF SECTION Toilet and Bath Accessories 10 28 05 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 10 28 05 TOILET AND BATH ACCESSORIES 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment, and incidentals as shown, specified, and required to furnish and install toilet and bath accessories Work. 2. Extent of toilet and bath accessories is shown and specified. 3. Types of products required include the following: a. Combination paper towel dispenser and waste receptacle. b. Sanitary napkin disposal units. c. Toilet tissue dispensers. d. Toilet seat tissue dispensers. e. Mirrors. f. Grab bars. g. Soap dispensers. h. Combination shelf with utility hook and mop strips. i. Pail hooks. j. Soap dishes. k. Miscellaneous fasteners, accessories and trim as required for a complete and functioning installation. B. Coordination: 1. Furnish inserts and anchoring devices to be set in concrete or built into masonry and recycled gypsum wallboard for installation of toilet and bath accessories. Refer to concrete and masonry Specifications for installation of inserts and anchorage devices. 2. Coordinate toilet and bath accessory locations with other work to prevent interference with clearances required for access by people with disabilities, and for proper installation, adjustment, operation, cleaning, and servicing of toilet and bath accessories 3. Review installation procedures under this and other Sections and coordinate installation of items to be installed with or before toilet and bath accessories Work. C. Related Sections: 1. Section 03 30 00, Cast-In-Place Concrete 2. Section 04 05 05, Unit Masonry Construction. 3. Section 08 71 00, Door Hardware. 4. Section 09 26 16, Gypsum Wallboard Assemblies Toilet and Bath Accessories 10 28 05 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 5. Section 09 30 13, Ceramic Tiling. 6. Section 10 21 13, Toilet Compartments. 1.02 REFERENCES A. Standards referenced in this Section are: 1. ANSI/ICC A117.1, Accessible and Usable Buildings and Facilities. 2. NFPA 70, National Electric Code. 1.03 QUALITY ASSURANCE A. Component Supply and Compatibility: 1. Provide products of the same manufacturer for each type of bath accessory unit and for units exposed in the same areas. B. Regulatory Requirements: 1. Comply with the following: a. International Building Code. b. Requirements of authorities having jurisdiction c. ANSI/ICC A117.1 d. Americans with Disabilities Act of 1990 (Public Law 101-336), Appendix A, to 28 CFR Part 36 - Americans with Disabilities Act Accessibility Guidelines for Buildings and Facilities (ADAAG). 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Shop Drawings: a. Schedule of toilet and bath accessories indicating proposed location for each item. 2. Product Data: a. manufacturer’s published literature, technical data, and specifications for each toilet and bath accessory item. 3. Samples: a. Standard and custom color charts for color selection by ENGINEER. Submit for each item under this Section where color or finish is not specified. B. Informational Submittals: Submit the following: 1. Manufacturer's Instructions: a. Setting drawings, templates, instructions, and directions for installing anchorage devices in other work. b. Instructions for storing and installing materials furnished. Toilet and Bath Accessories 10 28 05 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2.00 PRODUCTS 2.01 SYSTEM PERFORMANCE A. General: 1. Components and materials shall be suitable for their intended use and environment. 2. Stamped names or labels on exposed faces of units are unacceptable. 3. Provide locks with the same keying for each type of toile and bath accessory units in the Project, where possible. Furnish two keys for each lock. 4. Electrical components, devices, and accessories shall be listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. 2.02 SURFACE-MOUNTED PAPER TOWEL DISPENSER A. Products and Manufacturers: Provide one of the following: 1. No. 0210, by American Specialties, Inc. 2. B-262, by Bobrick Washroom Equipment, Inc. 3. Or equal. B. Requirements: 1. Size to dispense not less than 400 c-fold towels with interchangeable paper drop. 2. Construction: Cabinet and door not less than 22-gage stainless steel, No. 4 satin finish, all-welded construction, without mitered corners. Hang door with concealed, full-length stainless steel piano hinge 3. Provide with tumbler-lockset. 2.03 RECESSED PAPER TOWEL DISPENSER/DISPOSAL A. Products and Manufacturers: Provide one of the following: 1. No. 0467, by American Specialties, Inc. 2. Model 2017, by Bradley Corporation.2 3. Or equal. B. Requirements: 1. Size to dispense not less than 600 c-fold towels with interchangeable paper drop. 2. Construction: Cabinet and door not less than 22-gage stainless steel, No. 4 satin finish, all-welded construction, without mitered corners. Hang doors with concealed, full- length stainless steel piano hinge 3. Provide tumbler-lockset. 2.04 SURFACE-MOUNTED SANITARY NAPKIN DISPOSAL UNIT A. Products and Manufacturers: Provide one of the following: Toilet and Bath Accessories 10 28 05 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1. No. 0473-A by American Specialties, Inc. 2. No. B-254 by Bobrick Washroom Equipment, Inc. 3. Model 4722-15 by Bradley Corporation. 4. Or equal. B. Requirements: 1. Fabricate disposal units from not less than 22-gage stainless steel, with flange of one- piece seamless construction without metered corners. 2. Provide self-closing upper door equipped with full-length stainless steel piano hinge and lift handles on each end. 3. Trap door shall have hidden stainless steel spring tensioned self-catching lock and be hinged on front face. Provide fold-down stainless steel purse shelf of 22-gage stainless steel. 2.05 TOILET TISSUE DISPENSERS A. General: Provide toilet tissue dispensers at each water closet. B. Products and Manufacturers: Provide one of the following: 1. No. 0697-GAL, by American Specialties, Inc. 2. B-2840, by Bobrick Washroom Equipment, Inc. 3. Model 5263, by Bradley Corporation. 4. Or equal. C. Multi-roll Toilet Tissue Dispenser and Ash Tray: Fabricate shelf of not less than 18-gage stainless steel, to store and dispense not less than two 4.5-nch by 4.5-inch core tissue rolls. Fabricate flange from a single piece, with seamless construction. 2.06 TOILET SEAT TISSUE DISPENSERS A. General: Provide surface-mounted toilet seat tissue dispenser at each water closet. B. Products and Manufacturers: Provide one of the following: 1. No. 0477-SM, by American Specialties, Inc. 2. B-221, by Bobrick Washroom Equipment, Inc. 3. Model 583, by Bradley Corporation. 4. Or equal. C. Surface-mounted Toilet Seat Tissue Dispenser: Satin-finish stainless steel. Dispenses 250 single- or half-fold toilet seat covers. 2.07 MIRRORS A. Custom Sized Angle Framed Mirrors: Toilet and Bath Accessories 10 28 05 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements B. General: Provide single pane, polished tempered glass mirrors continuous above each non- handicapped lavatory. C. Products and Manufacturers: Provide one of the following: a. Custom Sized 0600-B Mirrors by American Specialties, Inc. b. Custom Sized B-290 Mirrors, by Bobrick Washroom Equipment, Inc. c. Model 780-2, by Bradley Corporation. d. Or equal. 2. Stainless Steel Frames: Fabricate frames from 3/4-inch by 3/8-inch 18-gage, Type 304 stainless steel angle with corners heliarc welded, ground and polished smooth to uniform satin finish. Provide all mirrors installed on concealed hanging brackets that lock onto top and bottom of frame by tamper-proof set screws. 2.08 GRAB BARS A. General: Provide grab bars where shown. Provide custom specials where required or specified. B. Products and Manufacturers: Provide one of the following: 1. 3200 P Series custom Type 56 with 54-inch leg and 36-inch leg, by American Specialties, Inc. 2. B-68137.99, by Bobrick Washroom Equipment, Inc. 3. Model 812-2, Type 059 by Bradley Corporation. 4. Or equal. C. Custom Stainless Steel Grab Bars: 1. Provide stainless steel knurled grab bars, 1.5-inch outside diameter, 16-gage. 2. Mounting: Concealed, with manufacturer’s standard flanges and anchorages for type of installation. 3. Provide custom dimensions specified. 2.09 AUTOMATIC DECK MOUNTED SOAP DISPENSERS A. General: Provide automatic deck mounted soap dispensers, one per lavatory. B. Products and Manufacturers: Provide one of the following: 1. No. 20333, by American Specialties, Inc. 2. Model 6315, by Bradley Corporation. 3. Or equal. C. Liquid Soap Dispenser: 1. Automatic Deck Mounted Soap Dispenser shall hold 54 oz of liquid soap within the viscosity range of 100 – 3500 cP(MPa•s) and dispense in cycles of single shot volume of approximately 0.04 oz. Toilet and Bath Accessories 10 28 05 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2. Operation is initiated by hands-free sensor controlled by microprocessor digital circuitry powered by four (4) D size 1.5 V batteries in a screwlocked compartment located under counter. 3. Unit shall have chrome plated brass tubing spout and nozzle housing with a polished finish over all exposed surfaces and a chrome plated sensor housing. 4. Unit shall have LED’s to indicate function, battery condition and soap supply level on front face. Below counter tank shall be translucent to show quantity of soap remaining at any time. Tank shall be easily disengaged and engaged into control housing by push button to facilitate refilling. 2.10 MISCELLANEOUS ITEMS A. Combination Shelf with Utility Hook and Mop Strip: 1. Products and Manufacturers: Provide one of the following: a. No. 1304-A, by American Specialties, Inc. b. B-239x34, by Bobrick Washroom Equipment, Inc. c. Model 9934, by Bradley Corporation. d. Or equal. 2. Provide 18-gage stainless steel shelf with 3/4-inch lip, five 18-gage stainless steel hook strips, and four mop holders. Shelf shall be 34 inches wide and eight inches deep. B. Pail Hooks: 1. Products and Manufacturers: Provide one of the following: a. No. 1307-3, by American Specialties, Inc. b. B-232X24, by Bobrick Washroom Equipment, Inc. c. Model 9943, by Bradley Corporation. d. Or equal. 2. One-piece channel strip fabricated from 20-gage stainless steel. Provide heavy-duty hooks fabricated from 11-gage stainless steel. Shelf shall be 26 inches long with three hooks. C. Undersink Guards: 1. Description: Insulating pipe covering for supply and drain piping assemblies that prevent direct contact with and burns from piping; allow service access without removing coverings. 2. Product and Manufacturer: Provide one of the following: a. HANDY SHIELD–MAXX, by Plumberex Specialty Products, Inc. b. Truebro Lav Guard 2, by IPS Corporation. c. Or Equal. 3. Material and Finish: Anti-microbial, molded plastic, white. Toilet and Bath Accessories 10 28 05 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 3.00 EXECUTION 3.01 INSPECTION A. Examine the areas and conditions under which toilet and bath accessories will be installed and notify ENGINEER in writing of conditions detrimental to the proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions are corrected. 3.02 INSTALLATION A. Install items required to meet accessibility codes in accordance with Laws and Regulations, and ANSI/ICC A117.1. B. Determine that substrates are completed and ready to accept surface-mounted or recessed accessories. Refer to Section 03 30 00, Cast-In-Place Concrete; Section 04 05 05, Unit Masonry Construction; Section 09 26 16, Gypsum Wallboard Assemblies; and Section 09 30 13, Ceramic Tiling, for substrate requirements. C. Use concealed fastenings where possible. D. Provide anchorage devices, fasteners, and other necessary anchorages, and attach accessories securely to walls, floors, and partitions in locations as shown and as required. E. Install concealed mounting devices and fasteners fabricated of the same material as the accessories as recommended by manufacturer. F. Install exposed mounting devices and fasteners finished to match the accessories. G. Provide theft-resistant fasteners for all mountings. H. Secure and install toilet and bath accessories in accordance with the manufacturer’s instructions for each item and each type of substrate construction. I. Lock grab bars to concealed mounting plate installed in wall. J. Coordinate installation of toilet and bath accessories with toilet compartments. Refer to Section 10 21 13, Toilet Compartments. 3.03 ADJUSTMENT AND CLEANING A. Adjust toilet and bath accessories for proper operation. B. After completion of installation, clean and polish all exposed surfaces. C. Deliver keys and instruction sheets to OWNER in accordance with Section 08 71 00, Door Hardware. END OF SECTION Fire Protection Specialties 10 44 00 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 10 44 00 FIRE PROTECTION SPECIALTIES 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment, and incidentals as shown, specified, and required to furnish and install all fire protection specialties Work. 2. Extent of fire protection specialties Work is shown and specified. B. Coordination: 1. Review installation procedures under other Sections and coordinate installation of items that must be installed with or before fire protection specialties. C. Related Sections: 1. Section 10 14 00, Signage. 1.02 REFERENCES A. Standards referenced in this Section are: 1. UL Fire Classification Rating. 1.03 QUALITY ASSURANCE A. Component Supply and Compatibility: 1. Provide fire protection specialties products from one manufacturer. B. Regulatory Requirements: Provide fire protection specialties approved and labeled by UL. 1.04 SUBMITTALS A. Action Submittals: 1. Product Data: Submit the following: a. Manufacturer’s technical data, certification of UL rating, and installation instructions for fire protection specialties. 2.00 PRODUCTS 2.01 FIRE EXTINGUISHERS A. General: Provide manufacturer’s standard mounting brackets for portable fire extinguishers size as specified. B. Multi Purpose Dry Chemical Fire Extinguishers: 1. Ten-pound capacity, enameled steel container with pressure indicating gauge, for Class A, Class B, Class C fires, UL rating 4A 60 BC. 2. Products and Manufacturers: Provide one of the following: Fire Protection Specialties 10 44 00 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements a. Cosmic Model 10E by J.L. Industries. b. Or equal. C. Recessed Fire Extinguisher Cabinets: 1. For each fire extinguisher provided under this Contract, provide a recessed fire extinguisher cabinet. Coordinate size of recessed fire extinguisher cabinets required with extinguisher selected, for complete system integration. 2. Provide cabinets with concealed hinges and handles with manufacturer’s standard door roller catches. Provide all features typically furnished with specified unit. 3. Provide two-hour fire-rated cabinets. 4. Cabinets shall have 302/304 stainless steel doors with No. 4 finish. Provide specified manufacturer’s minimum gages for all material. 5. Cabinet shall have 1/4-inch thick, clear tempered glass vision panel. 6. Product and Manufacturer: Provide products of one of the following: a. Embassy 5734 V17 (fire-rated) with No. 4 Stainless Steel Tub and with glass with Fire-FX option with vertical fire extinguisher decal by J.L. Industries. b. Or equal. 3.00 EXECUTION 3.01 INSPECTION A. Examine substrates and conditions under which fire protection specialties will be installed and notify ENGINEER in writing of conditions detrimental to proper and timely completion of the Work. Do not proceed with Work until unsatisfactory conditions have been corrected in manner acceptable to ENGINEER. 3.02 INSTALLATION OF FIRE EXTINGUISHERS A. When exact locations of fire protection specialties are not shown on Drawings, locate as directed by ENGINEER. B. Securely fasten products to structure, square and plumb, per Supplier’s instructions. Mounting heights shall be: 1. Install fire extinguishers with gross weight greater than 40 pounds with top of fire extinguisher no more than 3.5 feet above finished floor. 2. Install fire extinguishers with gross weight less than 40 pounds with top of fire extinguisher no more than 4.0 feet above finished floor. 3. Clearance between bottom of fire extinguisher and finished floor shall be at least four inches. C. Identification Devices: Provide signs level and plumb directly above surface mounted portable fire extinguishers, securely mounted, attached to substrate per sign manufacturer’s instructions. Signage shall be per Section 10 14 00, Signage. Fire Protection Specialties 10 44 00 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements D. Recharge fire extinguishers provided under this Contract so that most recent inspection date coincides as nearly as possible with date of Substantial Completion. Inform OWNER in writing of next required inspection and recharging date. END OF SECTION Lockers 10 51 00 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 10 51 00 LOCKERS 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish and install all locker Work. 2. Extent of lockers is shown. 3. Types of products required include the following: a. All welded, factory-assembled, heavy-duty single-tier metal lockers. b. Miscellaneous accessories, closures, identification labels and other components, trim and fasteners. B. Coordination: 1. Coordinate size and location of concrete bases. Concrete, reinforcement, and formwork requirements are specified in Section 03 30 00, Cast-in-Place Concrete. 2. Coordinate size and location of masonry bases. C. Related Sections: 1. Section 03 30 00, Cast-In-Place Concrete. 2. Section 04 05 05, Unit Masonry Construction. 1.02 REFERENCES A. Standards referenced in this Section are listed below: 1. American Society for Testing and Materials, (ASTM). a. ASTM A 666-1, Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate and Flat Bar. b. ASTM A 1008/A 1008M, Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability. 2. U.S. Architectural and Transportation Barriers Compliance Board. Americans with Disabilities Act (ADA), Accessibility Guidelines for Buildings and Facilities (ADAAG). Continual Revisions. 1.03 QUALITY ASSURANCE A. Provide metal lockers as complete units produced by a single manufacturer, including necessary mounting accessories, fittings, and fastenings. B. Color: 1. Provide locker units in color selected by ENGINEER from manufacturer's standard and custom colors. Minimum order requirements of the manufacturer shall not be acceptable cause by CONTRACTOR for rejection of ENGINEER'S color selection. 2. Unless otherwise shown, non-exposed surfaces may be manufacturer's standard neutral color as selected by ENGINEER. 3. Manufacturer's of "or equal" products shall be able to supply exactly the same C. Regulatory Requirements: Where metal lockers are indicated to comply with accessibility requirements, comply with Accessibility Guidelines for Buildings and Facilities (ADAAG) and the International Building Code. Lockers 10 51 00 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Shop Drawings: a. Shop Drawings for metal lockers, verifying dimensions affecting locker installations. Show lockers in detail, method of installation, fillers, trim, base and accessories. Include locker numbering sequence information. 2. Product Data: a. Copies of manufacturer's technical data, color charts, and installation instructions for the metal locker units. 3. Samples: Manufacturer's color charts showing the full range of colors available for units with factory-applied color finishes. a. For the following products, in manufacturer's standard sizes, showing the full range of color, texture, and pattern variations expected. Prepare Samples from the same material to be used for the Work. 1). Lockers. B. Closeout Submittals: Submit the following: 1. Warranty Documentation: Manufacturer's Warranty. 1.05 DELIVERY, STORAGE AND HANDLING A. Do not deliver metal lockers until building is enclosed and ready for their installation. Protect from damage during delivery, handling, storage, and installation. B. Deliver master keys, control keys, and combination control charts to OWNER. 1.06 PROJECT CONDITIONS A. Field Measurements: Verify the following by field measurements before fabrication and indicate measurement on Shop Drawings: 1. Concealed framing, blocking and reinforcements that support metal lockers before they are enclosed. 2. Recessed openings. 3. Masonry or concrete bases. 1.07 WARRANTY A. Provide manufacturer's ten year warranty against defects in materials and workmanship. 2.00 PRODUCTS 2.01 MATERIALS A. Cold-Rolled Steel Sheet: ASTM A 366/A 366M, matte finish, suitable for exposed applications, and stretcher leveled or roller leveled to stretcher-leveled flatness. B. Galvanized Steel Sheet: ASTM A 653/A 653M, commercial quality, G60 (Z180) coating designation; mill phosphatized; suitable for exposed applications, and stretcher leveled or roller leveled to stretcher-leveled flatness. C. Electrolytic Zinc-Coated Steel Sheet: ASTM A 591/A 591M, commercial quality, coating Class C; mill phosphatized; suitable for exposed applications; and stretcher leveled or roller leveled to stretcher-leveled flatness. Lockers 10 51 00 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements D. Stainless-Steel Sheet: ASTM A 666, Type 304, stretcher-leveled standard of flatness. Roller- apply texture to doors in manufacturer's standard pattern. E. Fasteners: Zinc- or nickel-plated steel, slotless-type exposed bolt heads, and self-locking nuts or lock washers for nuts on moving parts. 2.02 HEAVY DUTY LOCKER CONSTRUCTION A. Frames: Minimum 16 gage channels or 12 gage angles, with corners electrically welded to form a rigid one-piece structure. Form door stop at vertical members. B. Backs and Sides: Minimum 18 gage steel for backs; 16 gage steel for sides. Flange backs on vertical edges, and sides where they intermember with backs, making double-flanged rear corners. 1. Exposed ends of non-recessed lockers; minimum 16 gage steel. C. Tops, Bottoms and Shelves: Minimum 16 gage steel, flanged edges. D. Double Panel Doors: One-piece, formed solid doors with louvers top and bottom minimum 14 gage cold-rolled sheet steel with double bends on both sides and single bends on top and bottom and an 18-gage formed inner panel welded to outer door to form a reinforcing channel. Construct doors to prevent springing when opening or closing. Fabricate doors to swing 180 degrees. 1. Provide stamped louvered vents in door faces, as follows: a. For single-tier lockers, not less than six louver openings top and bottom. E. Door Hinges: Heavy-duty, not less than 16 gage steel, full-loop, continuous full length piano hinges. Weld hinges to inside of frame and secure to door with not less than two factory-installed fasteners, completely concealed and tamperproof when locker door is closed. F. Center Partition: Provide center partition in each 24-inch wide locker. G. Latching: Positive, automatic, pre-locking, pry-resistant latch and fully recessed latch with rubber bumpers riveted to door stops and heavy-duty, rigid non-moving 11 gage hasp containing strike and hole for padlock. 1. Provide stainless steel pan recessed into door containing no moving parts for through- the-door padlock. 2. Provide single point latch welded to door frame. H. Sizes: 1. Men’s Locker Room: 12-inches wide by 18-inches deep by 72-inches high. 2. Women’s Locker Room: 12-inches wide by 18-inches deep by 36-inches high. I. Products and Manufacturers: Provide one of the following: 1. All-Welded Lockers by Penco Products, Incorporated. 2. All-Welded Integrated Frame Lockers by Lyon Workplace Products. 3. Or equal. 2.03 ACCESSIBILTY LOCKERS A. Same construction and finish as regular lockers. B. Provide features and configurations to meet applicable accessibility codes. 2.04 FINISH Lockers 10 51 00 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. Chemically pretreat metal with degreasing and phosphatizing process. Electro-statically spray and bake enamel finish to all surfaces, exposed and concealed, except plates and non-ferrous metal. Provide manufacturer's full selection of standard and custom colors. 2.05 LOCKER ACCESSORIES A. Locking: Fabricate lockers to receive padlocks which shall be provided by OWNER. B. Equipment: Furnish each locker with the following accessories: 1. Single-Tier Units: Clothing rod, 7/8-inch diameter heavy chrome plated steel, three single-prong wall hooks, and shelf. C. Number Plates: Manufacturer's standard etched, embossed, or stamped, non-ferrous metal number plates with numerals not less than 3/8-inch high. Number the lockers in sequence as directed by ENGINEER. Attach plates to each locker door, near top, centered, with at least two stainless steel fasteners of the same finish as number plate. D. Continuous Closed Base: Minimum 16 gage cold-rolled steel, 4-inches high, fabricated to enclose base of lockers without additional fastening devices. Flange bottoms inward 3/4-inch for stiffening. Welded to locker bottom and factory- finished to match lockers. E. Continuously Sloping Tops: Manufacturer's standard, fabricated from minimum 20-gage steel sheet, for installation over lockers with separate flat tops. Fabricate tops in lengths as long as practicable, without visible fasteners at splice locations, finished to match lockers. Provide vertical end closures. F. Trim: Provide fill-in-panels, solid end panels and recessed trim consisting of 16 gage minimum cold-rolled steel, as necessary, to provide complete and finished installation. Factory-finish trim to match lockers. Secure trim to lockers with concealed fastening clips. Provide recessing trim on all top and sides as required for a complete and finished installation. 2.06 FABRICATION A. Construction: Provide all seams and joints including sides, back, top and bottom and hinges and shelves of welded construction. Bolts, screws or pop rivets are not approved. Fabricate lockers square, rigid, and without warp, with metal faces flat and free of dents or distortion. Make all exposed metal edges and welds safe to the touch. 3.00 EXECUTION 3.01 INSPECTION A. CONTRACTOR and his installer must examine the areas and conditions under which locker Work is to be installed and notify ENGINEER, in writing, of conditions detrimental to the proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions have been corrected in a manner acceptable to ENGINEER. 3.02 INSTALLATION A. Install metal lockers at the locations shown in accordance with the manufacturer's instructions for a plumb, level, rigid, and flush installation. B. Space fastenings about 48-inch on centers and apply through back-up reinforcing plates where necessary to prevent metal distortion. Conceal all fasteners. C. Install trim, to provide a flush, hairline joint against adjacent surfaces. Install with concealed fasteners. Lockers 10 51 00 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements D. Touch-up marred finishes or replace if not acceptable to ENGINEER. Use only materials and finishes as recommended or furnished by the locker manufacturer. E. Adjust doors and latches to operate easily without bind. Verify satisfactory operation of integral locking devices. END OF SECTION Window Blinds 12 21 00 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 12 21 00 WINDOW BLINDS 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment, and incidentals as shown, specified, and required to furnish and install all window blind Work. 2. Extent of window blind units is shown. 3. Types of products required include the following: a. Manually-operated horizontal window blinds. b. Miscellaneous accessories and materials. B. Coordination: 1. Review installation procedures under this and other Sections and coordinate with the Work of this Section. 2. Provide inserts and anchoring devices to be set in concrete or built into masonry and gypsum wallboard for installation of window blinds. Coordinate delivery with other work to avoid delay. 3. Refer to concrete and masonry Sections of the Specifications for installation of inserts and anchorage devices. Section 04 05 05, Unit Masonry Construction; and Section 09 21 16, Gypsum Wallboard Assemblies. C. Related Sections: 1. Section 04 05 05, Unit Masonry Construction. 2. Section 09 21 16, Gypsum Wallboard Assemblies. 1.02 REFERENCES A. Standards referenced in this Section are: 1. GANA, Glazing Manual. 2. NFPA 701, Methods of Fire Tests for Flame Propagation of Textiles and Films. 3. WCMA A100.1, American National Standard for Safety of Corded Window Covering Products. 1.03 QUALITY ASSURANCE A. Component Supply and Compatibility: 1. Provide all window blinds of each type of blinds required as complete units produced by one manufacturer, including hardware, accessory items, mounting brackets, and fastenings. 1.04 SUBMITTALS Window Blinds 12 21 00 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. Action Submittals: Submit the following: 1. Shop Drawings: a. Shop Drawings for special window blind components THAT are not fully dimensioned or detailed on manufacturer's product data. Include elevation layout indicating proposed division between window blind units and meeting edges at corners. b. Coordinated drawings showing required clearances to window obstructions and other obstructions that would interfere with window blind operation. Coordinate pocket size and mounting with manufacturer's proposed products and show details and all dimensions on Shop Drawings. c. Data sheets for window blinds proposed for use. 2. Product Data: a. Manufacturer's published literature, catalog sheets, and specifications for each type of window blind proposed for use. 3. Samples: a. Submit six-inch Samples of window blinds in all standard colors for selection by ENGINEER. b. ENGINEER's review of Samples will be for color and texture only. Compliance with other requirements of the Contract Documents is CONTRACTOR's responsibility. B. Informational Submittals: Submit the following: 1. Certificates: a. Manufacturer's certification of compliance with specified requirements for recycled louver material. C. Closeout Submittals: Submit the following: 1. Operations and Maintenance Data: Submit window blinds operations and maintenance manuals in accordance with Section 01 78 23, Operations and Maintenance Data. D. Maintenance Material Submittals: Submit the following: 1. Extra Stock Materials: Furnish extra materials, from the same product run as the materials furnished and installed, that match the materials installed and that are packaged with protective covering for storage and identified with labels describing contents. a. Window Blinds: Full-size units equal to five percent of the quantity installed for each size, color, texture, pattern, and gloss installed, but no fewer than one unit of each size, color, texture, pattern, abnd gloss. 1.05 DELIVERY, STORAGE, AND HANDLING A. Packing, Shipping, Handling, and Unloading: 1. Deliver window blinds in factory packaging, marked with manufacturer, product name, and installation location using same designations indicated on the Drawings. Window Blinds 12 21 00 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1.06 FIELD CONDITIONS A. Environmental Limitations: Do not install window blinds until construction and wet and finish work in spaces, including painting, is complete and dry and ambient temperature and humidity conditions are maintained at the levels indicated for the Project when occupied for its intended use. B. Field Measurements: Where window blinds are indicated to fit to other construction, verify dimensions of other construction by field measurements before fabrication and indicate measurements on Shop Drawings. Allow clearances for operating hardware of operable glazed units through entire operating range. Advise ENGINEER in writing of installation conditions that vary from those required in the Contract Documents. 2.00 PRODUCTS 2.01 MATERIALS A. Horizontal Window Blinds: 1. Products and Manufacturers: Provide one of the following: a. Riviera 1/2-inch Mini-Blinds, by Levolor Window Fashions, a Newell Rubbermaid Company. b. Décor 1/2-inch Solids Mini-Blinds, by Hunter Douglas Contract, Hunter Douglas, Inc. c. Or equal. 2. Head Channel: 0.025-inch thick tomized steel, U-shaped one-inch high by 1-9/16-inch wide with flanged edges at top, and coated with a baked-on finish. All hardware shall be enclosed in the metal head. 3. Tilter: 0.042-inch tomized steel with automatically disengaging worm and gear mechanism to eliminate overdrive and prevent strain or damage to window blinds. 4. Tilt Wand: Transparent with hexagonal cross section of 5/16-inch across flats. 5. Drum and Cradle: One for each window blind ladder as follows: a. Drum shall be 0.031-inch tomized steel having two holes with rolled edges to anchor barbs on both ladder ends. b. Cradles shall be 0.042-inch thick tomized steel, having two holes with rolled edges to guide cords through bottom of head channel without abrasion. 6. Tilt Rod: U-shaped with a circular radius of approximately 1/8-inch designed to achieve minimum torsional deflection. For window blinds greater than five feet wide and less than 6.67 feet long, or greater than 4.583 feet wide and greater than 6.67 feet long tilt rod shall be a solid D-shaped rod with an average cross section of 1/4-inch designed to achieve minimum torsional deflection. 7. End Braces: 0.037-inch thick tomized steel with reinforcing ribs and field adjustable tabs. 8. Installation Brackets: Provide brackets with a rivet-hinged safety locking front cover not less than 0.048-inch thick tomized steel with baked-on finish matching head channel. Window Blinds 12 21 00 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 9. Intermediate Brackets: 0.050-inch tomized steel installed with window blinds greater than five feet wide and less than 6.67 feet long, or greater than 4.583 feet wide and greater than 6.67 feet long. 10. Ladders (slat supports): Braided polyester yarn designed from maximum strength and flexibility combined with minimum stretch. Rungs shall consist of not less than two crossed cables interbraided with the vertical components. Ladders shall support the slats without visible distortion. Distance between ladders shall not exceed two feet for window blinds up to 6.67 feet long. For window blinds over 6.67 feet long, distance between ladders shall be not greater than 22 inches. 11. Slats: Virgin high magnesium aluminum, alloyed for maximum strength and corrosion resistance. Slats shall be nominally eight-gage, 1/2-inch wide with an elliptical crown formed after coating and curing. Slat ladder support distances shall prevent visible sag or bow after continued use indoors. Slats shall be unperforated. 12. Bottom Rail: 0.031-inch tomized steel formed after coating provided with color-compatible molded plastic ladder and end caps. 13. Lift Cord: Braided of high-strength flexible polyester fiber cord with minimum stretch and maximum abrasion resistance characteristics. Cord shall be of sufficient length, equalized to properly control raising and lowering of window blinds and spaced not more than 3.83 feet between cords. 14. Colors: Complete selection of manufacturer's standard colors. ENGINEER will select a maximum of three colors for the Work. 15. Accessories: Provide the following: a. Pocket installation brackets. b. Projection brackets to clear window hardware. c. Two-tone slats with neutral white on outside face. 2.02 FABRICATION AND OPERATION A. Product Safety Standard: Fabricate vertical louver blinds to comply with WCMA A100.1 including requirements for corded, flexible, looped devices; lead content of components; and warning labels. B. Prior to fabrication, verify actual opening dimensions by accurate Site measurements. Adjust dimensions for proper fit at all openings. C. Fabricate components of window blinds from non-corrosive, non-staining, non-fading materials which are compatible with each other, and which do not require lubrication during normal expected life. Use dissimilar metals or plastics for contact surfaces which slide against each other in operation of window blinds. D. Fabricate window blind units to completely fill the openings as shown, from head-to-sill and jamb-to-jamb. For continuous window wall installations, fabricate window blinds so that ends occur only at mullions or other defined vertical separations, unless otherwise shown. Window Blinds 12 21 00 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements E. Gear all operating equipment for reduction of the ratio of hand-movement to window blind-movement, so that window blinds operate easily and can be set accurately and smoothly. F. Concealed Components: 1. Noncorrodible or corrosion-resistant-coated materials. 2. Rotation-and-Traverse Mechanisms: With permanently lubricated moving parts. G. Installation Brackets: Constructed for easy removal and reinstallation of blind, for supporting headrail and operating hardware and for bracket positions and blind mounting method indicated. H. Installation Fasteners: Not less than two fasteners per bracket, fabricated from metal noncorrosive to brackets and adjoining construction; type designed for securing to supporting substrate; and supporting blinds and accessories under conditions of normal use. I. Color-Coated Finish: For metal components exposed to view unless anodized or plated finish is indicated. Apply manufacturer's standard baked finish complying with manufacturer's written instructions for surface preparation including pretreatment, application, baking, and minimum dry film thickness. 3.00 EXECUTION 3.01 INSPECTION A. Examine the substrates and conditions under which the window blinds Work will be installed and notify ENGINEER, in writing, of conditions detrimental to the proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions are corrected. 3.02 INSTALLATION A. General: 1. Install window blinds where shown and in accordance with manufacturer's instructions. Position units plumb and true, securely anchored in place with proper clips, brackets, and bolts for the type of mounting required. 2. Locate so exterior vane edges are not closer than two inches from interior faces of glass and not closer than 1.5 inches from interior faces of glazing frames through full operating ranges of blinds, in accordance with GANA Glazing Manual. 3. Install mounting and intermediate brackets to prevent deflection of headrails. 4. Install with clearances that prevent interference with adjacent blinds, adjacent construction, and operating hardware of glazed openings, other window treatments, and similar building components and furnishings. B. Divisions between window blinds are allowed only at mullions of continuous windows or openings where more than one window blind for one opening occurs. 3.03 ADJUSTING Window Blinds 12 21 00 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. Adjust window blinds to operate free of binding and malfunction through full operating ranges. 3.04 CLEANING AND PROTECTION A. Prior to Substantial Completion, clean window blind surfaces in accordance with manufacturer's written instructions. B. Provide final protection and maintain conditions in a manner acceptable to manufacturer and that ensures that window blinds are without damage or deterioration at Substantial Completion. C. Prior to Substantial Completion, replace damaged window blinds that cannot be acceptably repaired. END OF SECTION Facility Fire-Suppression Water-Service Piping 21 11 00 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 21 11 00 FACILITY FIRE-SUPPRESSION WATER-SERVICE PIPING 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install pipes, valves, and fittings normally encountered in fire protection systems, to provide complete and operating systems. 1.02 QUALITY ASSURANCE A. Installer’s Qualifications: 1. The installer shall be a qualified fire protection contractor, licensed by the State of Texas, Commission on Fire Prevention and Fire Marshall’s office. 2. The contractor shall have a minimum of 5 years experience in the design and installation of fire suppression systems similar to this project. Submit a list of 10 projects including references, names and telephone numbers of successfully completed projects similar to the project. 3. Welders shall meet the requirements of AWS D10.9, Level AR.3. B. Plan Review: 1. Submit complete fire protection design documents to the City of Denton, Texas, Fire Prevention Bureau for review and approval. 2. Submit complete fire protection design documents to the State of Texas, Fire Marshal’s office for review. Provide a letter to the Architect/Engineer indicating that documents have been reviewed by the Authority Having Jurisdiction (AHJ). Document remarks, indicating the names of reviewers and dates, or provide a copy of approvals. C. Source of Materials: 1. Provide products from domestic manufacturers who are regularly engaged in the production and manufacture of such equipment. 2. Valves shall be the U.L. listed and F.M. approved with the label or marking, including the pressure rating marked on the valve body. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Pipe installation shop drawings, and hydraulic calculations. 2. Identification of manufacturer and model number for all proposed material. 3. Pipe materials proposed, jointing methods, supports, floor and wall penetration seals. 4. Valve data and ratings. 5. Certification of material compliance with all listed industry standards. Facility Fire-Suppression Water-Service Piping 21 11 00 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. International Fire Code (IFC), latest edition with any local city amendments. 2. American National Standards Institute (ANSI)/American Society of Mechanical Engineers (ASME) Standards: ANSI/ASME B15.4 Cast-iron Threaded Fittings, Class 125 and 250 ANSI/ASME B15.9 Factory-made Wrought Steel Buttwelded Fittings ANSI/ASME B16.1 Cast-iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250 and 800 ANSI/ASME B16.3 Malleable Iron Threaded Fittings, Class 150 and 300 ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings ANSI/ASME B16.11 Forged Steel Fittings, Socket-welding and Threaded ANSI/ASME B16.18 Cast Copper Alloy Solder-Joint Pressure Fittings ANSI/ASME B16.22 Wrought Copper and Copper Alloy Solder Joint Pressure Fittings ANSI/ASME B16.25 Buttwelding Ends ANSI/ASME Sec. 9 Welding and Brazing Qualifications 3. American National Standards Institute (ANSI)/American Society of Testing and Materials (ASTM) Standards: ANSI/ASTM A 47 Malleable Iron Castings ANSI/ASTM A135 Electric Resistance-welded Steel Pipe ANSI/ASTM A234 Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures ANSI/ASTM B32 Solder Metal ANSI/ASTM B36.10 Welded and Seamless Wrought Steel Pipe ANSI/ASTM A795 Specification for Black and Hot-Dipped, Zinc-Coated, (Galvanized) Welded and Seamless Steel Pipe for Fire Protection Use ANSI/ASTM B75 Specification for Seamless Copper Tube ANSI/ASTM B88 Specification for Seamless Copper Water Tube 4. American National Standards Institute (ANSI)/American Welding Society (AWS) Codes: ANSI/AWS A5.8 Brazing Filler Metal ANSI/AWS D10.9 Specifications for Qualification of Welding Procedures and Welders for Piping and Tubing Facility Fire-Suppression Water-Service Piping 21 11 00 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 5. American National Standards Institute (ANSI)/American Water Works Association Standards: ANSI/AWWA C110 Ductile Iron and Gray Iron Fittings ANSI/AWWA C151 Ductile Iron Pipe, Centrifugally Cast ANSI/AWWA C606 Grooved and Shouldered Joints 6. American Society of Testing and Materials (ASTM) Standards: ASTM A53 Pipe, Steel, Black, and Hot-dipped, Zinc-coated Welded and Seamless ASTM B251 General Requirements for Wrought Seamless Copper and Copper Alloy Tube ASTM A536 Grooved Couplings and Fittings 7. National Fire Protection Association (NFPA) Publications: NFPA 13 Standard for the Installation of Sprinkler Systems NFPA 26 Supervision of Water Supply Valves NFPA 1961 Fire Hose NFPA 1963 Fire Hose Connection Threads NFPA 291 Recommended Practice for Fire Flow Testing and Marking of Hydrants 1.05 JOB CONDITIONS A. The fire protection system piping shall include the piping, all valves, piping, hangers, and other necessary appurtenances for a complete and operable piping system. 2.00 PRODUCTS 2.01 PIPE AND FITTINGS A. Pipe Fittings Above Grade: 1. Ferrous pipe (welded and seamless): a. Black steel pipe (for fire protection use) (ASTM A795, ANSI/ASTM A53), wrought steel pipe (ANSI B36.10M), electric resistance welded pipe (ASTM A135); rolled grooved steel pipe (ASTM A135 or A 53). b. Ferrous fittings, cast-iron threaded, Class 125 (ANSI B16.4) cast-iron flanged (ANSI B16.1); malleable iron threaded fittings (Class 125) (ANSI B16.3); factory wrought steel, buttweld (ANSI B16.9), (ANSI B16.25); forged steel, socket welded or threaded (ANSI B16.11); rigid radius grooved systems (AWWA C606) 250 psig. 2. Copper pipe and tube (drawn, seamless): a. Seamless, (ASTM B75/B 88); wrought seamless copper and copper alloy tube (ASTM B251) brazed joints (AWS A5.8 Class BCuP-3 or BCuP-4. Solder metal 95-5 tin antimony, grade 95 TA (ASTM B32). Facility Fire-Suppression Water-Service Piping 21 11 00 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements Copper fittings; wrought copper and bronze solder-joint pressure fittings (ANSI B16.22); cast bronze solder-joint pressure fittings (ANSI B16.18). 2.02 VALVES, GENERAL PURPOSE A. Gate Valves: 1. Above ground valves; 2-1/2 inches and larger, cast-iron, rising stem, outside screw and yoke, 175 psig (ASTM A126, Class B), one-piece yoke bonnet, bronze yoke bushings, solid wedge discs, bronze for 3-1/2 inch and smaller valves, cast-iron with bronze disc ring above 3-1/2 inch pipe size, flanged 2 inches and smaller, bronze body, rising stem, outside screw and yoke, 175 psig, threaded outlet (ANSI/ASME B1.20.1). Acceptable manufacturers: Stockham, Clow, Central and Nibco. 2. Indicator Posts: Vertical-type, cast-iron body with operating wrench, extension rod, and adjustable cast-iron barrel of length required for depth of burial of valve. UL 789 and FM Global, listing. Acceptable Manufacturers: Kennedy, Meuller, Clow, and Nibco. B. Butterfly Valves: 1. General: Wafer-type valves with components that extend beyond the valve body shall be installed in a manner that does not interfere with the operation of any system component. 2. Slow-close, UL listed/FM approved outside indicating style, ductile iron body with EPDM rubber molded or polymid finish, and cast-iron disc, EPDM coated, grooved, or wafer style ends. Integral supervised open, double pole single throw supervisory tamper switch. Acceptable manufacturers and models: Central, Model A-BFV; Victaulic, Series 708; Grinnell, GRUVLOK. C. Ball Valves: For water shut-off: 1. Ball valves 2 inches and less: Rated 175-lb. minimum water, oil, air and gas pressure, brass or bronze construction, seat material as recommended by manufacturer for material conveying, lever handle, threaded or soldered connections. Throttling valves shall be provided with memory stops. Acceptable manufacturers and models: Crane, 9302, 9322; ITT Grinnell, 3500, 3500SJ; Milwaukee, BA-200, BA-250; Watts, B-6000, B- 6001; Nibco, T-580, S-580. D. Ball Valves: UL listed/FM approved, supervised bronze body, (ASTM B584) 300 psi non- shock, full port, design up to 2 inches, standard port in 2-1/2 inch sizes. Cast bronze ball (ASTM B584) coated wheel handle, with factory mounted internal tamper switch, grooved or threaded. Acceptable manufacturers: Watts, Nibco, Victaulic and Stockham. E. Globe Valves: For trim and drain use, UL listed/FM approved, 175 psig, bronze body (ASTM B62) graphite impregnated packing, bronze packing nut, threaded. Acceptable manufacturers: Watts, Nibco, Crane, Grinnell, Stockham and United. F. Check Valves: 1. Swing check: 2-1/2 inches and smaller, horizontal swing, renewable disc, bronze body (ASTM B62) rubber (TFE) seat disc, threaded outlet. Acceptable manufacturers: Watts, Nibco and Stockham. Facility Fire-Suppression Water-Service Piping 21 11 00 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2. Lift check: 2-1/2 inches and smaller, 250 psig non-shock inline lift type, bronze body (ASTM B584) stainless steel seam (ASTM B582) 316 stainless steel spring, Buna-N rubber disc, TFE seat ring, threaded outlet. Acceptable manufacturers: Nibco, Crane, Victaulic, Grinnell and United. 3. Wafer Check: For all sizes, 250 psig, UL listed/FM approved, cast-iron body, stainless steel clapper assembly resilient elastomer seal, non-shock enamel finish. Acceptable manufacturers: Viking, Grinnell, Central and United. G. Hose Outlet Angle Globe Valve: Fire hose valve 300 psig, UL listed/FM approved bronze body (ASTM B62) hose outlet (7.5 threads/inch) with threaded cap and chain, rising stem, screw-in bonnet, renewable disc, 2-1/2 to 1-1/2 inch hose thread adapter. Acceptable manufacturers: Nibco, Grinnell and Crane. H. Hose Outlet Valves, Pressure Reducing: Fire hose valve, UL listed cast brass, inside screw and yoke, angle hose end (male hose thread), pressure regulating valve with monitor switch adapter, indicator bonnet, 400 psig inlet pressure. Acceptable manufacturers: Potter Roemer, Inc., Elkhart and Moon/Allenco. I. Fire Department Siamese Connections (FDC): 1. Flush Siamese FDC: UL listed/FM approved polished chrome plated brass, straight body; two separate drop clapper valves, plugs and chains, 2-1/2 inches by 2-1/2 inches by 4 inches. Automatic ball drip drain, escutcheon with integral raised lettering, “auto spkr”. Acceptable manufacturers and models: Elkhart, 166; Potter Roemer, 5020; and Allenco, 276. 2. Free Standing, Siamese FDC: UL listed/FM approved, two-way cast brass body, polished chrome finish or rough chrome finish. 4 inches by 2-1/2 inches seamless cover sleeve, identification base plate. Lettering on escutcheon: “auto spkr”. Acceptable manufacturers: Elkhart, Potter, Roemer and Allenco. 2.03 HOSE, RACKS, REELS, CABINETS A. Hose Rack Assembly (Class III Service): UL listed/FM approved; semi-automatic hose rack for folded hose storage with water retention device and combination nozzle clip for one man operation, welded steel cover, red polyester coating. 1-1/2-inch, 100-ft., 500-lb. test (300- lb. U.L.) 100 percent synthetic jacket with extruded polyester lining. Acceptable manufacturers: Potter Roemer, Allenco/Moon and Elkhart. B. Fire Hose Cabinet, Fully Recessed: 20 gauge white polyester coated steel box, anodized aluminum panels with spring clips, extruded door and frame with satin finish, all seams and corners mitered, no visible assembly screws. Full glass (tempered) panel. 3.00 EXECUTION 3.01 PREPARATION A. Ream pipe and tube ends to full inside diameter. B. Remove burrs and bevel plain end ferrous pipe. C. Remove scale and foreign material, inside and outside, before assembly. Facility Fire-Suppression Water-Service Piping 21 11 00 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 3.02 PIPE INSTALLATION A. Install piping in accordance with NFPA 13 and NFPA 24 for sprinkler systems and NFPA 14 for standpipe and hose systems. B. Route piping in an orderly manner, plumb and parallel to the building structure. Maintain gradient. C. Install piping to conserve building space and not interfere with use of space and other work. D. Group piping whenever practical at common elevations. E. Install piping to allow for expansion and contraction without stressing the pipe, joints, or connected equipment. F. Slope piping and arrange systems to drain at low points. G. Die cut screw joints with full cut standard taper pipe threads with approved non-toxic joint compound applied to male threads only. H. In steel piping, main sized saddle branch connections or direct connection of branch lines to the mains will be permitted if the main is one pipe size larger than the branch line for up to 6-inch diameter mains and if the main is two pipe sizes larger than the branch for 8-inch and larger mains. Do not project branch pipes inside the main. I. Do not penetrate building structural members unless indicated to do so or without the specific approval of the Engineer. When cutting is approved, the actual size of holes shall be no larger than the diameter of the pipe plus 1/2-inch clearance. J. Provide sleeves when penetrating floors and walls. K. Seal pipe and sleeve penetration to achieve fire resistance equivalent to rating of the wall or floor penetrated. L. Prepare pipe, fittings, supports, and accessories for finish painting. Where pipe support members are welded to structural building framing, scrape, brush clean, and apply one coat of zinc rich primer to welding. Color shall be Red. M. On main water supply piping below grade, install steel rod pipe clamps at the 90 degree bend from horizontal to vertical riser. Provide approved thrust restraint systems. N. Support horizontal piping from the structure using ferrous pipe hangers for ferrous pipe and copper hangers for copper pipe and all-thread steel rods (or brass for copper). Provide pipe hangers capable of supporting five times the weight of the water-filled piping plus 250 pounds. The maximum spacing of hangers shall be not greater than 10 feet for pipe sizes up to 1-1/4 inches and 12 feet for larger pipe sizes. Supports for non-metallic pipe shall be in accordance with the manufacturer’s requirements. O. Support risers at the ground level and not less than each second floor in multi-floor installations. P. Inspector’s test piping shall not be less than 1-inch diameter and each location shall be equipped with a globe valve. 3.03 VALVE INSTALLATION A. Install valves with stems upright or horizontal, not inverted. Facility Fire-Suppression Water-Service Piping 21 11 00 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements B. Provide gate valves or butterfly valves for shut-off or isolating service. C. Provide drain valves at main shut-off valves and at low points of piping and apparatus. 3.04 FIELD QUALITY CONTROL A. Perform testing required by NFPA 13 and regulatory authorities. Include the cost of such testing in the proposal. B. Hydrostatically test fire systems at not less than 200 psig for 2 hours, or at 50 psig in excess of the maximum static pressure when the static pressure exceeds 215 psig. Measure hydrostatic pressure at the low point of the system being tested. C. Prepare a Material and Test Certificate, in accordance with NFPA 13. Obtain certificates of approval from regulatory authorities. Submit certificates in the final submittal data to the Engineer. END OF SECTION Facility Fire Hydrants 21 11 16 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 21 11 16 FACILITY FIRE HYDRANTS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install fire hydrant and appurtenances, operators, bolts, nuts and gaskets. 1.02 QUALITY ASSURANCE A. Acceptable Manufacturers: 1. Contact Client for acceptable manufacturers. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedure” and shall include: 1. If requested, the fire hydrant manufacturer shall submit with the shop drawings a list of similar installations which have been in satisfactory operation for at least 3 years. 2. Certification of Compliance with AWWA C502 as record data. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American National Standards Institute (ANSI) Standards: ANSI B16 Cast Iron Pipe Flanges and Flanged Fittings 2. American Society for Testing and Materials (ASTM) Standards: ASTM A126 Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings ASTM A536 Standard Specification for Ductile Iron Castings ASTM D2000 Classification System for Rubber Products in Automotive Applications ASTM A307 Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength 3. American Water Works Association (AWWA) Standards: AWWA C111 Rubber-Gasket Joints AWWA C502 Dry-Barrel Fire Hydrants Facility Fire Hydrants 21 11 16 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2.00 PRODUCTS 2.01 FIRE HYDRANTS A. General: Fire hydrants to be installed as shown on the plans or furnished for general installation shall be dry-barrel, traffic model conforming to AWWA Standard for Dry-Barrel Fire Hydrants, AWWA Standard C502. B. Supplementary Details: 1. Type of Shut-Off: Contact Client for standards. Valve action shall provide positive shutoff at minimum closing torque. Wedge action closing gates shall not be permitted. Scissor type main valves shall not be permitted unless approved by the Owner’s Representative. 2. Inlet Connection: Mechanical joint unless otherwise specified. Inlet connection shall be for a 6-inch cast iron pipe with minimum net valve opening of 5-1/4 inches unless otherwise specified. 3. Delivery Classification: Number and size of pumper and hose nozzles shall be client’s standard. 4. Bury Length: Ground to bottom of connection pipe shall be 4 feet, or as specified by the Owner’s Representative. 5. Harnessing Lugs: Furnished with the hydrants. 6. Nozzle Cap Gasket: Furnished on all nozzle caps; long life; black rubber; conforming to Rubber Products in Automotive Applications ASTM D2000 or equal. 7. Drain Valve and Outlet: Hydrants shall be equipped with two drainholes and provided with an automatic and positively operating, noncorroding drain or dip valve so as to drain the hydrant completely when the main valve is shut. 8. Direction to Open: Shall be Client Standard. The number of turns to open shall be in accordance with AWWA C502, Section 2.9.3. 9. Color of Finish Paint Above Ground Line: After placement, the outside of the hydrant above the finished ground line shall be thoroughly cleaned and painted with two coats of paint in accordance with Client Standards. 10. Operating and Cap Nuts: Shall be Client’s standard. C. Breakable Type Hydrants: 1. Breakable or Sleeve Type Couplings: The barrel of the hydrant between the elbow and the top cap shall be made in two parts connected by a swivel flange or breakable flange which shall permit facing of the nozzles in any desired direction in increments of 45 degrees or less. The complete hydrant shall be of such design that when the hydrant barrel is broken through traffic collision or otherwise, it may be replaced without disturbing the bottom of the hydrant. a. The materials used for gaskets between the upper and lower barrels and the base and nozzle section shall be compounded to conform to ASTM D2000. Facility Fire Hydrants 21 11 16 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements b. Provision shall be made in the design of the stem to disconnect the stem from the hydrant parts above the standpipe break point in the event of traffic accidents. If breakable or sleeve type couplings are used, they shall have sufficient torsional strength so that a torsional failure of the stem shall occur at some point other than at the coupling. Design of the coupling shall be such that when the coupling is broken, no parts shall come loose and fall into the hydrant barrel, and the break shall not occur through the pins or bolts holding the coupling to the stem. D. Main Valve Seats: Designed so that incorrect positioning is impossible. E. Gaskets - Ground Line: The valve body flange gaskets shall be fabricated from “Accopac” CS- 301 manufactured by Armstrong Cork Company or an equal approved by Owner’s Representative prior to substitution. They shall be full face or ring type with the lower flange recessed to hold the gasket in place. F. Nozzle Cap Chains: In accordance with AWWA C502, Section 3.2.8.2. G. Flanges: All flanges other than break flanges shall be equipped with mechanical joints. Gland bolts shall be high-strength, low-alloy, corrosion-resistant steel conforming to ASTM A325, Type 3. H. Operating Stems: The spindle of the operating stem and the stem nuts for hydrants having the operating threads located in the barrel or waterway shall be manganese bronze, Everdur or other high quality noncorrodible metal. Barrel bolts and nuts shall meet the requirements of ASTM A307. I. All working parts in the waterway, except for sliding stem support mechanisms, shall be bronze-to-bronze or bronze-to-iron. J. O-Ring: Hydrant stem packing boxes shall be provided with O-ring grooves and sealed with O-rings. O-rings shall be furnished in lieu of stem packing. They shall be of the double O- ring type designed so that the rubber rings shall move against a bronze, stainless steel or other noncorrodible metal surface. O-ring shall be in accordance with ASTM D2000. K. Extensions: Fire hydrants shall be designed to accept 6-inch, 12-inch, or 18-inch extension. L. Hydrant Heads: Nozzle may be faced in any desired direction. M. Upperstem Thread Lubrication: Upperstem thread lubrication may be accomplished with oil or grease. When oil is used, it shall be in conjunction with a functional oil reservoir and an oil filler port. The hydrant shall be factory filled with a USP white mineral oil such as Lubriplate No. 3-V (SAE 20), Mobile Whiterex 425 or equal. Means for field check of oil lubrication level shall be provided. When grease is used, the hydrant shall be factory lubricated with a food grade grease such as Libriplate No. 630-AA (medium soft) or equal. Means for field lubrication without disassembly shall be provided. 3.00 EXECUTION 3.01 INSTALLATION A. Install hydrants at the locations shown on the Plans or as directed by the Owner’s Representative. Set hydrants truly vertical and securely brace with concrete until self- standing. Surround hydrants with a minimum of 7 cubic feet of washed gravel or stone. Facility Fire Hydrants 21 11 16 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements B. Install fire hydrants using special mechanical joint anchoring fittings. Install a flanged by MJ gate valve in accordance, on the main line tee. 1. Wrap and protect the gate valve, including bolts at joints, and the bottom of the fire hydrant with 3-mil. polyvinyl to prevent direct contact with concrete blocking. 3.02 FIELD QUALITY CONTROL A. Upon completion of installation of the equipment, conduct an acceptance test to verify the satisfactory operation of each unit. The test shall be conducted in a manner approved by and in the presence of the Owner’s Representative. Check the unit for general operation and leakage. The unit shall perform in a manner acceptable to the Owner’s Representative before final acceptance is made by the Owner. 3.03 SCHEDULES A. Paint the fire hydrants to conform to the Owner’s color coding. END OF SECTION Wet-Pipe Sprinkler Systems 21 13 13 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 21 13 13 WET-PIPE SPRINKLER SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to design and install a complete wet-pipe sprinkler system. Piping shall be in accordance with Section 21 11 00 “Facility Fire-Suppression Water-Service Piping.” 1.02 QUALITY ASSURANCE A. Installer’s Qualifications: 1. The installer shall be a qualified fire protection contractor, licensed by the State of Texas, Commission on Fire Prevention and Fire Marshall’s office. 2. The installer shall have a minimum of 5 years’ experience in the design and installation of fire suppression systems similar to this project. Submit a list of 10 projects including references, names and telephone numbers of successfully completed projects similar to the project. B. Plan Review: 1. Submit complete fire protection design documents to the City of Denton, Texas, Fire Prevention Bureau for review and approval. 2. Submit complete fire protection design documents to the Authority Having Jurisdiction (AHJ) for review. Provide a letter to the Architect/Engineer indicating that documents have been reviewed by the AHJ in the submittal process. Document remarks, indicating the names of reviewers and dates, or provide a copy of approvals. C. Water Pressure: Available water pressures and fire flow residual pressure information shall be obtained by the contractor in accordance with NFPA 291 “Fire Flow Testing and Marking of Fire Hydrants” prior to performing hydraulic calculations or design. D. Industry Approvals: Fire protection equipment and components shall be UL/FM listed, and bear the UL and FM label or marking. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Design data and calculations. 2. Shop Drawings. 3. Specifications and product data for all equipment. 4. Copies of approvals from the City authority having jurisdiction. 5. Certification of testing and acceptance. 6. Operation and Maintenance Manuals. a. Submit operation and maintenance manuals for approval. Wet-Pipe Sprinkler Systems 21 13 13 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements b. Include written maintenance data on components of system, servicing requirements, and record drawings. c. Provide typed instructions relative to the sprinkler controls. Encase instructions in metal frame with glass or lucite cover and mount as instructed. B. Prepare record drawings which include a set of shop drawings approved by the proper agencies and red-marked to show any revisions made at the job site. Include certificates of approval for the system, issued by the regulatory agencies, or as required by this Section. 1.04 HYDRAULIC CALCULATIONS A. Hydraulic calculations shall be as outlined in NFPA 13 except that calculations shall be performed by computer using software specifically designed for fire protection system design. Software which uses k-factors for typical branch lines is not acceptable. Calculations shall be taken back to the water supply source unless water supply data is otherwise indicated. Calculations shall be substantiate that the design area indicated is the hydraulically most demanding. Water supply curves and system requirements shall be plotted on semi-logarithmic graph paper so as to present a summary of the complete hydraulic calculation. A summary sheet listing sprinklers in the design area and their respective hydraulic reference points, elevations, actual discharge pressures and actual flows shall be provided. Elevations of hydraulic reference points (nodes) shall be indicated. Documentation shall identify each pipe individually and the nodes connected thereto. The diameter, length, flow, velocity, friction loss, number and type fittings, total friction loss in the pipe, equivalent pipe length and Hazen-Williams coefficient shall be indicated for each pipe. For gridded systems, calculations shall show peaking of demand area friction loss to verify that the hydraulically most demanding area is being used. Also for gridded systems, a flow diagram indicating the quantity and direction of flows shall be included. A drawing showing hydraulic reference points (nodes) and pipe designations used in the calculations shall be included and shall be independent of shop drawings. 1.05 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. International Fire Code (IFC), latest edition with any local city amendments. 2. National Fire Protection Association (NFPA) Publications: NFPA 13 Standard for the Installation of Sprinkler Systems NFPA 25 Inspection, Testing and Maintenance of Water Based Fire Protection Systems NFPA 26 Supervision of Valves Controlling Water Supplies NFPA 70 National Electrical Code NFPA 72 National Fire Alarm Code NFPA 291 Recommended Practice for Fire Flow Testing and Marking of Hydrants Wet-Pipe Sprinkler Systems 21 13 13 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1.06 DELIVERY AND STORAGE A. Handle materials carefully so that they are protected from damage. Store sprinkler heads, valves, and alarms inside storage buildings. 1.07 JOB CONDITIONS A. The fire protection system shall include the fire main to the building, main riser, all valves, system alarms, piping, hangers, and detectors, conduit, wiring, panels and other appurtenances necessary for an approved complete and operable system. 2.00 PRODUCTS 2.01 MATERIALS A. Sprinkler Heads: 1. Standard Sprinklers: Standard UL/FM upright, pendent, or sidewall sprinkler with fusible link, center strut, or glass bulb. Chrome factory coated. Acceptable manufacturers and models: a. Glass Bulb: Central Model TY-B Grinnell Model F980 Viking Model “M” Firematic Model “A” b. Fusible Link: Central Model “A” or “H” Grinnell Model F950 Viking Model “M” (Fusible Link) Firematic Model “A” (Center Link) 2. Early Suppression Fast Response: Early Suppression Fast Response type, UL/FM upright, pendent, or sidewall sprinkler with fusible link or glass Bulb. Chrome factory coated, acceptable manufacturers and models: Central Model “ESFR” or “BV-QR” Grinnell Model “A” Viking Model “M” Firematic Model “A” Reliable Model “F1FR” B. Pressure Gauges: FM approved with a maximum limit not less than twice the normal working pressure at the point installed; dial type, liquid filled with glass view port. Provide gauge cock with each gauge. Wet-Pipe Sprinkler Systems 21 13 13 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements C. Control Valve Supervisory Switch: Tamper resistant switch for monitoring the open position of post-indicator and control values. UL/FM, two single pole-double throw snap action switches enclosed in a NEMA 1 housing with damper resistant screws. Acceptable manufacturers and models: Grinnell, Model OSYSO; Potter and Model PCVS. 2.02 EXTRA STOCK A. Provide extra sprinkler heads under provisions of NFPA 13, but in no case less than two sprinkler heads of each type and rating. B. Provide suitable wrenches for each size and type of head. C. Provide a metal storage cabinet for extra heads and wrenches and install as close to the standpipe as is practical or where directed by the Owner. 3.00 EXECUTION 3.01 PREPARATION A. Coordinate work of this Section with other affected work. Use reflected ceiling plans, mechanical plans, and electrical lighting plans to avoid conflicts with lights, ducts, piping, and structure. 3.02 INSTALLATION A. Install the sprinkler system before installing finishes, furniture, or other components which could be damaged by water. B. Position sprinkler heads in patterns that align transversely and longitudinally, coordinate with lighting fixtures and ceiling diffusers, and are in line along both diagonals. C. Position sprinkler heads a minimum of 2 inches from any obstruction. D. Protect sprinkler heads which are subject to damage with sprinkler head guards. E. Apply strippable tape or paper cover to ensure concealed sprinkler heads and concealed head plates do not receive field paint finish. Replace any sprinkler head with field paint. F. Route pipe to minimize obstruction to other work. Conceal all pipe above ceilings unless indicated otherwise. G. Provide 3/4-inch ball drip at low point of fire department connection and pipe to floor drain or through exterior wall. H. Power driven studs are prohibited as hanger supports. I. Provide a dry sprinkler system or other approved sprinkler system, in areas subject to freezing temperatures. J. Provide upright pendent sprinkler heads in mechanical rooms and equipment rooms. 3.03 FIELD QUALITY CONTROL A. Perform testing required by NFPA 13 and regulatory authorities. Include the cost of such testing in the proposal. Wet-Pipe Sprinkler Systems 21 13 13 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements B. Hydrostatically test systems at not less than 200 psig for 2 hours, or at 50 psig in excess of the maximum static pressure when the static pressure exceeds 215 psig. Measure hydrostatic pressure at the low point of the system being tested. C. Prepare a Material and Test Certificate, in accordance with NFPA 13 Obtain certificates of approval from regulatory authorities. Submit certificates in the final submittal data to the Engineer. END OF SECTION Plumbing Systems 22 00 01 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 22 00 01 PLUMBING SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED A. Provide labor, materials, equipment and incidentals for complete, operable plumbing systems. Provide appurtenances for every pipe, valve, and fixture or equipment item for a complete operable system. 1.02 QUALITY ASSURANCE A. Verify location, size, depth and pressure of each utility prior to beginning Work. If conditions are found that will adversely affect the installation, notify the Owner’s Representative in writing before proceeding with Work. B. Plumbing fixtures and trim of like kind shall be of the same manufacturer throughout the Project, in the following categories: 1. Water closets, lavatories, urinals, bathtubs. 2. Countertop sinks. 3. Electric water coolers. 4. Emergency shower, eye and face washes. 5. Faucets, mixing valves (other than thermostatic mixing valves). 6. Tailpiece, fixture traps, escutcheons, arm extensions, strainers. 7. Fixture carriers. 1.03 WATER USAGE REQUIREMENTS A. Water saving performance standards of the Texas Commission on Environmental Quality (TCEQ) adopted April 26, 2012, shall apply to every fixture included for this Project. 1. The maximum flow from a sink faucet shall not exceed 2.20 gallons of water per minute at 60 psig. 2. The maximum flow from a lavatory faucet shall not exceed 0.50 gallons of water per minute at 60 psig. 3. The maximum volume of water per flush from a urinal and associated flush valve shall not exceed 0.50 gallons of water per flush. 4. The maximum volume of water per flush from a toilet (water closet) shall not exceed 1.60 gallons (1.6 gpf) 1.04 SUBMITTALS A. Provide Submittals in accordance with Section 01 33 00 “Submittal Procedures” and include manufacturer’s Product Data sheets for the following: 1. Plumbing fixtures and trim. Plumbing Systems 22 00 01 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2. Piping materials and valves. 3. Equipment and accessories. B. Operation and Maintenance Data: Submit operation and maintenance data in accordance with Division 01. 1.05 STANDARDS A. Authority Having Jurisdiction: Perform all Work in accordance with the regulations and ordinances of federal, state, and local agencies, who have lawful jurisdiction over the Place of Record. Notify proper authorities for inspections as Work progresses. B. Codes and Ordinances: The design and installation shall be in accordance with the applicable provisions of the latest edition of the following codes and ordinances. These codes and ordinances shall apply as if written here in their entirety: 1. International Plumbing Code (IPC), with any local city amendments. 2. International Energy Conservation Code (IECC), with any local city amendments. 3. Texas Accessibility Standards (TAS). 4. Occupational Safety and Health Standards (OSHA). 5. Texas Water Commission; Water Conservation Standards. C. Standards: 1. The design and installation shall be in accordance with the applicable provisions of the following standards. These standards shall apply as if written here in their entirety: a. American National Standards Institute (ANSI)/ American Society of Mechanical Engineers (ASME). b. American National Standards Institute (ANSI)/ American Society for Testing Materials (ASTM). c. American National Standards Institute (ANSI)/ American Welding Society (AWS). d. American National Standards Institute (ANSI)/ American Water Works Association (AWWA). e. American National Standards Institute (ANSI)/ National Fire Protection Association (NFPA). f. American Society of Testing and Materials (ASTM) Publications. g. American Welding Society (AWS) Specifications. h. American Water Works Administration (AWWA) Publications. i. American Society of Sanitary Engineering (ASSE). j. Cast Iron Soil Pipe Institute (CIPE) Standards. Plumbing Systems 22 00 01 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1.06 DELIVERY AND STORAGE A. Deliver and store equipment and materials in accordance with Division 01. Handle pipe in a manner which prevents damage. Store on raised platforms or wood runners in neat piles. Prevent debris or dirt from entering open ends of pipe. 1.07 JOB CONDITIONS A. Drawings are schematic and intended to show the general arrangement and extent of the Work. Follow dimensions without regard to scale. Determine the exact location and arrangement of piping with regard to the actual equipment furnished, the surrounding conditions and the Work installed by other trades. B. Review the Drawings and each Section of the Specifications. Install Work indicated, regardless of which Drawing or Section of the Specifications it occurs. No allowances shall be made for the Contractor’s failure to review complete Contract Documents. C. Locate by field measurement the exact rough-in and final connection location of all fixtures, drains and plumbing. Center pipe between walls and chases. D. Conform to the manufacturer’s rough-in and installation requirements for each fixture equipment and appliance. E. Perform cutting and patching required to install the Work under the requirements of the individual trade. Patching shall restore the area to the original condition. No structural member shall be cut without the written approval of the Engineer. F. Schedule Work to avoid conflicts with other trades. G. For pipe penetrations through metal roofs, conform to the metal roofing manufacturer’s installation requirements. 1.08 GUARANTEES A. In addition to the Contractor’s standard 1 year guarantee, provide the manufacturer’s warranty for all equipment installed. Include warranties in the O & M Manual, in accordance with Division 01. 2.00 PRODUCTS 2.01 PIPE AND FITTINGS A. Water Piping Buried Within 5 Feet of Building: 1. Copper Tubing: For 2-inch diameter and less, (ASTM B88), Type L or K or annealed. Fittings: ANSI/ASME B16.18, cast copper or ANSI/ASME B16.22, wrought copper. Joints: AWS A5.8 BCuP silver braze. B. Water Piping Above Grade: 1. Copper Tubing: For 4-inch diameter and less, (ASTM B88), Type L, hard drawn. Fittings: ANSI/ASME B16.18, cast brass, or ANSI/ASME B16.22, wrought copper. Joints: (ANSI/ASTM B32), solder, (Grade 95TA) or Copper Pipe 2 through 6 inches may be installed using mechanical type couplings on roll-grooved pipe; coupling housing, ductile Plumbing Systems 22 00 01 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements iron (ASTM A536) grade 65-45-12, with factory coat copper alkyd enamel paint. Gaskets, flanges, shall be rated for the system by the manufacturer. 2. PEX Tubing: PEX tubing (ASTM F877) 175 psig pipe, SDR 9 tubing. Fittings: (ASTM F1807) metal insert type with copper crimp rings and matching PEX tube dimensions. Manifold system: Multiple outlet, plastic corrosion-resistant metal assembly complying with ASTM F877 and with plastic or corrosion resistant metal valve for each outlet. PEX tubing installed in plenums and above ceilings shall be wrapped or coated with an approved fire retardant to comply with the local code. C. Sanitary Drain, Sanitary Waste and Vent Piping (DWV) Buried: 1. Cast Iron Pipe: (ASTM A74) service weight. Fittings: Cast iron. All cast iron soil pipe and fittings shall be marked with the collective trademark of the Cast Iron Soil Pipe Institute and be listed by NSF International. Joints: Hub-and-spigot, CISPI HSN compression type with (ASTM C564) neoprene gaskets. 2. PVC DWV Pipe: Polyvinyl Chloride, Schedule 40 (ASTM D2665) pipe, and fittings (ASTM D2466). 3. PVC Sewer Pipe (beyond 5 feet of building): Polyvinyl Chloride Gravity Sewer Pipe (ASTM 3034) SDR 35, or (ASTM F789) PS 46 and Fittings, with elastomeric Joints. (Uni- Bell B-4-82, ASTM D3212). 4. Reinforced Concrete Pipe (RCP): Pipe shall be RCP class III, and shall conform to ASTM C76 for Circular Pipe. D. Sanitary Drain, Sanitary Waste and Vent Piping (DWV) Above Grade: 1. Cast Iron Pipe: (ASTM A74), service weight. Fittings: Cast iron. Joints: Hub-and-spigot, CISPI HSN compression type with (ASTM C564) neoprene gaskets. 2. Cast Iron Pipe: (CISPI 301), hubless, service weight. Fittings: Cast iron. All cast iron pipe and fittings shall be marked with the collective trademark of the Cast Iron Soil Pipe Institute and shall be listed by NSF International. Joints: Cast-iron couplings (ASTM A48, Class 30-A) with neoprene gaskets (ASTM C1277, ASTM D412 18-8 and CISPI 310) stainless steel bolts and nuts; manufactured by MG Piping Products Co. or equal. 3. Copper Pipe: (ASTM B306), DWV. Fittings; (ANSI/ASME B16.3), cast bronze, or (ANSI/ASME B16.29), wrought copper. Joints: (ANSI/ASTM B32), solder, Grade 50B. 4. PVC Pipe: (ASTM D2665), Schedule 40. Fittings: PVC DWV Type, Schedule 40, (ASTM D2665). Joints: (ASTM D2855) and (D2564), solvent weld. PVC pipe installed in plenums and above ceilings shall be wrapped or coated with an approved fire retardant to comply with the local code. E. Condensate Drain Piping, Above Grade: 1. Copper Tubing: For 4-inch diameter and less, (ASTM B88), Type L, hard drawn. Fittings: ANSI/ASME B16.18, cast brass, or ANSI/ASME B16.22, wrought copper. Joints: (ANSI/ASTM B32), solder, (Grade 95TA) or Copper Pipe 2 through 6 inches may be installed using mechanical type couplings on roll-grooved pipe; coupling housing, ductile iron (ASTM A536) grade 65-45-12, with factory coat copper alkyd enamel paint. Gaskets, flanges, shall be rated for the system by the manufacturer. Plumbing Systems 22 00 01 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2.02 FLANGES, UNIONS, AND COUPLINGS A. Pipe size 2 inches and under: 150 psig malleable iron unions for threaded ferrous piping; bronze unions for copper pipe, solder joints. B. Dielectric Connections: Union with galvanized or plated steel threaded end, copper solder end, water impervious isolation barrier. 2.03 VALVES (WITHIN 5 FEET OF BUILDING) A. Gate Valves (For Water Shut-Off and Pumped Waste Drain Shut-Off): 1. Gate Valves 3 inches and Less: MSS-SP-80, rated 175-lb. minimum water pressure, brass or bronze construction screw-in bonnet, rising stem, solid wedge disc, threaded or soldered connections. Acceptable manufacturers and models: Nibco, T-111, S-111 ITT; Grinnell, 3010, 3010SJ; Watts, B-3100 & B-3101 and Milwaukee, 148, 149. B. Ball Valves (For Water Shut-Off and Throttling): 1. Ball Valves 2 inches and Less: Full-port, rated 175-lb. minimum water, oil, air and gas pressure, brass or bronze construction, seat material as recommended by manufacturer for material conveying, lever handle, threaded or soldered connections. Throttling valves shall be provided with memory stops. Acceptable manufacturers and models: ITT Grinnell, 3500, 3500SJ; Milwaukee, BA-200, BA-250; Watts, B-6000, B-6001 and Nibco, T-580, S-580. C. Butterfly Valves (For Water Shut-Off and Throttling): 1. Butterfly Valves 2 inches and Less: Rated 175-lb. water, oil, air and gas pressure, brass or bronze construction, seat material as recommended by manufacturer for material conveying, lever handle, threaded or soldered connections. Throttling valves shall be provided with memory stops. Acceptable manufacturer and model: Watts, BF-03 and Milwaukee, BB2-100, BB2-350. 2.04 SPECIAL PIPE FITTINGS A. Flexible Ball Joints for Sanitary Waste Piping: Double Ball Flexible Expansion Joint: Ductile- iron fitting with combination of flanged and mechanical-joint ends complying with AWWA C110 or AWWA C153. Include gasketed double ball-joint section and ductile-iron gland, rubber gasket, polyethylene wrap (for underground installation), and steel bolts. Acceptable manufacturer and model: EBAA Iron Sales, Flex-Tend Series. 2.05 EXPANSION JOINTS A. Except where otherwise indicated or specified, expansion joints shall be single arch spool type with control unit. Expansion joints shall be fabricated of synthetic elastomers and fabric with metallic reinforcement. Joints shall be provided with split steel retaining rings. Flanges and retaining rings shall be drilled to match standard 125-lb. ANSI B16.1. Plumbing Systems 22 00 01 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2.06 DOMESTIC WATER HEATERS AND ACCESSORIES A. Electric Water Heaters (Direct Fired): 1. Domestic Water Heater (WH1): ASHRAE 90.1-1999 energy efficient, standard or lowboy height electric vertical type, interior-lined tank, anode protection, drain valve, safety relief valve, high-temperature cut-off, individual operating thermostats, insulated tank, baked enamel exterior steel jacket, and UL listed. Provide with expansion tank and heat traps as recommended by the water heater manufacturer. a. Acceptable Manufacturers and Models: 1). Rheem: ELD30. 2). State: P6 Series. 3). A.O. Smith: HNT Series. 4). Lochinvar: ET or ES Series. 2. Water Heating System Accessories: a. Expansion Tank for Water Heater: Bladder type, factory pre-charged, fabricated steel shell, heavy duty butyl FDA approved bladder, 150 PSIG working pressure, 200 F operating temperature. Tank head shall be galvanized or polypropylene lined. Pre-charge tank to static pressure of system. 1). Acceptable Manufacturers and Models: a). Taco: CAX Series. b). Amtrol: ST Series. c). Watts: DET Series. b. Water Heater Drain Pan: 1). Aluminum Alloy or Cold Rolled Steel, .032 thick complete with 1-inch PVC Drain, Steel, zinc plated Lock Nut, and neoprene flange gasket. 2). Acceptable Manufacturers and Models: a). Holdrite: Quick Pan Series. c. Wells for temperature regulator sensor and high limit sensor at water. d. Outlet. e. ASME rated pressure and temperature relief valve on water outlet. f. Thermostatic air vent on steam side downstream of control valve. g. ASME rated pressure relief valve on steam inlet on downstream side of control valve. h. Thermometers and pressure-gauge tappings in water inlet and outlet. i. Vacuum breaker and pressure-gauge tapping with pig-tail siphon in shell. Plumbing Systems 22 00 01 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2.07 PLUMBING FIXTURES AND TRIM A. Water Closets: 1. Water Closet (WC1): Accessible wall-mounted, flush-valve type, white vitreous china, siphon-jet action, elongated bowl, 1-1/2-inch top inlet spud, and designed to operate on 1.28 gallons per flush maximum. Mounting height to be 17 to 19 inches from finished floor to top of seat. Provide floor mounted carrier to support heavy fixture weight. Acceptable manufacturers and models: American Standard, 2257.001; Briggs 7781; Toto, CT708E; Kohler, K-4325; Zurn, Z5610-BWL. 2. Water Closet (WC2): Wall-mounted, flush-valve type, white vitreous china, siphon-jet action, elongated bowl, 1-1/2-inch top inlet spud, and designed to operate on 1.28 gallons per flush maximum. Mounting height to be 15 inches from finished floor to top of seat. Provide floor mounted carrier to support heavy fixture weight. Acceptable manufacturers and models: American Standard, 2257.001; Briggs 7781; Toto, CT708E; Kohler, K-4325; Zurn, Z5610-BWL. B. Flush-Valves for Water Closets: 1. Flush-Valve for Water Closets: Exposed type, chrome-plated, 1-inch supply inlet, screw driver back-check angle stop, vacuum breaker, lever activating handle, solid ring pipe support 1-1/2-inch top outlet spud with wall and spud flanges. Inlet of flush-valve shall be 11-1/2 inches maximum, above rim of water closet, coordinate flush valve location with grab bars for accessible installations. Acceptable manufacturers and models: Sloan, Royal III-1.6 or -1.28; Delany, U402-1.28 and Zurn, Z-6000-AV-HET.WS-1 (typical note: flush valves need to indicate 1.6 or 1.28 gpf and model numbers need to match. Delany only seems to come in 1.28 now). C. Seats for Water Closets: 1. Seat for Water Closets: White, posture molded, elongated type, open front, extra heavy construction, concealed check stainless steel hinges, and rubber bumpers. Provide with antimicrobial agent option. Acceptable manufacturers and models: Olsonite, 10CC; Church/Bemis, 1955C; Beneke, 527 or 533 and Kohler, K-4680-CA series. D. Water Closet Carriers: 1. Carriers for Water Closets: Heavy duty, wall-mounted, floor supported type, adjustable height, compatible with specified water closet, complete with chrome-plated finished trim, foot support, through wall frame, and required accessories of the appropriate type for the pipe materials specified. Assembly shall also include an adjustable horizontal cast iron closet fitting of the inlet type compatible with the piping type and arrangement as shown on the Drawings. Acceptable manufacturers: Josam, Jay R. Smith, Tyler/Wade, Mifab, Watts Drainage, and Zurn. E. Urinals: 1. Urinal (UR1): Accessible wall-mounted, white vitreous china, 14-inch minimum elongate rim type, siphon-jet action, flushing rim, integral trap, 3/4-inch top inlet spud and designed to operate on .125 gallon per flush maximum (mounting height plus 17 inches from finished floor to rim). Acceptable manufacturers and models: American Standard, 6042.001EC; Kohler, K-4991-ET; Zurn, Z5738.207.00 Series. Plumbing Systems 22 00 01 - 8 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements F. Flush-Valves for Urinals: 1. Flush-Valve for Urinals: Exposed type, chrome-plated, 3/4-inch supply inlet, screw driver back-check angle stop, vacuum breaker, lever activating handle, 3/4-inch top outlet spud with wall and spud flanges and designed for .125 gallon per flush maximum. Acceptable manufacturers and models: Sloan Regal, 111-1.28; Delany, 451.0125 and Zurn, Z-6003AV-ULF. G. Urinal Carriers: 1. Carriers for Urinals: Mounted on concrete block walls only, wall-supported type, compatible with specified urinal, complete with chrome finished exposed trim, hanger wall plate, adjustable through the wall supporting rods, and accessories. Acceptable manufacturers and models: Josam, 17835; Jay R. Smith, 828; Tyler/Wade, W461; Mifab, MC-30; Watts Drainage CA-481 and Zurn, Z-1259. 2. Carriers for Urinals: Mounted on concrete block walls or walls other than concrete block, wall and floor supported type, compatible with specified urinal, complete with chrome-plated finished exposed trim, adjustable through the wall frame including top and bottom hanger plates, steel uprights, block foot supports, and accessories. Acceptable manufacturers and models: Josam, 17810 Series; Jay R. Smith, 637 Series; Tyler/Wade, W-400-AM11 Watts Drainage CA-321 and Zurn, Z-1222 Series. H. Lavatories: 1. Lavatory (L1): Countertop mounted, White vitreous china, size 20 by 17 inches, oval, self-rimming, fitting ledge, template and sealant, front overflow, and 4-inch center holes. Acceptable manufacturers and models: American Standard, 0476.028; Eljer, 051- 3514; Toto, LT501.4; Briggs, 6534; Zurn, Z5114; Kohler, K-2196-4. I. Faucets for Lavatories: 1. Faucet for Lavatories: Chrome-plated brass, 4-inch centers, soft flow vandal proof spout, with chrome-plated brass wrist-blade handles. Maximum flow is 2.20 gpm. Acceptable manufacturers and models: Chicago Faucet, 802; T & S Brass, B-871; Royal Brass, 905-A-BH.3; Speakman, SC-3063; American Standard, 5400.142 H lever, Cambridge/Delta 21T143, Symmons, S-240-LWG Moen 8215 and Zurn, Z-81104. J. Supplies and Stops for Lavatories: 1. Supply and Stop for Lavatories: Supplied through the wall, chrome-plated cast brass stop, 1/2-inch female standard pipe thread inlet by 3/8-inch O.D. compression type outlet angle stop, wheel or four armed handle, 3/8-inch O.D. chrome-plated copper flexible riser, and wall escutcheon. Acceptable manufacturers and models: McGuire, 2165LK; Eljer, American Standard, Cambridge/Delta, Zurn and Engineered Brass (Just), Specified trim. K. Strainer and Tailpiece for Lavatories: 1. Offset Strainer for Lavatories: Heavy Duty 17-gauge chrome plated wheelchair strainer and tailpiece, cast grid drain plug with strainer. Acceptable manufacturers and models: McGuire, 155WC; Eljer, American Standard, Cambridge/Delta, Specified Trim ST155WC, Zurn and Engineered Brass (Just). Plumbing Systems 22 00 01 - 9 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements L. P-Trap for Lavatories: 1. P-Trap for Lavatories: 17-gauge chrome-plated brass size 1-1/4 inches, integral cleanout, and wall escutcheon. Acceptable manufacturers: McGuire, B8872; Eljer, American Standard, Cambridge/Delta, Zurn and Engineered Brass (Just) Specified Trim. M. Lavatory Insulation Kits: Fully molded closed cell vinyl insulation 3/16-inch thick with nylon fasteners. K factor of 1.17 (ASTM C177) self-extinguishing burn characteristics (ASTM D635). Insulation kit for p-trap, tailpiece, trap arm, hot and cold water supplies, white. Acceptable manufacturers and models; Truebro Inc., #102 with accessory #105; Brocar Products Inc., Plumberex, and TCI Products. N. Sinks: 1. Sink (S1): Countertop mounted, double compartment, 18-gauge stainless steel, self- rimming, faucet deck, with four 1-1/2-inch diameter holes, 4-inch centers, with undercoated underside. Size 21 by 33 by 5-1/2 inches deep. Acceptable manufacturers and models: Elkay, LRAD-3321 and Just, DL-ADA-3321-A-GR -L or R. 2. Sink (S2): Countertop mounted, single compartment, 18-gauge stainless steel, self- rimming, faucet deck, with four 1-1/2-inch diameter holes, 4-inch centers, with undercoated underside. Size 25 by 21-1/4 by 5-3/8 inches deep. Acceptable manufacturers and models: Elkay, GE1-2521; and Just, SL-ADA-2125-A-GR -L or R. O. Faucets for Sinks: 1. Faucets for Sinks: Chrome-plated brass, deck mount, 8-inch centers, swing gooseneck soft flow spout with 8- to 9-inch reach (centerline of spout inlet to centerline of spout outlet), vinyl hose with deck mounted automatic spray diverter, and chrome-plated brass lever or wing handles. Faucet shall automatically divert water to spray when spray handle is used. Hose connection to faucet shall be provided with backflow preventer under counter. Maximum flow is 2.20 gpm. Acceptable manufacturer and models: Chicago Faucet, 1102, E3, 1000; T & S Brass, B-1172, B-970; Royal Brass, 5269.3-BH-136; Speakman, SC-5773; American Standard, 7231.000 with .342H lever or .352H Cross handles, Cambridge/Delta, 2276LHP; Kohler, K-10445; Moen 8799 and Zurn, Z-87163- HS. P. Supplies and Stops for Sinks: 1. Supply and Stop for Sinks: Supplied through the wall, chrome-plated cast brass stop, 1/2-inch female standard pipe thread inlet by 3/8-inch O.D. compression type outlet angle stop, wheel or four armed handle, 3/8-inch O.D. chrome-plated copper flexible riser, and wall escutcheon. Acceptable manufacturers and models: McGuire, 2165LK; Eljer, American Standard, Specified Trim , Cambridge/Delta, Zurn and Engineered Brass (Just). Q. Strainer and Tailpiece for Sinks: 1. Offset Strainer for Sinks: 17-gauge chrome plated wheelchair strainer and tailpiece, cast grid drain plug with strainer. Acceptable manufacturers: McGuire, 1149WC or PW1149WC (includes pre-wrapped insulation); Eljer, American Standard, Cambridge/Delta, Zurn, Specified Trim and Engineered Brass (Just). Plumbing Systems 22 00 01 - 10 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements R. P-Traps for Sinks: 1. P-Trap for Sinks: Chrome-plated, 17-gauge cast brass, size 1-1/2 inches, with integral cleanout, and wall escutcheon. Acceptable manufacturers; McGuire, B8912; Eljer, American Standard, Specified Trim, Cambridge/Delta, Zurn and Engineered Brass (Just). S. Insulation Kit for Accessible Sinks: 1. Sink Insulation Kits: Fully molded closed cell vinyl insulation 3/16 inch thick with nylon fasteners. K factor of 1.17 (ASTM C177) self-extinguishing burn characteristics (ASTM D635). Insulation kit for p-trap, tailpiece, trap arm, hot and cold water supplies, white. Acceptable manufacturers; Truebro Inc., #102 with accessory #105; Brocar Products Inc., Plumberex, TCI Products. Insulation kit is not required if a trap/supplies enclosure is provided under another division. T. Electric Water Coolers: 1. Electric Water Cooler (EWC1): Wall-mounted, bi-level, wheelchair type, front and sides push bars, stainless steel top, stainless steel cabinet with a flexible hooded bubbler. Wheelchair unit shall be mounted up plus 36 to top of bubbler. Water cooler shall deliver 7.5 gph minimum of 50 F water, based upon 80 F inlet water temperature and 90 F ambient air temperature. Acceptable manufacturers and models: Elkay, EZSTL-8C; Haws, HWUACO8L; Halsey Taylor, HAC8FSBL-Q; Oasis, PR8ACSL; Acorn A112108F and Sunroc, ADA-D8-BL. Provide with optional apron mounted to bottom of higher unit. U. Supplies and Stops for Electric Water Coolers: 1. Supply and Stop for Electric Water Coolers: Supplied through the wall, chrome-plated brass, 1/2-inch female standard pipe thread inlet by 3/8-inch O.D. compression type outlet angle stop, wheel or four-armed handle, with flexible riser and wall escutcheon. Acceptable manufacturers and models: McGuire, 2166LK; Eljer, American Standard, Cambridge/Delta, Specified Trim, Zurn and Engineered Brass (Just). V. P-Trap for Electric Water Coolers: 1. P-Trap for Electrical Water Coolers: 17-gauge chrome-plated brass, size 1-1/4 inches, integral cleanout, and wall escutcheons. Acceptable manufacturers and models: McGuire, B8912; Eljer, American Standard, Cambridge/Delta, Zurn and Engineered Brass (Just). W. Electric Water Cooler Carriers: 1. Carriers for Electric Water Coolers Mounted on Concrete Block Walls Only: Wall- supported type, compatible with specified electric water cooler, complete with hanger wall plate, adjustable through the wall supporting rods and accessories. Acceptable manufacturers and models: Josam, 17835, 17590; Jay R. Smith, 826; Tyler/Wade, W- 461; Mifab, MC-33 (Bi-Level type); Watts Drainage CA-481, and Zurn, Z-1259. 2. Carriers for Electric Water Coolers Mounted on Concrete Block Walls or Walls other than Concrete Block: Wall and floor supported type, compatible with specified electric water cooler, complete with adjustable through the wall frame including top and bottom hanger plates, steel uprights, and block foot supports, and accessories. Acceptable manufacturers and models: Josam, 17900; Jay R. Smith, 830; Tyler/Wade, W400-AM11; HAWS, 6800; MC-33 (Bi-Level type); Watts Drainage CA-321 and Zurn, Z-1225. Plumbing Systems 22 00 01 - 11 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements X. Services Sinks: 1. Service Sink (SSK1): Wall-mounted enameled cast iron, stainless steel rim guard, plain high back splash, wall hanger, and 3-inch drain. Size 24 by 20 inches. Acceptable manufacturers and models: American Standard, 7692.000 or 7695.000; Kohler, K-6719 and Eljer, 242-0125. Y. Faucets for Service Sinks: 1. Faucets for Service Sinks: Chrome-plated, 3/4-inch hose thread outlet, wall-mounted for concealed supply pipe, wall brace, integral stops, pail hook, and vacuum breaker. Maximum flow is 2.20 gpm. Acceptable manufacturers and models: Chicago Faucet, 897; T & S Brass, B-665-BSTR; Royal Brass, 552-49; Speakman, SC-5811-RCP; American Standard, 8344.111; Fiat, 830AA; Moen 8124, Cambridge/Delta 28T2263, Stern Williams, T-15-VB and Zurn, Z-841MI. Z. Traps for Service Sinks: 1. Trap for Wall-Mounted Service Sink: 3 -inch cast iron, above floor, integral cleanout, and floor support flange. Acceptable manufacturers and models: Kohler, K-6673; American Standard, 7798.030; and McGuire, PF003. AA. Service Sink Carriers: 1. Carriers For Service Sinks, Mounted on Concrete Block Walls or Walls other than Concrete Block: Wall and floor supported type, compatible with specified service sink, complete with adjustable through the wall frame including top hanger plate steel uprights, and block foot supports, and accessories. Acceptable manufacturers and models: Josam, 17550; Jay R. Smith, 800; Tyler/Wade, W461; Mifab, MC-60; Watts Drainage CA-421 and Zurn, Z-1224. BB. Stainless Steel Wall Panel for Service Sinks: 1. Stainless steel Wall Panel: Type 304 20-gauge stainless steel (CS-2343-62) wall and back panels. 12-inch height by length and width of service sink. CC. Emergency Shower/Eyewash Units: 1. Accessible Combination Emergency Shower/Eyewash Unit (ESE1): Exposed column type with floor flange, all stainless steel construction, shower head actuated by a stay open ball valve with rigid pull rod and handle, eyewash with large stainless steel bowl and two soft stream heads actuated by stay open ball valve with push-flag and foot treadle. Shall be ADA/TAS approved. Water supply pipe connection size shall be 1-1/4-inch inlet and if used, waste pipe connection size shall be 1-1/4-inch drain. Acceptable manufacturers: Speakman, SE-603-ADA; Haws; Guardian; and Encon. 2.08 PLUMBING SPECIALTIES A. Roof Drainage: 1. Downspout Nozzle (DSN): Cast bronze nozzle, wall flange and no-hub inlet connection. a. Acceptable Manufacturers and Models: 1). Josam: Series 25010. 2). Jay R. Smith: Series 1770. Plumbing Systems 22 00 01 - 12 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 3). Wade: Series W-3940. 4). Zurn: Series Z-199. 5). Mifab: Series R-1940. 6). Watts Drainage: Series RD-940. B. Floor Drains: 1. Floor Drain (FD1) (for use in Finished Floors without square tile): ANSI A112.21.1; cast iron body, double drainage flange, weepholes, bottom outlet, vandal proof secured 6- inch diameter nickel bronze adjustable flat strainer, and non-puncturing flashing collar. Provide with trap primer connection adapter if trap primers are used for the floor drain. a. Acceptable Manufacturers and Models: 1). Josam: Series 30000-6A. 2). Jay R. Smith: Series 2005 or 2010. 3). Wade: Series W-1100. 4). Zurn: Series Z-415. 5). Mifab: Series F-1100. 2. Floor Drain (FD2) (for use in Unfinished Floors): ANSI A112.21.1; cast iron body, double drainage flange, weepholes, bottom outlet, vandal proof secured 7-inch diameter nickel bronze adjustable heavy duty tractor type flat strainer, and non-puncturing flashing collar. Provide with trap primer connection adapter if trap primers are used for the floor drain. a. Acceptable Manufacturers and Models: 1). Josam: Series 30000-E. 2). Jay R. Smith: Series 2005 or 2010. 3). Wade: Series W-1100-TS, Series W-1100-EF. 4). Zurn: Series Z-415-N, Series Z-415-I, Series Z-415-E. 5). Mifab: Series F-1300-C. 6). Watts Drainage: Series FD-100, Series FD-300. C. Floor Sink Drains: 1. Floor Sink Drain (FS1): ANSI A112.21.1; square cast iron body, double drainage flange, weepholes, bottom outlet aluminum dome strainer, non-puncturing flashing collar, porcelain enamel or epoxy coated interior and full 3/4 1/2 less grate. Size 8 by 8 by 6 inches. Provide with trap primer connection adapter. a. Acceptable Manufacturers and Models: 1). Josam: Series 4900. 2). Jay R. Smith: Series 3100. 3). Tyler/Wade: Series W-9110-24. Plumbing Systems 22 00 01 - 13 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 4). Zurn: Series ZN-1815. 5). Mifab: Series FS-1520. 6). Watts Drainage: Series FS-710. D. Hub Drains: 1. Hub Drain (HD): Satin finish nickel-bronze body and supplementary dome strainer, 8- inch diameter top. Provide with trap primer connection adapter. Acceptable manufacturers and models: Josam, F5A and Zurn, Z-326. E. Cleanouts: 1. Floor Cleanout (FCO) (for Use in Finished Floors): Cast iron body, adjustable type, inside caulk connection, vandal proof secured, standard round nickel bronze top, threaded brass plug. a. Acceptable Manufacturers and Models: 1). Josam: Series 56000. 2). Jay R. Smith: Series 4128-NB. 3). Wade: Series W-6000. 4). Zurn: Series Z-1405-2. 5). Mifab: Series C-1100. 6). Watts Drainage: Series CO-200. 2. Wall Cleanout (WCO): Recessed wall type, cast iron body with threaded brass plug, flush mounted stainless steel access cover with countersunk center screw and vandal proof secured. a. Acceptable Manufacturers and Models: 1). Josam: Series 58710. 2). Jay R. Smith: Series 4402. 3). Wade: Series W-8450-R. 4). Zurn: Series ZN-1440-1. 5). Mifab: Series C-1400. 6). Watts Drainage: Series CO-380. 3. Plug Cleanout (PCO): Cast iron body with threaded brass plug, specify with no access cover. a. Acceptable Manufacturers and Models: 1). Josam: Series 58710, Less cover. 2). Jay R. Smith: Series 4402, Less cover. 3). Wade: Series W-8450-R, Less cover. 4). Zurn: Series ZN-1440, Less cover. Plumbing Systems 22 00 01 - 14 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 5). Watts Drainage: Series CO-380, less cover. 4. Grade Cleanout (GCO & DGCO): Cast iron body, with straight body for caulking into soil pipe hub with countersunk tapered threaded bronze plug. Provide “T” handle wrench. Double Grade Cleanouts (DGCO) will require two GCO’s as described above, along with the proper two-way cleanout pipe fitting. a. Acceptable Manufacturers and Models: 1). Josam: Series 58850-22. 2). Jay R. Smith: Series 4338. 3). Wade: Series W-8530. 4). Zurn: Series Z-1450. 5). Mifab: Series C-1300. 6). Watts Drainage: Series CO-260. F. Backflow Preventers: 1. Reduced Pressure Backflow Preventers (RPBFP): a. Reduced Pressure Backflow Preventer (2 inches and smaller): ANSI/ASSE 1013; complete unit of two independently acting check valves together with an automatically operating pressure relief valve, two ball valves, strainer, and four test cocks, bronze or iron body with bronze internal parts, 150 psi working pressure, and shall comply with AWWA Standard C506. 1). Acceptable Manufacturers and Models: a). Cla-Val Co.: RP-2 (1-1/2 inches and smaller). b). Watts: 009QT. c). Hersey: FRP-II. d). Febco: 825Y. e). Wilkins: 975XL. 2. Vertical Installation Type Reduced Pressure Backflow Preventers: a. Reduced Pressure Backflow Preventer (2-1/2 inches and larger): ANSI/ASSE 1013; complete unit of two independently acting check valves together with an automatically operating pressure relief valve, two gate valves, and four test cocks, bronze or iron body with bronze internal parts, 150 psi working pressure, and shall comply with AWWA Standard C506. 1). Acceptable Manufacturers and Models: a). Wilkins: 475DAV (4, 6 and 8 inches only). b). AMES: Silver Bullet 4000 SS (2-1/2 to 10 inches). c). Watts: 775 series (2-1/2 to 10 inches). Plumbing Systems 22 00 01 - 15 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements G. Water Hammer Arrestors: 1. Water Hammer Arrestors (WHA): ANSI A112.26.1, ASSE 1010, and PDI WH-201; permanently sealed bellows or expanding chamber. Sizing designations indicated on the Drawings are standard classifications established by Plumbing and Drainage Institute “Standard PDI-WH201.” Verify that system pressure meets minimum required for water hammer arrestor provided. a. Acceptable Manufacturers and Models: 1). Josam: 75000. 2). Jay R. Smith: 5000. 3). Wade: “SHOKSTOP” Series. 4). Zurn: Z-1700. 5). Sioux Chief: “Hydra-Rester” Series. 6). Watts: No. 15M2 Series. 7). PPP: SC & SWA Series. 8). Mifab: WHB Series. H. Trap Seals: 1. Trap Seals (TS): Flexible elastomeric or neoprene trap seal device utilizes a normally closed seal to prevent evaporation of the liquid trap seal and also protects against sewer gases from backing up into the building or surrounding areas. The device opens when liquid enters to allow drainage to flow through into the building drainage piping, and closes when there is no drainage flow entering the drain. Provide in all floor drains, floor sinks, area drains and hub drains connected to the sanitary sewer system or to other systems that may have sewer gases present in the drainage system. a. Acceptable Manufacturers and Models: 1). ProVent Systems, Inc.: ProSet Trap Guard Series, 800.262.5355 or www.trapguard.com. 2). Mifab: Mi-Gard Series. 3). SureSeal. 4). Jay R. Smith Mfg. Co.: Quad Close Series. I. Thermostatic Mixing Valves: 1. Thermostatic Mixing Valve Station (TMVS): High-low flow thermostatic mixing valve with pressure regulating valve to maintain set temperature at high and low flow conditions. Valve to automatically close hot water port if cold water pressure fails or close cold water port if hot water pressure fails, and closes both ports if thermostatic element fails. TMV shall include check valves, stops, and strainers. Mixing valve shall be installed in a surface mounted or a recessed stainless steel cabinet. a. Acceptable Manufacturers and Models: 1). Powers: SH1430 Series. Plumbing Systems 22 00 01 - 16 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2). Symmons: Temptrol. 3). Lawler: 802 or 805 Series. 4). Armstrong: Rada Series. J. Hose Bibbs: 1. Hose Bibb (HB): Chrome plated brass, provided with wall flange, 1/2-inch female NPT inlet by 3/4-inch male N.H.T. outlet, with chrome plated vacuum breaker in conformance with ANSI/ASSE 1011. a. Acceptable Manufacturers and Models: 1). Chicago Faucet: 15-E27 or 7-E27. 2). T&S Brass: B-702-B-972. 3). Royal Brass: 5115-136-G. 4). Woodford: 24P. 5). Watts: SC8-1. 2. Hose Bibb (HB): Brass, 1/2-inch male NPT inlet by 3/4-inch male N.H.T. outlet, with vacuum breaker in conformance with ANSI/ASSE 1011. a. Acceptable Manufacturers and Models: 1). Chicago Faucet: 7T-R27. 2). Woodford: 24CP. 3). Watts: SC8-1. K. Wall Hydrants: 1. Non-Freeze Wall Hydrant (NFWH1): ANSI/ASSE 1019; exposed wall hydrant type, with chrome plated brass or nickel bronze finish on brass castings, freezeless, 3/4-inch hose thread nozzle, integral vacuum breaker, and loose key handle. a. Acceptable Manufacturers and Models: 1). Woodford: 65. 2). Josam: 71050. 3). Jay R. Smith: 5609. 4). Wade: W-8620. 5). Zurn: Z-1310. 6). Watts: HY-420. L. Ice Maker Outlet Boxes: 1. Ice Maker Outlet Box (IMOB): Recessed 16-gauge steel cabinet with white powder coated finish, 1/2-inch domestic water ball valve meeting lead-free requirements. a. Acceptable Manufacturers and Models: 1). Guy Gray: MIB1DAB, or approved equal. Plumbing Systems 22 00 01 - 17 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements M. Pipe Hangers and Supports: 1. Hangers for pipe sizes 1/2 to 1-1/2 inches: Malleable iron, adjustable swivel, split ring. 2. Hangers for pipe sizes 2 to 4 inches and cold pipe sizes 6 inches and over: Carbon steel, adjustable, clevis. 3. Multiple or Trapeze Hangers: Steel channels with welded spacers and hanger rods; cast iron roll and stand for hot pipe sizes 6 inches and over. 4. Vertical Support: Steel riser clamp. 5. Floor Support for pipe sizes to 4 inches and all cold pipe sizes: Cast iron adjustable pipe saddle, locknut nipple, floor flange, and concrete pier or steel support. 6. Copper Pipe Support: Carbon steel ring, adjustable, copper plated. 7. Shields for insulated piping 2 inches and smaller: 18 gage galvanized steel shield over insulation in 180 degree segments, minimum 12-foot long at pipe support. 8. Shields for Vertical Copper Pipe Risers: Sheet lead. 9. Support horizontal piping as follows: Pipe Size Max. Hanger Spacing Hanger Diameter 1/2” to 1-1/4” 6’-6” 3/8” 1-1/2” to 2” 10’-0” 3/8” 2-1/2” to 3” 10’-0” 1/2” 4” to 6“ 10’-0” 5/8” PVC (All Sizes) 6’-0” 3/8” C.I. Bell and Spigot (or No-Hub) 5’-0” and at Joints 10. Hanger Notes: a. Install hangers to provide minimum 1/2-inch space between finished covering and adjacent Work. b. Place a hanger within 12 inches of each horizontal elbow. c. Use hangers with 1-1/2-inch maximum vertical adjustment. d. Support horizontal cast iron pipe adjacent to each hub, with 5-inch maximum spacing between hangers. e. Support vertical piping at every floor. Support vertical cast iron pipe at each floor at hub. f. Where several pipes can be installed in parallel and at same elevation, provide multiple or trapeze hangers. Consult with project structural engineer for approval. g. Support riser piping independently of connected horizontal piping. h. For below floor hanger installations, place one hanger at each pipe penetration thru a concrete grade beam, at either side, a minimum of 12 inches from the face of the grade beam. Plumbing Systems 22 00 01 - 18 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements N. Hanger Rods: 1. Steel Hanger Rods: Threaded both ends. O. Inserts: 1. Inserts: Malleable iron case of galvanized steel shell and expander plug for threaded connection with lateral adjustment, top slot for reinforcing rods, lugs for attaching to forms; size inserts to suit threaded hanger rods. P. Insulation: 1. Pipe insulation for domestic hot and cold water pipe, roof drains and horizontal roof drain pipe. a. Heavy duty preformed fiberglass (ASTM C547, type 1, 2 or 3). Schuller, Knauf or Certainteed. b. Preformed flexible elastomeric insulation (ASTM C534) Armstrong “Armaflex”, or Schuller “Rubatex.” c. Preformed unicellular polyolefin foam (ASTM C534) tubular preslit with adhesive. IMCOA. Insulation Schedule Cold Water 1” thick up to 2” pipe size 1-1/2” thick over 2” pipe size Hot Water 1” thick up to 2” pipe size 1-1/2” thick over 2” pipe size Roof Drain Bodies and Pipe 1/2” thick up to and including 4” pipe size and body, 1” thick for pipe sizes over 4” d. Provide all purpose jacket, high density white kraft bonded to aluminum foil, reinforced with fiberglass yarn lap and butt, self-sealing, pressure sensitive. Schuller “Micro-Lok”, Certainteed “Snap-On.” e. PVC fitting covers, one piece pre molded high impact PVC white gloss insulating fitting covers and jackets. Schuller “Zeston 2000PVC.” 2. Fire-Test-Response Characteristics: As determined by testing materials identical to those specified in this Section according to ASTM E84, by a testing and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and sealer and cement material containers with appropriate markings of applicable testing and inspecting agency. a. Insulation Installed Indoors: Flame-spread rating of 25 or less, and smoke- developed rating of 50 or less. b. Insulation Installed Outdoors: Flame-spread rating of 75 or less, and smoke- developed rating of 150 or less. Q. Piping Identification: 1. Install manufactured pipe markers indicating service on each piping system. Install with flow indication arrows showing direction of flow. Plumbing Systems 22 00 01 - 19 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements a. Pipes with OD, Including Insulation, Less than 6 inches: Pre-tensioned pipe markers. Use size to match pipe and ensure a tight fit. b. Pipes with OD, Including Insulation, 6 inches and Larger: Shaped pipe markers. Use size to match pipe and secure with fasteners. c. Locate pipe markers and color bands on piping as follows: Near each valve and control device; Near each branch connection, excluding short takeoffs; Where flow pattern is not obvious, mark each pipe at branch; At other points of origination and termination; Spaced at maximum intervals of 50 feet along each run; Reduce intervals to 25 feet in areas of congested piping and equipment. 3.00 EXECUTION 3.01 PREPARATION A. Establish invert elevations for drainage piping within 5 feet of building. Minimum slopes for drainage pipe is 1/4 inch per foot for 2 1/2-inch diameter and less and 1/8 inch per foot for 3-inch diameter pipe and greater. 3.02 INSTALLATION A. Pipe, Valves and Fittings: 1. Provide non-conducting dielectric connections wherever jointing dissimilar metals. 2. Provide clearance for installation of insulation, and access to valves and fittings. 3. Provide access doors where valves and equipment are not accessible. Coordinate size and location of access doors with applicable Section. 4. Install sanitary drainage piping true to line with proper grading. Connect horizontal branches to one another with 45 degrees “Y” fittings, combination “Y” and 1/8 bend fittings. Connect horizontal lines to vertical stacks using 45 degrees “Y” branches, 60 degree “Y” branches, or combination “Y” and 1/8 bend fittings. Horizontal branches turning down to vertical stacks may use a short sweep or 1/2 bend. Branches connecting to mains or to other branches shall enter the branch line at a 45 degree angle, tilted 45 degrees upward, so that the entry is from the side and top. 5. Materials exposed within ducts or plenums (ceiling spaces used as supply or return air plenums) shall have a flame-spread index of not more than 25 and a smoke-developed rating of not more than 50 when tested in accordance with the test for Surface Burning Characteristics of Materials, IBC Standard. Wrap or enclose with rated materials, any CPVC, PVC or PEX piping installed in rated spaces, including return air plenums. 6. Piping hangers shall be sized large enough to allow insulation to pass through. Hangers for piping 2-1/2 inches and greater shall be provided with pipe covering protection saddle, or high compressive strength insulation saddle. Hangers for piping 2 inches and less shall be provided with pipe covering shields. On cold water piping provide vapor barrier through hanger. Plumbing Systems 22 00 01 - 20 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 7. Anchor piping with regard to the transmission of vibration and noise. Securely anchor copper piping to studs or wood blocking with “C” clamp of proper size for piping. At each fixture location where the piping penetrates the partition, back the elbow inside the partition, or chase, with wood blocking. Anchor with “C” clamps or cast brass drop ear elbows to prevent movement. Do not use wire as an anchoring device. 8. Piping shall not come into direct contact with metal studs, beams, or other construction elements. Provide a non-metallic separation between dissimilar metals when copper piping is installed in direct contact with steel. 9. Install unions in piping 2 inches and smaller and flanges in piping 2-1/2 inches and larger, adjacent to each valve and at final connection to each piece of equipment having threaded pipe connection. 10. Install piping adjacent to equipment and specialties to allow service and maintenance. 11. Install piping free of sags and bends. B. Plumbing Specialties and Equipment: 1. Pipe relief valves and drains to nearest floor drain. Minimum slope 1/16 inch per foot. Provide 1-inch air gap. 2. Install equipment plumb and square to wall on a 4-inch thick (minimum) reinforced concrete housekeeping pad. 3. Provide all interconnecting electrical power and control wiring from control panels to equipment and accessories for a complete operable systems. All exposed wiring shall be in conduit. Comply with Division 26. 4. Extend cleanouts to finished floor or wall surface. Lubricate threaded cleanout plugs with mixture of graphite and linseed oil. Ensure clearance at cleanout for rodding of drainage system. 5. Encase grade cleanouts in concrete flush with grade when not located in concrete, pavement, sidewalk, etc. 6. Grade cleanouts located in pavement or sidewalks shall have a brass or cast iron cover that extends to grade and a brass cap shall be installed. 7. Trap all drains connected to the sanitary sewer. 8. Install floor and area drains with top depressed 1/2 inch below finished floor elevation. 9. In addition to cleanouts, as shown on the Drawings, Contractor shall provide any additional cleanouts required by local codes and ordinances at no additional cost to the Owner. 10. Outlet of plumbing vents and flues shall be located a minimum of 25 feet from fresh air intakes. Provide offset as required. 11. Relief valve discharge drain from reduced pressure backflow preventers shall be piped full outlet size down to nearest floor drain. Drain line shall terminate above floor drain with air gap unless otherwise indicated on the Drawings. 12. Prior to ordering and installing water hammer arrestors, verify that the pressure at the point of installation does not drop to below 30 psig at any time. If the pressure drops Plumbing Systems 22 00 01 - 21 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements below 30 psig, do not install piston type water hammer arrestors. Install bellows type arrestors under low pressure circumstances. Provide access panel directly in front of each water hammer arrestor. C. Plumbing Fixtures and Connections: 1. Furnish and install plumbing fixtures, as noted on the Drawings. Each fixture shall be complete with trim and fittings, including traps and supply fittings. Set fixture with close tolerance to wall and floor surfaces. 2. Provide all wall mounted fixtures with floor carriers. Install and secure fixtures in place with wall supports carriers and bolts. Exposed bolts, nuts, etc. shall be stainless steel or chrome-plated brass. 3. Seal fixtures to wall and floor surfaces with white mildew resistant sealant. 4. Mount fixtures to Architectural Drawings interior wall elevations, manufacturers recommended elevations or the requirements of the ADA or TAS, whichever is applicable. 5. Provide removable insulation covering on stops and supplies and drains and P-traps on all handicapped lavatories. All lavatories in rooms with handicapped water closets are considered handicapped lavatories. 6. Provide accessible stops on all water supplies to fixtures and equipment. 7. Provide accessible water hammer arresters on hot and cold water supplies to plumbing fixtures and/or fixture groups in accordance with Standard PDI-WH-201. Water hammer arresters shall be as shown on diagrams and if not shown, provide for plumbing fixtures and/or fixture groups in accordance with Standard PDI-WH-201. 8. Provide drainage and vent piping run-outs to plumbing fixtures and drains, with approved trap, of sizes indicated, but in no case smaller than required by the governing Plumbing Code. 9. Provide drainage piping run-outs to urinals of cast iron material. Copper or brass material is prohibited. D. Trenching, Excavation and Backfill: 1. Perform excavating and backfilling necessary for the installation of Work. Shore, bail, pump and maintain all trenches dry until the Work is completed. Keep trenches open until piping has been inspected, tested and approved. Take necessary precautions to protect the public from open trenches. Erect and maintain barricades and warning devices in accordance with OSHA requirements. 2. Backfill trenches after piping has been tested and approved. Material for backfilling shall be a clean, sandy loam up to 4 inches above the top of pipe. Above that point, use overburden removed in the excavation process. Overburden shall be free of trash, debris, rocks or boulders. Deposit backfill material in 12-inch layers and compact to the density of the adjacent, undisturbed soil. Remove all excess material from the Site. 3.03 TESTING Plumbing Systems 22 00 01 - 22 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. Piping Systems: 1. General: Furnish pumps, compressors,-gauges, equipment and personnel required, and test as necessary to demonstrate the integrity of the finished installation. 2. Soil, Sanitary Waste and Vent: Unless otherwise directed by the authority having jurisdiction, plug all openings except for the highest opening and fill with water to the point of overflow. Perform a water test consisting of no less than 10 feet of head shall be applied to the system. Allow to stand 1 hour or longer as required. The system should be water tight and leak free. If leaks exist, repair and retest. 3. Water: Unless otherwise directed by the authority having jurisdiction, hydrostatically test and make tight the entire system at 120 psi. Retain for 4 hours. The system should be water tight and leak free. If leaks exist, repair and retest. 3.04 DEMONSTRATION OF EQUIPMENT A. Prior to final acceptance, Contractor and Manufacturer’s Representative of Domestic Water Heaters and associated accessories and controls, each shall provide a minimum of 4 hours (or as long as required by the Owner) to demonstrate to the Owner the proper operation of the equipment. B. Prior to final acceptance, Contractor shall provide a minimum of 4 hours (or as long as required by the Owner) to demonstrate to the Owner the proper operation of all the plumbing equipment and associated accessories and controls. 3.05 FLUSHING A. General: After piping systems have been tested and approved, systems shall be flushed. Furnished compressors, pumps, equipment, personnel, etc. required to flush piping systems. B. Soil, Sanitary Waste and Vent: Unless otherwise directed by the authority having jurisdiction, thoroughly flush piping systems with water until free of debris, or detrimental materials that may cause partial or full blockage. As a minimum comply with the International Plumbing Code, Section 302, of the latest edition. C. Water Piping: Unless otherwise directed by the authority having jurisdiction, flush piping with water until water flows clear for a minimum of 60 seconds per 100 linear feet of piping being flushed at a velocity of 9 feet per second. D. All strainers and filters shall be cleaned and replaced prior to start-up. 3.06 DISINFECTION OF DOMESTIC WATER PIPING SYSTEM A. Prior to starting Work, verify system is complete, flushed and clean. B. Inject disinfectant, free chlorine in liquid, powder, tablet or gas form, throughout system to obtain 50 to 80 mg/L residual. C. Bleed water from outlets to ensure distribution and test for disinfectant residual at minimum five remote outlets. D. Maintain disinfectant in system for 24 hours. Plumbing Systems 22 00 01 - 23 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements E. Flush disinfectant from system until residual equal to that of incoming water or 1.0 mg/L. F. Take Samples no sooner than 24 hours after flushing, from five remote outlets and from water entry, and analyze in accordance with AWWA C601. G. Disinfection and disinfection procedures shall be witnessed and approved by the Owners Representative. H. After disinfection is completed, submit “Disinfection Certificate of Approval” for domestic water piping systems to the Owners Representative stating that all test results are satisfactory. Certificate of Approval must be signed by Contractor, Testing Laboratory. Certificate shall show the date, time and residual of each of the following tests: 1. Initial disinfection residual (50 ppm minimum) - five Samples. 2. Final disinfection residual (25 ppm minimum) - five Samples. 3. After flushing residual (5 ppm maximum) - five Samples. 4. Analyze in accordance AWWA C601 - five Samples. 3.07 CLOSING IN UNINSPECTED WORK A. Do not cover up or enclose Work until it has been properly and completely inspected and approved. Should any of the Work be covered up or enclosed prior to all required inspections and approvals, uncover the Work as required. After it has been completely inspected and approved, make all repairs and replacements as necessary to the satisfaction of the Owner’s representative. Repairs and replacements shall be at no additional cost to the Owner. END OF SECTION Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-1 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements 22 13 44 PACKAGED SEWAGE LIFT STATION (DUPLEX GRINDER PUMPS) 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install complete factory- built and tested wetwell lift station, consisting of submersible grinder pumps suitably mounted in a basin constructed of fiberglass reinforced polyester resin. Station shall include internal piping, valves, discharge valve vault, electrical controls and all necessary internal wiring. 1.02 QUALITY ASSURANCE A. ACCEPTABLE MANUFACTURERS 1. Flygt (Xylem) 2. Zoeller 3. Approved equal. B. MANUFACTURER'S REPRESENTATIVE FOR STARTUP AND TESTING 1. The MANUFACTURER shall provide the services of qualified factory trained technician(s) who shall inspect the placement and wiring of each station, perform field tests as specified herein, and instruct the OWNER’S personnel in the operation and maintenance of the equipment before the stations are accepted by the OWNER. 2. All equipment and materials necessary to perform testing shall be the responsibility of the. INSTALLING CONTRACTOR. This includes, as a minimum, a portable generator and power cable (if temporary power is required), water in each basin (filled to a depth sufficient to verify the high level alarm is operating), and opening of all valves in the system. These steps shall be completed prior to the qualified factory trained technician(s) arrival on site. 3. Upon completion of the installation, the authorized factory technician(s) will perform the following test on each station: 1. Make certain the discharge shut-off valve in the station is fully open. 2. Turn ON the alarm power circuit and verify the alarm is functioning properly. 3. Turn ON the pump power circuit. Initiate the pump operation to verify automatic “on/off” controls are operative. The pump should immediately turn ON. 4. Consult the Manufacturer’s Service Manual for detailed start-up procedures. Upon completion of the start-up and testing, the MANUFACTURER shall submit to the ENGINEER the start-up authorization form describing the results of the tests performed for each grinder pump station. Final acceptance of the system will not occur until authorization forms have been received for each pump station installed and any installation deficiencies corrected. Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-2 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements 1.03 FACTORY TEST A. Each pump shall be submerged and operated for 5 minutes (minimum). Included in this procedure will be the testing of all ancillary components such as, the anti-siphon valve, check valve, discharge assembly and each unit’s dedicated level controls and motor controls. All factory tests shall incorporate each of the above listed items. Actual appurtenances and controls which will be installed in the field shall be particular to the tested pump only. A common set of appurtenances and controls for all pumps is not acceptable. Certified test results shall be available upon request showing the operation of each grinder pump at two different points on its curve, with a maximum pressure of no less than 80 psi and a factory bearing vibration test. The Engineer reserves the right to inspect such testing procedures with representatives of the Owner, at the Grinder Pump Manufacturer’s facility. B. All completed stations shall be factory leak tested to assure the integrity of all joints, seams and penetrations. All necessary penetrations such as inlets, discharge fittings and cable connectors shall be included in this test along with their respective sealing means (grommets, gaskets etc). 1.04 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Shop Drawings: Drawings shall show complete physical description and performance capabilities of the equipment, including, but not necessarily limited to dimensions, weights, materials, assemblies, performance curves, power requirements and ratings, rated voltage and amperage, and wiring diagrams as may be applicable. 2. Product Data Sheets (See Attachment A at the end of this Section for Submittal Data Sheet for Vertical Pumping Units.) 3. Operation and Maintenance Manuals 1.05 STANDARDS The applicable provisions of the following standards shall apply as if written here in their entirety: A. American Water Works Association (AWWA): B. American National Standards Institute (ANSI) C. American Standards for Testing and Materials (ASTM) D. National Electrical Manufacturers Association (NEMA) E. Test Code of the Hydraulic Institute Standards (HIS) F. Institute of Electrical and Electronic Engineers (IEEE) 1.06 DELIVERY AND STORAGE [NOT USED] 1.07 WARRANTY The grinder pump manufacturer shall provide a part(s) and labor warranty on the complete station and accessories, including, but not limited to, the panel for a period of 24 months after notice of Owner’s acceptance, but no greater than 27 months after receipt of shipment. Any Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-3 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements manufacturing defects found during the warranty period will be reported to the manufacturer by the Owner and will be corrected by the manufacturer at no cost to the Owner. 1.08 JOB CONDITIONS A. PERFORMANCE REQUIREMENTS 1. The pumps shall be capable of delivering 36 GPM against a rated total dynamic head of 24 feet (11 PSIG). The pump(s) must also be capable of operating at negative total dynamic head without overloading the motor(s). Under no conditions shall in-line piping or valving be allowed to create a false apparent head. 2. Liquid to be pumped is domestic wastewater. 3. It is desired that the pump have its highest efficiency at the designated optimum head, and this efficiency, as well as the efficiency at other operating conditions will be considered in evaluating the pump. 2.00 PRODUCTS 2.01 PUMP A. The pump shall be of the semi-open impeller type with pump-out vanes to reduce seal area pressure. The pump shall be a chopper type pump, where the chopping/maceration of materials is accomplished by the action of the leading edges of the impeller blades moving across the cutter bar at the intake openings. The pump shall be manufactured with a set clearance between the impeller and cutter bar of 0.010 to 0.015 inch. Cutter bar shall extend diametrically across entire pump suction opening. A removable disintegrator tool located below intake opening shall be provided to prevent suction blockage, to break up large solids and to induce flow. B. The impeller, disintegrator tool and cutter bar shall be minimum 500 Brinell hardness, heat- treated A148 Gr. 90 60 cast alloy steel. The pump casing and bearing housing shall be ductile cast iron. C. A separate oil-filled bearing housing shall be provided between the pump casing and submersible motor to isolate the lower mechanical seal on the motor from the pumped media. An additional mechanical seal below the thrust bearings in the bearing housing shall be provided to isolate pumped media from the bearing housing, with a maximum of 1.2 inches of overhang from the centerline of the lowest bearing to the seal faces. The mechanical shaft seal shall be Alloy 20 welded metal bellows type with silicon-carbide seal faces. The seal shall ride on a 316 stainless steel shaft sleeve, with the seal bellows tension set by three set screws. Shaft thrust in both directions shall be taken up by either a double-row angular contact ball bearing or by two back-to-back mounted single-row angular contact ball bearings, which bear against a machined shoulder on one side and the seal sleeve on the other side. The impeller is to be rigidly held in place with no axial adjustments. D. An automatic oil level monitor shall be provided to automatically shut down the pump and signal an alarm upon loss of oil. The seal faces and open bearings shall be oil-bath lubricated by SAE No. 10 turbine oil or equal non-foaming oil. Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-4 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements 2.02 MOTORS A. The submersible motor shall be UL listed and suitable for Class I, Group D, Division I hazardous locations, rated at 460 volts, 3 phase, and 60 Hertz, rated for continuous duty in 25 C liquid and for 15 minutes in air without overheating. Motor shall be equipped with tandem mechanical seals in oil bath and dual moisture sensing probes. Motor shall include two normally closed, automatic resetting thermostats connected in series and imbedded in adjoining phases. Motor frame shall be cast iron, and all hardware and shaft shall be stainless steel. B. Horsepower rating of motor shall be equal to or greater than the total horsepower requirements of the pump when operating at any head between the shut-off and minimum heads, including power requirements for hydraulic losses, shaft bearing loss, and motor thrust bearing loss from pump thrust. The motor shall have a service factor of 1.15. C. The motor shall be supplied with a space heater for operation on 120-volt, 1-phase, 60-Hz service. D. The motor shall be designed in accordance with applicable provisions of the NEMA Standard Publication for Motors and Generators, MG1 1978, with subsequent revisions thereto. E. Except where otherwise specified herein, motor shall conform to Section 01 60 00 “Product Requirements.” Motor windings shall be full Class F insulated. 2.03 SPECIAL TOOLS Furnish with the equipment, one (1) set of any special tools or devices required for the assembly, operation, and maintenance of all equipment furnished. 2.04 TANK AND INTEGRAL ACCESSWAY A. The tank shall be furnished with one EPDM grommet fitting to accept a 4.50" OD DWV or Schedule 40 pipe. The tank capacities shall be as shown on the contract drawings. B. The Drywell accessway shall be an integral extension of the Wetwell assembly and shall include a lockable cover assembly providing low profile mounting and watertight capability. The accessway design and construction shall enable field adjustment of the station height in increments of 4" or less without the use of any adhesives or sealants requiring cure time before installation can be completed. C. The station shall have all necessary penetrations molded in and factory sealed. To ensure a leak free installation no field penetrations will be acceptable. D. All discharge piping shall be constructed of 304 stainless steel. The discharge shall terminate outside the accessway bulkhead with a stainless steel, 1-1/4” Female NPT fitting. The discharge piping shall include a stainless steel ball valve rated for 235 psi WOG; PVC ball valves or brass ball/gate will not be accepted. The bulkhead penetration shall be factory installed and warranted by the manufacturer to be watertight. E. The accessway shall include a single NEMA 6P Electrical Quick Disconnect (EQD) for all power and control functions, factory installed with accessway penetrations warranted by the manufacturer to be watertight. The EQD will be supplied with 32’, 25’ of useable Electrical Supply Cable (ESC) outside the station, to connect to the alarm panel. The ESC shall be installed in the basin by the manufacturer. Field assembly of the ESC into the basin is not acceptable because of potential workmanship issues. The EQD shall require no tools for connecting, seal against water before the electrical connection is made, and include radial seals to assure a watertight seal regardless of tightening torque. Plug-type connections of Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-5 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements the power cable onto the pump housing will not be acceptable due to the potential for leaks and electrical shorts. A junction box shall not be permitted in the accessway due to the large number of potential leak points. The EQD shall be so designed to be conducive to field wiring as required. The accessway shall also include an integral 2-inch vent to prevent sewage gases from accumulating in the tank. 2.05 CHECK VALVE A. The pump discharge shall be equipped with a factory installed, gravity operated, flapper- type integral check valve built into the stainless steel discharge piping. The check valve will provide a full-ported passageway when open, and shall introduce a friction loss of less than 6 inches of water at maximum rated flow. Moving parts will be made of a 300 series stainless steel and fabric reinforced synthetic elastomer to ensure corrosion resistance, dimensional stability, and fatigue strength. A nonmetallic hinge shall be an integral part of the flapper assembly providing a maximum degree of freedom to assure seating even at a very low back-pressure. The valve body shall be an injection molded part made of an engineered thermoplastic resin. The working pressure of the valve shall be at least 235 psi. Ball-type check valves are unacceptable due to their limited sealing capacity in slurry applications. 2.06 ANTI-SIPHON VALVE A. The pump discharge shall be equipped with a factory-installed, gravity-operated, flapper- type integral anti-siphon valve built into the stainless steel discharge piping. Moving parts will be made of 300 Series stainless steel and fabric-reinforced synthetic elastomer to ensure corrosion resistance, dimensional stability, and fatigue strength. A nonmetallic hinge shall be an integral part of the flapper assembly, providing a maximum degree of freedom to ensure proper operation even at a very low pressure. The valve body shall be injection- molded from an engineered thermoplastic resin. Holes or ports in the discharge piping are not acceptable anti-siphon devices due to their tendency to clog from the solids in the slurry being pumped. The anti-siphon port diameter shall be no less than 60% of the inside diameter of the pump discharge piping. 2.07 CORE UNIT A. The grinder pump station shall have a cartridge type, easily removable core assembly consisting of pump, motor, grinder, all motor controls, check valve, anti-siphon valve, level controls, electrical quick disconnect and wiring. The core unit shall be installed in the basin by the manufacturer. Field assembly of the pump and controls into the basin is not acceptable because of potential workmanship issues and increased installation time. In some cases, stations taller than 96” may be shipped on their side without the cores assembled in the basin for freight purposes but this is the only exception. The core unit shall seal to the tank deck with a stainless steel latch assembly. The latch assembly must be actuated utilizing a single quick release mechanism requiring no more than a half turn of a wrench. The watertight integrity of each core unit shall be established by a 100 percent factory test at a minimum of 5 PSIG. 2.08 CONTROLS A. All necessary motor starting controls shall be located in the cast iron enclosure of the core unit secured by stainless steel fasteners. Locating the motor starting controls in a plastic enclosure is not acceptable. The wastewater level sensing controls shall be housed in a separate enclosure from motor starting controls. The level sensor housing must be sealed Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-6 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements via a radial type seal; solvents or glues are not acceptable. The level sensing control housing must be integrally attached to pump assembly so that it may be removed from the station with the pump and in such a way as to minimize the potential for the accumulation of grease and debris accumulation, etc. The level sensing housing must be a high-impact thermoplastic copolymer over-molded with a thermo plastic elastomer. The use of PVC for the level sensing housing is not acceptable. B. Non-fouling wastewater level controls for controlling pump operation shall be accomplished by monitoring the pressure changes in an integral air column connected to a pressure switch. The air column shall be integrally molded from a thermoplastic elastomer suitable for use in wastewater and with excellent impact resistance. The air column shall have only a single connection between the water level being monitored and the pressure switch. Any connections are to be sealed radially with redundant O-rings. The level detection device shall have no moving parts in direct contact with the wastewater and shall be integral to the pump core assembly in a single, readily-exchanged unit. Depressing the push to run button must operate the pump even with the level sensor housing removed from the pump. C. All fasteners throughout the assembly shall be 300 Series stainless steel. High-level sensing will be accomplished in the manner detailed above by a separate air column sensor and pressure switch of the same type. Closure of the high-level sensing device will energize an alarm circuit as well as a redundant pump-on circuit. For increased reliability, pump ON/OFF and high-level alarm functions shall not be controlled by the same switch. Float switches of any kind, including float trees, will not be accepted due to the periodic need to maintain (rinsing, cleaning) such devices and their tendency to malfunction because of incorrect wiring, tangling, grease buildup, and mechanical cord fatigue. To assure reliable operation of the pressure switches, each core shall be equipped with a factory installed equalizer diaphragm that compensates for any atmospheric pressure or temperature changes. Tube or piping runs outside of the station tank or into tank-mounted junction boxes providing pressure switch equalization will not be permitted due to their susceptibility to condensation, kinking, pinching, and insect infestation. The grinder pump will be furnished with a 6 conductor 14 gauge, type SJOW cable, pre-wired and watertight to meet UL requirements with a FACTORY INSTALLED NEMA 6P EQD half attached to it. 2.09 ALARM PANEL A. Each grinder pump station shall include a NEMA 4X, UL-listed alarm panel suitable for wall or pole mounting. The NEMA 4X enclosure shall be manufactured of thermoplastic polyester to ensure corrosion resistance. The enclosure shall include a hinged, lockable cover with padlock, preventing access to electrical components, and creating a secured safety front to allow access only to authorized personnel. The enclosure shall not exceed 10.5" W x 14" H x 7" D, or 12.5" W x 16" H x 7.5" D if certain options are included. B. The alarm panel shall contain one 15-amp, double-pole circuit breaker for the pump core’s power circuit and one 15-amp single-pole circuit breaker for the alarm circuit. The panel shall contain a push-to-run feature, an internal run indicator, and a complete alarm circuit. All circuit boards in the alarm panel are to be protected with a conformal coating on both sides and the AC power circuit shall include an auto resetting fuse. C. The alarm panel shall include the following features: external audible and visual alarm; push-to-run switch; push-to-silence switch; redundant pump start; and high level alarm capability. The alarm sequence is to be as follows when the pump and alarm breakers are on: Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-7 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements 1. When liquid level in the sewage wet-well rises above the alarm level, audible and visual alarms are activated, the contacts on the alarm pressure switch activate, and the redundant pump starting system is energized. 2. The audible alarm may be silenced by means of the externally mounted, push-to-silence button. 3. Visual alarm remains illuminated until the sewage level in the wet-well drops below the “off” setting of the alarm pressure switch. a. The visual alarm lamp shall be inside a red, oblong lens at least 3.75" L x 2.38" W x 1.5" H. Visual alarm shall be mounted to the top of the enclosure in such a manner as to maintain NEMA 4X rating. The audible alarm shall be externally mounted on the bottom of the enclosure, capable of 93 dB @ 2 feet. The audible alarm shall be capable of being deactivated by depressing a push-type switch that is encapsulated in a weatherproof silicone boot and mounted on the bottom of the enclosure (push- to-silence button). b. For duplex stations, in addition to the above, two high level indicator lights shall be mounted within the enclosure on the duplex panel’s alarm circuit board. During high level alarm indication on duplex stations, the appropriate indicator light will illuminate to indicate which core requires service. c. The entire alarm panel, as manufactured, shall be listed by Underwriters Laboratories, Inc. 3.00 EXECUTION 3.01 DELIVERY A. All grinder pump units will be delivered to the job site 100 percent completely assembled, including testing, ready for installation. Field installation of the pump in tanks under 96 inches is not allowed. Field installation of the level sensor into the tank is not allowed. Grinder pump stations will be individually mounted on wooden pallets. 3.02 INSTALLATION A. Earth excavation and backfill are specified under SITE WORK, but are also to be done as a part of the work under this section, including any necessary sheeting and bracing. B. The CONTRACTOR shall be responsible for handling ground water to provide a firm, dry subgrade for the structure, and shall guard against flotation or other damage resulting from general water or flooding. C. The grinder pump stations shall not be set into the excavation until the installation procedures and excavation have been approved by the ENGINEER. D. Remove packing material. Users instructions MUST be given to the OWNER. Hardware supplied with the unit, if required, will be used at installation. The basin will be supplied with a standard 4" inlet grommet (4.50" OD) for connecting the incoming sewer line. Appropriate inlet piping must be used. The basin may not be dropped, rolled or laid on its side for any reason. Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-8 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements E. Installation shall be accomplished so that 1" to 4" of accessway, below the bottom of the lid, extends above the finished grade line. The finished grade shall slope away from the unit. The diameter of the excavated hole must be large enough to allow for the concrete anchor. F. A 6" inch (minimum) layer of naturally rounded aggregate, clean and free flowing, with particle size of not less than 1/8" or more than 3/4" shall be used as bedding material under each unit. G. A concrete anti-flotation collar, as detailed on the drawings, and sized according to the manufacturer’s instructions, shall be required and shall be pre-cast to the grinder pump or poured in place. Each grinder pump station with its pre-cast anti-flotation collar shall have a minimum of three lifting eyes for loading and unloading purposes. H. If the concrete is poured in place, the unit shall be leveled, and filled with water, to the bottom of the inlet, to help prevent the unit from shifting while the concrete is being poured. The concrete must be manually vibrated to ensure there are no voids. If it is necessary to pour the concrete to a level higher than the inlet piping, an 8" sleeve is required over the inlet prior to the concrete being poured. I. The CONTRACTOR will provide and install a 4-foot piece of 4-inch SCH 40 PVC pipe with water tight cap, to stub-out the inlet for the property owners’ installation contractor, as depicted on the contract drawings. J. The electrical enclosure shall be furnished, installed and wired to the grinder pump station by the CONTRACTOR. An alarm device is required on every installation, there shall be NO EXCEPTIONS. It will be the responsibility of the CONTRACTOR and the ENGINEER to coordinate with the individual property owner(s) to determine the optimum location for the Alarm Panel. K. The CONTRACTOR shall mount the alarm device in a conspicuous location, as per national and local codes. The alarm panel will be connected to the grinder pump station by a length of 6 conductor 12 gauge type TC cable as shown on the contract drawings. The power and alarm circuits must be on separate power circuits. The grinder pump stations will be provided with 32’, 25’ of useable, electrical supply cable to connect the station to the alarm panel. This cable shall be supplied with a FACTORY INSTALLED EQD half to connect to the mating EQD half on the core. 3.03 BACKFILL REQUIREMENTS A. Proper backfill is essential to the long-term reliability of any underground structure. Several methods of backfill are available to produce favorable results with different native soil conditions. The most highly recommended method of backfilling is to surround the unit to grade using Class I or Class II backfill material as defined in ASTM 2321. Class 1A and Class 1B are recommended where frost heave is a concern, Class 1B is a better choice when the native soil is sand or if a high, fluctuating water table is expected. Class 1, angular crushed stone offers an added benefit in that it doesn’t need to be compacted. B. Class II, naturally rounded stone, may require more compactive effort, or tamping, to achieve the proper density. If the native soil condition consists of clean compactable soil, with less than 12 percent fines, free of ice, rocks, roots and organic material, it may be an acceptable backfill. Soil must be compacted in lifts not to exceed one foot to reach a final Proctor Density of between 85 percent and 90 percent. Heavy, non-compactable clays and silts are not suitable backfill for this or any underground structure such as inlet or discharge lines. Packaged Sewage Lift Station (Duplex Grinder Pumps) 22 13 44-9 DTN1810 – Lake Lewisville Water Treatment Plant Phase II Improvements C. Another option is the use of a flowable fill (i.e., low slump concrete). This is particularly attractive when installing grinder pump stations in augured holes where tight clearances make it difficult to assure proper backfilling and compaction with dry materials. Flowable fills should not be dropped more than 4 feet from the discharge to the bottom of the hole to avoid separation of the constituent materials. D. Backfill of clean native earth, free of rocks, roots, and foreign objects shall be thoroughly compacted in lifts not exceeding 12" to a final Proctor Density of not less than 85 percent. Improper backfilling may result in damaged accessways. The grinder pump station shall be installed at a minimum depth from grade to the top of the 1 1/4" discharge line, to assure maximum frost protection. The finish grade line shall be 1" to 4" below the bottom of the lid, and final grade shall slope away from the grinder pump station. E. All restoration will be the responsibility of the CONTRACTOR. Per unit costs for this item shall be included in the CONTRACTOR’S bid price for the individual grinder pump stations. The properties shall be restored to their original condition in all respects, including, but not limited to, curb and sidewalk replacement, landscaping, loaming and seeding, and restoration of the traveled ways, as directed by the ENGINEER. END OF SECTION Heating, Ventilating, and Air Conditioning 23 00 00 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 00 00 HEATING, VENTILATING, AND AIR CONDITIONING 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes the following: 1. Piping materials and installation instructions common to most piping systems. 2. Transition fittings. 3. Dielectric fittings. 4. Sleeves. 5. Mechanical demolition. 6. Equipment installation requirements common to equipment sections. 7. Painting and finishing. 8. Supports and anchorages. 9. HVAC coil protective coatings. 1.03 DEFINITIONS A. Finished Spaces: Spaces other than mechanical and electrical equipment rooms, furred spaces, pipe and duct shafts, unheated spaces immediately below roof, spaces above ceilings, unexcavated spaces, crawlspaces, and tunnels. B. Exposed, Interior Installations: Exposed to view indoors. Examples include finished occupied spaces and mechanical equipment rooms. C. Exposed, Exterior Installations: Exposed to view outdoors or subject to outdoor ambient temperatures and weather conditions. Examples include rooftop locations. D. Concealed, Interior Installations: Concealed from view and protected from physical contact by building occupants. Examples include above ceilings and in duct shafts. E. Concealed, Exterior Installations: Concealed from view and protected from weather conditions and physical contact by building occupants but subject to outdoor ambient temperatures. Examples include installations within unheated shelters. F. The following are industry abbreviations for plastic materials: 1. ABS: Acrylonitrile-butadiene-styrene plastic. 2. CPVC: Chlorinated polyvinyl chloride plastic. 3. PE: Polyethylene plastic. 4. PVC: Polyvinyl chloride plastic. Heating, Ventilating, and Air Conditioning 23 00 00 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements G. The following are industry abbreviations for rubber materials: 1. EPDM: Ethylene-propylene-diene terpolymer rubber. 2. NBR: Acrylonitrile-butadiene rubber. 1.04 SUBMITTALS A. Welding Certificates. 1.05 QUALITY ASSURANCE A. Steel Support Welding: Qualify processes and operators according to AWS D1.1, “Structural Welding Code--Steel.” B. Steel Pipe Welding: Qualify processes and operators according to ASME Boiler and Pressure Vessel Code: Section IX, “Welding and Brazing Qualifications.” 1. Comply with provisions in ASME B31 Series, “Standards of Pressure Piping.” 2. Certify that each welder has passed AWS qualification tests for welding processes involved and that certification is current. C. Electrical Characteristics for Mechanical Equipment: Equipment of higher electrical characteristics may be furnished provided such proposed equipment is approved in writing; connecting electrical services, circuit breakers, and conduit sizes are appropriately modified; and all is provided at no additional cost. If minimum energy ratings or efficiencies are specified, equipment shall comply with requirements. 1.06 DELIVERY, STORAGE, AND HANDLING A. Deliver pipes and tubes with factory-applied end caps. Maintain end caps through shipping, storage, and handling to prevent pipe end damage and to prevent entrance of dirt, debris, and moisture. B. Store plastic pipes protected from direct sunlight. Support to prevent sagging and bending. 1.07 COORDINATION A. Arrange for pipe spaces, chases, slots, and openings in building structure during progress of construction, to allow for mechanical installations. B. Coordinate installation of required supporting devices and set sleeves in poured-in-place concrete and other structural components as they are constructed. C. Coordinate requirements for access panels and doors for mechanical items requiring access that are concealed behind finished surfaces. Access panels and doors are specified in Division 08. 2.00 PRODUCTS 2.01 MANUFACTURERS A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection: Heating, Ventilating, and Air Conditioning 23 00 00 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified. 2.02 PIPE, TUBE, AND FITTINGS A. Refer to individual Division 23 piping Sections for pipe, tube, and fitting materials and joining methods. B. Pipe Threads: ASME B1.20.1 for factory-threaded pipe and pipe fittings. 2.03 JOINING MATERIALS A. Refer to individual Division 23 piping Sections for special joining materials not listed below. B. Pipe-Flange Gasket Materials: Suitable for chemical and thermal conditions of piping system contents. 1. ASME B16.21, non-metallic, flat, asbestos-free, 1/8-inch (3.2-mm) maximum thickness unless thickness or specific material is indicated. a. Full-Face Type: For flat-face, Class 125, cast-iron and cast-bronze flanges. b. Narrow-Face Type: For raised-face, Class 250, cast-iron and steel flanges. 2. AWWA C110, rubber, flat face, 1/8 inch (3.2 mm) thick, unless otherwise indicated; and full-face or ring type, unless otherwise indicated. C. Flange Bolts and Nuts: ASME B18.2.1, carbon steel, unless otherwise indicated. D. Plastic, Pipe-Flange Gasket, Bolts, and Nuts: Type and material recommended by piping system manufacturer, unless otherwise indicated. E. Solder Filler Metals: ASTM B32, lead-free alloys. Include water-flushable flux according to ASTM B813. F. Brazing Filler Metals: AWS A5.8, BCuP Series, copper-phosphorus alloys for general-duty brazing, unless otherwise indicated; and AWS A5.8, BAg1, silver alloy for refrigerant piping, unless otherwise indicated. G. Welding Filler Metals: Comply with AWS D10.12 for welding materials appropriate for wall thickness and chemical analysis of steel pipe being welded. H. Solvent Cements for Joining Plastic Piping: 1. ABS Piping: ASTM D2235. 2. CPVC Piping: ASTM F493. 3. PVC Piping: ASTM D2564. Include primer according to ASTM F656. 4. PVC to ABS Piping Transition: ASTM D3138. I. Fiberglass Pipe Adhesive: As furnished or recommended by pipe manufacturer. 2.04 DIELECTRIC FITTINGS A. Description: Combination fitting of copper alloy and ferrous materials with threaded, solder-joint, plain, or weld-neck end connections that match piping system materials. Heating, Ventilating, and Air Conditioning 23 00 00 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Insulating Material: Suitable for system fluid, pressure, and temperature. C. Dielectric Unions: Factory-fabricated, union assembly, for 250-psig (1725-kPa) minimum working pressure at 180 F (82 C). 1. Manufacturers: a. Capitol Manufacturing Co. b. Central Plastics Company. c. Epco Sales, Inc. d. Hart Industries, International, Inc. e. Watts Industries, Inc.; Water Products Div. f. Zurn Industries, Inc.; Wilkins Div. D. Dielectric Flanges: Factory-fabricated, companion-flange assembly, for 150- or 300-psig (1035- or 2070-kPa) minimum working pressure as required to suit system pressures. 1. Manufacturers: a. Capitol Manufacturing Co. b. Central Plastics Company. c. Epco Sales, Inc. d. Watts Industries, Inc.; Water Products Div. E. Dielectric-Flange Kits: Companion-flange assembly for field assembly. Include flanges, full- face- or ring-type neoprene or phenolic gasket, phenolic or polyethylene bolt sleeves, phenolic washers, and steel backing washers. 1. Manufacturers: a. Advance Products & Systems, Inc. b. Calpico, Inc. c. Central Plastics Company. d. Pipeline Seal and Insulator, Inc. 2. Separate companion flanges and steel bolts and nuts shall have 150- or 300-psig (1035- or 207- kPa) minimum working pressure where required to suit system pressures. F. Dielectric Couplings: Galvanized-steel coupling with inert and non-corrosive, thermoplastic lining; threaded ends; and 300-psig (2070-kPa) minimum working pressure at 225 F (107 C). 1. Manufacturers: a. Calpico, Inc. b. Lochinvar Corp. G. Dielectric Nipples: Electroplated steel nipple with inert and non-corrosive, thermoplastic lining; plain, threaded, or grooved ends; and 300-psig (2070-kPa) minimum working pressure at 225 F (107 C). Heating, Ventilating, and Air Conditioning 23 00 00 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1. Manufacturers: a. Perfection Corp. b. Precision Plumbing Products, Inc. c. Sioux Chief Manufacturing Co., Inc. d. Victaulic Co. of America. 2.05 SLEEVES A. Galvanized-Steel Sheet: 0.0239-inch (0.6-mm) minimum thickness; round tube closed with welded longitudinal joint. B. Steel Pipe: ASTM A53/A53M, Type E, Grade B, Schedule 40, galvanized, plain ends. C. Cast Iron: Cast or fabricated “wall pipe” equivalent to ductile-iron pressure pipe, with plain ends and integral waterstop, unless otherwise indicated. D. Stack Sleeve Fittings: Manufactured, cast-iron sleeve with integral clamping flange. Include clamping ring and bolts and nuts for membrane flashing. 1. Underdeck Clamp: Clamping ring with set screws. E. Molded PE: Reusable, PE, tapered-cup shaped, and smooth-outer surface with nailing flange for attaching to wooden forms. 2.06 HVAC COIL PROTECTIVE COATINGS A. Coating Type: Aluminum impregnated polyurethane coating. B. Application: Provide coating on HVAC copper tube coils. C. The coating manufacturer shall be able to document the successful completion of accelerated product testing of a minimum 3000 hours in both salt spray (ASTM B117) and acidic salt spray tests (ASTM G85); and shall provide a 3-year warranty for the coating applied on aluminum-finned, copper tube coils. D. The product application process shall include the application of a chromate-free conversion layer applied to the coil that achieves total coverage and penetration. E. An aluminum-impregnated polyurethane topcoat shall be applied that ensures total penetration and coverage without bridging or significantly affecting the heat transfer ability of the coil. F. The total dry film thickness of the topcoat shall be 20 to 25 microns. (0.020 to 0.025 mm) The coating shall provide protection against ultraviolet radiation and be temperature resistant up to 194 F (90 C). G. Product: “PoluAl” by Blygold America, “Bronz-Glow” or approved equal. 3.00 EXECUTION 3.01 MECHANICAL DEMOLITION A. Refer to Divisions 1 and 2 for general demolition requirements and procedures. Heating, Ventilating, and Air Conditioning 23 00 00 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Disconnect, demolish, and remove mechanical systems, equipment, and components indicated to be removed. 1. Piping to Be Removed: Remove portion of piping indicated to be removed and cap or plug remaining piping with same or compatible piping material. 2. Piping to Be Abandoned in Place: Drain piping and cap or plug piping with same or compatible piping material. 3. Ducts to Be Removed: Remove portion of ducts indicated to be removed and plug remaining ducts with same or compatible ductwork material. 4. Ducts to Be Abandoned in Place: Cap or plug ducts with same or compatible ductwork material. 5. Equipment to Be Removed: Disconnect and cap services and remove equipment. 6. Equipment to Be Removed and Reinstalled: Disconnect and cap services and remove, clean, and store equipment; when appropriate, reinstall, reconnect, and make equipment operational. 7. Equipment to Be Removed and Salvaged: Disconnect and cap services and remove equipment and deliver to Owner. C. If pipe, insulation, or equipment to remain is damaged in appearance or is unserviceable, remove damaged or unserviceable portions and replace with new products of equal capacity and quality. 3.02 PIPING SYSTEMS - COMMON REQUIREMENTS A. Install piping according to the following requirements and Division 23 Sections specifying piping systems. B. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Indicated locations and arrangements were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on Coordination Drawings. C. Install piping in concealed locations, unless otherwise indicated and except in equipment rooms and service areas. D. 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. E. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal. F. Install piping to permit valve servicing. G. Install piping at indicated slopes. H. Install piping free of sags and bends. I. Install fittings for changes in direction and branch connections. J. Install piping, pipe hangers and supports to allow application of insulation. Heating, Ventilating, and Air Conditioning 23 00 00 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements K. Select system components with pressure rating equal to or greater than system operating pressure. L. Wrap or enclose with rated materials PVC piping installed in rated spaces, including return air plenums. M. Install sleeves for pipes passing through concrete and masonry walls, gypsum-board partitions, and concrete floor and roof slabs. 1. Cut sleeves to length for mounting flush with both surfaces. a. Exception: Extend sleeves installed in floors of mechanical equipment areas or other wet areas 2 inches (50 mm) above finished floor level. Extend cast-iron sleeve fittings below floor slab as required to secure clamping ring if ring is specified. 2. Install sleeves in new walls and slabs as new walls and slabs are constructed. 3. Install sleeves that are large enough to provide 1/4-inch (6.4-mm) annular clear space between sleeve and pipe or pipe insulation. Use the following sleeve materials: a. Steel Pipe Sleeves: For pipes smaller than NPS 6 (DN 150). b. Steel Sheet Sleeves: For pipes NPS 6 (DN 150) and larger, penetrating gypsum- board partitions. c. Stack Sleeve Fittings: For pipes penetrating floors with membrane waterproofing. Secure flashing between clamping flanges. Install section of cast-iron soil pipe to extend sleeve to 2 inches (50 mm) above finished floor level. Refer to Division 07 for flashing. 1). Seal space outside of sleeve fittings with grout. 4. Except for underground wall penetrations, seal annular space between sleeve and pipe or pipe insulation, using joint sealants appropriate for size, depth, and location of joint. Refer to Division 07 for materials and installation. N. Aboveground, Exterior-Wall Pipe Penetrations: Seal penetrations using sleeves and mechanical sleeve seals. Select sleeve size to allow for 1-inch (25-mm) annular clear space between pipe and sleeve for installing mechanical sleeve seals. 1. Install steel pipe for sleeves smaller than 6 inches (150 mm) in diameter. 2. Install cast-iron “wall pipes” for sleeves 6 inches (150 mm) and larger in diameter. 3. Mechanical Sleeve Seal Installation: Select type and number of sealing elements required for pipe material and size. Position pipe in center of sleeve. Assemble mechanical sleeve seals and install in annular space between pipe and sleeve. Tighten bolts against pressure plates that cause sealing elements to expand and make watertight seal. O. Underground, Exterior-Wall Pipe Penetrations: Install cast-iron “wall pipes” for sleeves. Seal pipe penetrations using mechanical sleeve seals. Select sleeve size to allow for 1-inch (25-mm) annular clear space between pipe and sleeve for installing mechanical sleeve seals. Heating, Ventilating, and Air Conditioning 23 00 00 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1. Mechanical Sleeve Seal Installation: Select type and number of sealing elements required for pipe material and size. Position pipe in center of sleeve. Assemble mechanical sleeve seals and install in annular space between pipe and sleeve. Tighten bolts against pressure plates that cause sealing elements to expand and make watertight seal. P. Fire-Barrier Penetrations: Maintain indicated fire rating of walls, partitions, ceilings, and floors at pipe penetrations. Seal pipe penetrations with firestop materials. Refer to Division 07 for materials. Q. Verify final equipment locations for roughing-in. R. Refer to equipment specifications in other Sections of these Specifications for roughing-in requirements. 3.03 PIPING JOINT CONSTRUCTION A. Join pipe and fittings according to the following requirements and Division 23 Sections specifying piping systems. B. Ream ends of pipes and tubes and remove burrs. Bevel plain ends of steel pipe. C. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly. D. Soldered Joints: Apply ASTM B813, water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B828 or CDA’s “Copper Tube Handbook,” using lead-free solder alloy complying with ASTM B32. E. Brazed Joints: Construct joints according to AWS’s “Brazing Handbook,” “Pipe and Tube” Chapter, using copper-phosphorus brazing filler metal complying with AWS A5.8. F. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows: 1. Apply appropriate tape or thread compound to external pipe threads unless dry seal threading is specified. 2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged. Do not use pipe sections that have cracked or open welds. G. Welded Joints: Construct joints according to AWS D10.12, using qualified processes and welding operators according to Part 1 “Quality Assurance” Article. H. Flanged Joints: Select appropriate gasket material, size, type, and thickness for service application. Install gasket concentrically positioned. Use suitable lubricants on bolt threads. I. Plastic Piping Solvent-Cement Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following: 1. Comply with ASTM F402 for safe-handling practice of cleaners, primers, and solvent cements. 2. ABS Piping: Join according to ASTM D2235 and ASTM D2661 Appendixes. 3. CPVC Piping: Join according to ASTM D2846/D2846M Appendix. Heating, Ventilating, and Air Conditioning 23 00 00 - 9 DTN18104 – Lake Lewisville WTP/RWPS Improvements 4. PVC Pressure Piping: Join schedule number ASTM D1785, PVC pipe and PVC socket fittings according to ASTM D2672. Join other-than-schedule-number PVC pipe and socket fittings according to ASTM D2855. 5. PVC Non-pressure Piping: Join according to ASTM D2855. 6. PVC to ABS Non-pressure Transition Fittings: Join according to ASTM D3138 Appendix. J. Plastic Pressure Piping Gasketed Joints: Join according to ASTM D3139. K. Plastic Non-pressure Piping Gasketed Joints: Join according to ASTM D3212. L. PE Piping Heat-Fusion Joints: Clean and dry joining surfaces by wiping with clean cloth or paper towels. Join according to ASTM D2657. 1. Plain-End Pipe and Fittings: Use butt fusion. 2. Plain-End Pipe and Socket Fittings: Use socket fusion. M. Fiberglass Bonded Joints: Prepare pipe ends and fittings, apply adhesive, and join according to pipe manufacturer’s written instructions. 3.04 PIPING CONNECTIONS A. Make connections according to the following, unless otherwise indicated: 1. Install unions, in piping NPS 2 (DN 50) and smaller, adjacent to each valve and at final connection to each piece of equipment. 2. Install flanges, in piping NPS 2-1/2 (DN 65) and larger, adjacent to flanged valves and at final connection to each piece of equipment. 3. Dry Piping Systems: Install dielectric unions and flanges to connect piping materials of dissimilar metals. 4. Wet Piping Systems: Install dielectric coupling and nipple fittings to connect piping Materials of dissimilar metals. 3.05 EQUIPMENT INSTALLATION - COMMON REQUIREMENTS A. Install equipment to allow maximum possible headroom unless specific mounting heights are indicated. B. Install equipment level and plumb, parallel and perpendicular to other building systems and components in exposed interior spaces, unless otherwise indicated. C. Install mechanical equipment to facilitate service, maintenance, and repair or replacement of components. Connect equipment for ease of disconnecting, with minimum interference to other installations. Extend grease fittings to accessible locations. D. Install equipment to allow right of way for piping installed at required slope. 3.06 PAINTING A. Painting of mechanical systems, equipment, and components is specified in Division 09. B. Damage and Touchup: Repair marred and damaged factory-painted finishes with materials and procedures to match original factory finish. Heating, Ventilating, and Air Conditioning 23 00 00 - 10 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.07 ERECTION OF METAL SUPPORTS AND ANCHORAGES A. Refer to Division 05 Sections for miscellaneous metal fabrications and structural steel. B. Cut, fit, and place miscellaneous metal supports accurately in location, alignment, and elevation to support and anchor mechanical materials and equipment. C. Field Welding: Comply with AWS D1.1. 3.08 ERECTION OF WOOD SUPPORTS AND ANCHORAGES A. Cut, fit, and place wood grounds, nailers, blocking, and anchorages to support, and anchor mechanical materials and equipment. B. Select fastener sizes that will not penetrate members if opposite side will be exposed to view or will receive finish materials. Tighten connections between members. Install fasteners without splitting wood members. C. Attach to substrates as required to support applied loads. END OF SECTION Common Motor Requirements for HVAC Equipment 23 05 13 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 05 13 COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. Section includes general requirements for single-phase and polyphase, general-purpose, horizontal, small and medium, squirrel-cage induction motors for use on alternating current power systems up to 600 V and installed at equipment manufacturer's factory or shipped separately by equipment manufacturer for field installation. 1.03 DEFINITIONS A. Factory-Installed Motor: A motor installed by motorized-equipment manufacturer as a component of equipment. 1.04 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. 1.05 COORDINATION A. Coordinate features of motors, installed units, and accessory devices and features that comply with the following: 1. Compatible with the following: a. Magnetic controllers. b. Multispeed controllers. c. Reduced-voltage controllers. 2. Designed and labeled for use with variable frequency controllers, and suitable for use throughout speed range without overheating. 3. Matched to torque and horsepower requirements of the load. 4. Matched to ratings and characteristics of supply circuit and required control sequence. 5. Ambient and environmental conditions of installed location. 2.00 PRODUCTS 2.01 GENERAL MOTOR REQUIREMENTS A. Comply with NEMA MG 1 unless otherwise indicated. Common Motor Requirements for HVAC Equipment 23 05 13 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Comply with IEEE 841 for severe-duty motors. C. Motor requirements apply to factory-installed motors except as follows: 1. Different ratings, performance, or characteristics for a motor are specified in another Section. 2. Manufacturer for a factory-installed motor requires ratings, performance, or characteristics, other than those specified in this Section, to meet performance specified. 2.02 MOTOR CHARACTERISTICS A. Duty: Continuous duty at ambient temperature of 105 F (40 C) and at altitude of 3300 feet (1005 m) 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. C. Enclosure: Unless indicated otherwise, provide the following enclosure type: 1. Open Dripproof (ODP): Ventilation openings are arranged to prevent liquid drops from affecting performance when falling within a 15-degree angle from the vertical. Use: Indoors, in moderately clean environments. 2. Totally Enclosed, Nonventilated (TENV): No ventilation openings in housing. Cooling by convection and radiation only. This enclosure type is limited to small integral (5 HP and smaller), fractional, and subfractional motor sizes. Use: In damp, dirty, corrosive, or contaminated environments. 3. Totally Enclosed, Fan Cooled (TEFC): A fan on the motor shaft, outside the stator housing and within a protective shroud, blows cooling air over the motor. Use: Outdoors. 4. Totally Enclosed, Air Over (TEAO): Motors used in vane- or tube-axial or propeller fan applications where the velocity and temperature of the airstream are appropriate for cooling the motor without the energy waste of another fan on the motor shaft. 5. Severe Duty: Totally enclosed. The enclosure is designed to withstand harsh, wet, and chemically laden environments typically encountered in chemical and industrial processing plants. The motors have extra seals, gasketing, and corrosion-resistant finishes on both the interior and exterior enclosure surfaces. Motors are manufactured to IEEE 841 requirements. Use: In harsh, wet, and chemically laden environments. 6. Explosion Proof (EP): Totally enclosed. The enclosure is designed to withstand an internal explosion of a specific gas or vapor mixture and to prevent the escape of ignition products to the gas or vapor mixture surrounding the motor. Motors must be UL approved or CSA International (CSA) certified for specific hazard classifications, and are covered by NFPA 70, Article 500, for use in hazardous locations, Class I, Group A, B, C, or D. Common Motor Requirements for HVAC Equipment 23 05 13 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 7. Dust-Ignition-Proof: Totally enclosed. The enclosure is designed to exclude ignitable amounts of dust or amounts that might affect performance or rating, and to prevent the escape of ignition products to cause ignition of exterior accumulations or atmospheric suspensions of a specific dust on or in the vicinity of the enclosure. Motors must be UL approved or CSA certified for specific hazard classifications, and are covered by NFPA 70, Article 500, for use in hazardous locations, Class II, Group E, F, or G. 2.03 POLYPHASE MOTORS A. Description: NEMA MG 1, Design B, medium induction motor. B. Efficiency: Premium efficient as defined in NEMA MG 1. C. Service factor: 1.15. D. Stator: Copper windings, unless otherwise indicated. 1. Multispeed motors shall have separate winding for each speed. E. Rotor: Random wound squirrel cage. F. Bearings: Regreasable, shielded, antifriction ball bearings suitable for radial and thrust loading. G. Temperature Rise: Match insulation rating. H. Insulation: Class F, unless otherwise indicated. 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. 2.04 ADDITIONAL REQUIREMENTS FOR POLYPHASE MOTORS 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: Inverter – duty rated. Ratings, characteristics, and features coordinated with and approved by controller manufacturer. 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. 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. C. Severe-Duty Motors: Comply with IEEE 841, with 1.15 minimum service factor. Common Motor Requirements for HVAC Equipment 23 05 13 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.05 SINGLE-PHASE MOTORS A. Motors larger than 1/20 HP shall be one of the following, to suit starting torque and requirements of specific motor application: 1. Permanent-split capacitor. 2. Split-phase. 3. Capacitor start, inductor run. 4. Capacitor start, capacitor run. B. Multispeed Motors: Variable-torque, permanent-split-capacitor type. C. Bearings: Prelubricated, antifriction ball bearings or sleeve bearings suitable for radial and thrust loading. D. Motors 1/20 HP and Smaller: Shaded-pole type. E. Thermal Protection: Internal protection to automatically open power supply circuit to motor when winding temperature exceeds a safe value calibrated to temperature rating of motor insulation. Thermal-protection device shall automatically reset when motor temperature returns to normal range. 3.00 EXECUTION (NOT USED) END OF SECTION Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 05 29 HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes hangers and supports for mechanical system piping and equipment. 1. Trapeze pipe hangers. 2. Thermal-hanger shield inserts. 3. Equipment supports. 1.03 DEFINITIONS A. MSS: Manufacturers Standardization Society for the Valve and Fittings Industry. B. Terminology: As defined in MSS SP-90, “Guidelines on Terminology for Pipe Hangers and Supports.” 1.04 PERFORMANCE REQUIREMENTS A. Design channel support systems for piping to support multiple pipes capable of supporting combined weight of supported systems, system contents, and test water. B. Design heavy-duty steel trapezes for piping to support multiple pipes capable of supporting combined weight of supported systems, system contents, and test water. C. Design seismic restraint hangers and supports for piping and equipment. D. Design and obtain approval from authorities having jurisdiction for seismic restraint hangers and supports for piping and equipment. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Acceptable Manufacturers: 1. Pipe Hangers: a. AAA Technology and Specialties Co., Inc. b. B-Line Systems, Inc. c. Carpenter & Patterson, Inc. d. Empire Tool & Manufacturing Co., Inc. e. Globe Pipe Hanger Products, Inc. Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements f. Grinnell Corp. g. GS Metals Corp. h. Michigan Hanger Co., Inc. i. National Pipe Hanger Corp. j. PHD Manufacturing, Inc. k. PHS Industries, Inc. l. Piping Technology & Products, Inc. 2. Channel Support Systems: a. B-Line Systems, Inc. b. Grinnell Corp.; Power-Strut Unit. c. GS Metals Corp. d. Michigan Hanger Co., Inc.; O-Strut Div. e. National Pipe Hanger Corp. f. Thomas & Betts Corp. g. Unistrut Corp. h. Wesanco, Inc. 3. Thermal-Hanger Shield Inserts: a. Carpenter & Patterson, Inc. b. Michigan Hanger Co., Inc. c. PHS Industries, Inc. d. Pipe Shields, Inc. e. Rilco Manufacturing Co., Inc. f. Value Engineered Products, Inc. 2.02 MANUFACTURED UNITS A. Pipe Hangers, Supports, and Components: MSS SP-58, factory-fabricated components. Refer to “Hanger and Support Applications” Article in Part 3 for where to use specific hanger and support types. 1. Galvanized, Metallic Coatings: For piping and equipment that will not have field-applied finish. 2. Nonmetallic Coatings: On attachments for electrolytic protection where attachments are in direct contact with copper tubing. B. Channel Support Systems: MFMA-2, factory-fabricated components for field assembly. Calculation and detail of each support is required. 1. Coatings: Manufacturer’s standard finish, unless bare metal surfaces are indicated. Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. Nonmetallic Coatings: On attachments for electrolytic protection where attachments are in direct contact with copper tubing. C. Thermal-Hanger Shield Inserts: 100-psi (690-kPa) minimum compressive-strength insulation, encased in sheet metal shield. 1. Material for Cold Piping: ASTM C552, Type I cellular glass or water-repellent-treated, ASTM C533, Type I calcium silicate with vapor barrier. 2. For Clevis or Band Hanger: Insert and shield cover lower 180 degrees of pipe. 3. Insert Length: Extend 2 inches (50 mm) beyond sheet metal shield for piping operating below ambient air temperature. 2.03 MISCELLANEOUS MATERIALS A. Mechanical-Anchor Fasteners: Insert-type attachments with pull-out and shear capacities appropriate for supported loads and building materials where used. Do not use in lightweight concrete or concrete slabs less than 4 inches (100 mm) thick. B. Structural Steel: ASTM A36/A 36M, steel plates, shapes, and bars, black and galvanized. C. Grout: ASTM C1107, Grade B, factory-mixed and -packaged, nonshrink and nonmetallic, dry, hydraulic-cement grout. 1. Characteristics: Post hardening and volume adjusting; recommended for both interior and exterior applications. 2. Properties: Nonstaining, noncorrosive, and nongaseous. 3. Design Mix: 5000-psi (34.5-MPa), 28-day compressive strength. 3.00 EXECUTION 3.01 HANGER AND SUPPORT APPLICATIONS A. Specific hanger requirements are specified in Sections specifying equipment and systems. B. Comply with MSS SP-69 for pipe hanger selections and applications that are not specified in piping system Specification Sections. C. Horizontal-Piping Hangers and Supports: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Adjustable Steel Clevis Hangers (MSS Type 1): For suspension of noninsulated or insulated stationary pipes, NPS 1/2 to NPS 30 (DN15 to DN750). 2. Yoke-Type Pipe Clamps (MSS Type 2): For suspension of 120 to 450 F (49 to 232 C) pipes, NPS 4 to NPS 16 (DN100 to DN400), requiring up to 4 inches (100 mm) of insulation. 3. Carbon- or Alloy-Steel, Double-Bolt Pipe Clamps (MSS Type 3): For suspension of pipes, NPS 3/4 to NPS 24 (DN20 to DN600), requiring clamp flexibility and up to 4 inches (100 mm) of insulation. 4. Steel Pipe Clamps (MSS Type 4): For suspension of cold and hot pipes, NPS 1/2 to NPS 24 (DN15 to DN600), if little or no insulation is required. Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 5. Pipe Hangers (MSS Type 5): For suspension of pipes, NPS 1/2 to NPS 4 (DN15 to DN100), to allow off-center closure for hanger installation before pipe erection. 6. Adjustable Swivel Split- or Solid-Ring Hangers (MSS Type 6): For suspension of noninsulated stationary pipes, NPS 3/4 to NPS 8 (DN20 to DN200). 7. Adjustable Steel Band Hangers (MSS Type 7): For suspension of noninsulated stationary pipes, NPS 1/2 to NPS 8 (DN15 to DN200). 8. Adjustable Band Hangers (MSS Type 9): For suspension of noninsulated stationary pipes, NPS 1/2 to NPS 8 (DN15 to DN200). 9. Adjustable Swivel-Ring Band Hangers (MSS Type 10): For suspension of noninsulated stationary pipes, NPS 1/2 to NPS 2 (DN15 to DN50). 10. Split Pipe-Ring with or without Turnbuckle-Adjustment Hangers (MSS Type 11): For suspension of noninsulated stationary pipes, NPS 3/8 to NPS 8 (DN10 to DN200). 11. Extension Hinged or Two-Bolt Split Pipe Clamps (MSS Type 12): For suspension of noninsulated stationary pipes, NPS 3/8 to NPS 3 (DN10 to DN80). 12. U-Bolts (MSS Type 24): For support of heavy pipe, NPS 1/2 to NPS 30 (DN15 to DN750). 13. Clips (MSS Type 26): For support of insulated pipes not subject to expansion or contraction. 14. Pipe Saddle Supports (MSS Type 36): For support of pipes, NPS 4 to NPS 36 (DN100 to DN900), with steel pipe base stanchion support and cast-iron floor flange. 15. Pipe Stanchion Saddles (MSS Type 37): For support of pipes, NPS 4 to NPS 36 (DN100 to DN900), with steel pipe base stanchion support and cast-iron floor flange and with U- bolt to retain pipe. 16. Adjustable Pipe Saddle Supports (MSS Type 38): For stanchion-type support for pipes, NPS 2-1/2 to NPS 36 (DN65 to DN900), if vertical adjustment is required, with steel pipe base stanchion support and cast-iron floor flange. 17. Single Pipe Rolls (MSS Type 41): For suspension of pipes, NPS 1 to NPS 30 (DN25 to DN750), from two rods if longitudinal movement caused by expansion and contraction might occur. 18. Adjustable Roller Hangers (MSS Type 43): For suspension of pipes, NPS 2-1/2 to NPS 20 (DN65 to DN500), from single rod if horizontal movement caused by expansion and contraction might occur. 19. Complete Pipe Rolls (MSS Type 44): For support of pipes, NPS 2 to NPS 42 (DN50 to DN1050), if longitudinal movement caused by expansion and contraction might occur but vertical adjustment is not necessary. 20. Pipe Roll and Plate Units (MSS Type 45): For support of pipes, NPS 2 to NPS 24 (DN50 to DN600), if small horizontal movement caused by expansion and contraction might occur and vertical adjustment is not necessary. 21. Adjustable Pipe Roll and Base Units (MSS Type 46): For support of pipes, NPS 2 to NPS 30 (DN50 to DN750), if vertical and lateral adjustment during installation might be required in addition to expansion and contraction. Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Vertical-Piping Clamps: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Extension Pipe or Riser Clamps (MSS Type 8): For support of pipe risers, NPS 3/4 to NPS 20 (DN20 to DN500). 2. Carbon- or Alloy-Steel Riser Clamps (MSS Type 42): For support of pipe risers, NPS 3/4 to NPS 20 (DN20 to DN500), if longer ends are required for riser clamps. E. Hanger-Rod Attachments: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Steel Turnbuckles (MSS Type 13): For adjustment up to 6 inches (150 mm) for heavy loads. 2. Steel Clevises (MSS Type 14): For 120 to 450 F (49 to 232 C) piping installations. 3. Swivel Turnbuckles (MSS Type 15): For use with MSS Type 11, split pipe rings. 4. Malleable-Iron Sockets (MSS Type 16): For attaching hanger rods to various types of building attachments. 5. Steel Weldless Eye Nuts (MSS Type 17): For 120 to 450 F (49 to 232 C) piping installations. F. Building Attachments: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Steel or Malleable Concrete Inserts (MSS Type 18): For upper attachment to suspend pipe hangers from concrete ceiling. 2. Top-Beam C-Clamps (MSS Type 19): For use under roof installations with bar-joist construction to attach to top flange of structural shape. 3. Side-Beam or Channel Clamps (MSS Type 20): For attaching to bottom flange of beams, channels, or angles. 4. Center-Beam Clamps (MSS Type 21): For attaching to center of bottom flange of beams. 5. Welded Beam Attachments (MSS Type 22): For attaching to bottom of beams if loads are considerable and rod sizes are large. 6. C-Clamps (MSS Type 23): For structural shapes. 7. Top-Beam Clamps (MSS Type 25): For top of beams if hanger rod is required tangent to flange edge. 8. Side-Beam Clamps (MSS Type 27): For bottom of steel I-beams. 9. Steel-Beam Clamps with Eye Nuts (MSS Type 28): For attaching to bottom of steel I- beams for heavy loads. 10. Linked-Steel Clamps with Eye Nuts (MSS Type 29): For attaching to bottom of steel I- beams for heavy loads, with link extensions. 11. Malleable Beam Clamps with Extension Pieces (MSS Type 30): For attaching to structural steel. Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements 12. Welded-Steel Brackets: For support of pipes from below or for suspending from above by using clip and rod. Use one of the following for indicated loads: a. Light (MSS Type 31): 750 lb. (340 kg). b. Medium (MSS Type 32): 1500 lb. (675 kg). c. Heavy (MSS Type 33): 3000 lb. (1350 kg). 13. Side-Beam Brackets (MSS Type 34): For sides of steel or wooden beams. 14. Plate Lugs (MSS Type 57): For attaching to steel beams if flexibility at beam is required. 15. Horizontal Travelers (MSS Type 58): For supporting piping systems subject to linear horizontal movement where head room is limited. G. Saddles and Shields: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Steel Pipe-Covering Protection Saddles (MSS Type 39): To fill interior voids with insulation that matches adjoining insulation. 2. Protection Shields (MSS Type 40): Of length recommended by manufacturer to prevent crushing insulation. 3. Thermal-Hanger Shield Inserts: For supporting insulated pipe, 360-degree insert of high- density, 100-psi (690-kPa) minimum compressive-strength, water-repellent-treated calcium silicate or cellular-glass pipe insulation, same thickness as adjoining insulation with vapor barrier and encased in 360-degree sheet metal shield. H. Spring Hangers and Supports: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Restraint-Control Devices (MSS Type 47): Where indicated to control piping movement. 2. Spring Cushions (MSS Type 48): For light loads if vertical movement does not exceed 1- 1/4 inches (32 mm). 3. Spring-Cushion Roll Hangers (MSS Type 49): For equipping Type 41 roll hanger with springs. 4. Spring Sway Braces (MSS Type 50): To retard sway, shock, vibration, or thermal expansion in piping systems. 5. Variable-Spring Hangers (MSS Type 51): Preset to indicated load and limit variability factor to 25 percent to absorb expansion and contraction of piping system from hanger. 6. Variable-Spring Base Supports (MSS Type 52): Preset to indicated load and limit variability factor to 25 percent to absorb expansion and contraction of piping system from base support. 7. Variable-Spring Trapeze Hangers (MSS Type 53): Preset to indicated load and limit variability factor to 25 percent to absorb expansion and contraction of piping system from trapeze support. Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements 8. Constant Supports: For critical piping stress and if necessary to avoid transfer of stress from one support to another support, critical terminal, or connected equipment. Include auxiliary stops for erection, hydrostatic test, and load-adjustment capability. These supports include the following types: a. Horizontal (MSS Type 54): Mounted horizontally. b. Vertical (MSS Type 55): Mounted vertically. c. Trapeze (MSS Type 56): Two vertical-type supports and one trapeze member. 3.02 HANGER AND SUPPORT INSTALLATION A. Pipe Hanger and Support Installation: Comply with MSS SP-69 and MSS SP-89. Install hangers, supports, clamps, and attachments as required to properly support piping from building structure. B. Channel Support System Installation: Arrange for grouping of parallel runs of piping and support together on field-assembled channel systems. 1. Field assemble and install according to manufacturer’s written instructions. C. Heavy-Duty Steel Trapeze Installation: Arrange for grouping of parallel runs of horizontal piping and support together on field-fabricated, heavy-duty trapezes. 1. Pipes of Various Sizes: Support together and space trapezes for smallest pipe size or install intermediate supports for smaller diameter pipes as specified above for individual pipe hangers. 2. Field fabricate from ASTM A36/A36M, steel shapes selected for loads being supported. Weld steel according to AWS D-1.1. D. Install building attachments within concrete slabs or attach 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, and expansion joints, and at changes in direction of piping. Install concrete inserts before concrete is placed; fasten inserts to forms and install reinforcing bars through openings at top of inserts. E. Install mechanical-anchor fasteners in concrete after concrete is placed and completely cured. Install fasteners according to manufacturer’s written instructions. F. Install hangers and supports complete with necessary inserts, bolts, rods, nuts, washers, and other accessories. G. Install hangers and supports to allow controlled thermal and seismic movement of piping systems, to permit freedom of movement between pipe anchors, and to facilitate action of expansion joints, expansion loops, expansion bends, and similar units. H. Load Distribution: Install hangers and supports so that piping live and dead loads and stresses from movement will not be transmitted to connected equipment. I. Pipe Slopes: Install hangers and supports to provide indicated pipe slopes and so maximum pipe deflections allowed by ASME B31.9, “Building Services Piping,” is not exceeded. J. Insulated Piping: Comply with the following: Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1. Attach clamps and spacers to piping. a. Piping Operating above Ambient Air Temperature: Clamp may project through insulation. b. Piping Operating below Ambient Air Temperature: Use thermal-hanger shield insert with clamp sized to match OD of insert. c. Do not exceed pipe stress limits according to ASME B31.9. 2. Install MSS SP-58, Type 39 protection saddles, if insulation without vapor barrier is indicated. Fill interior voids with insulation that matches adjoining insulation. a. Option: Thermal-hanger shield inserts may be used. Include steel weight- distribution plate for pipe NPS 4 (DN100) and larger if pipe is installed on rollers. 3. Install MSS SP-58, Type 40 protective shields on cold piping with vapor barrier. Shields shall span arc of 180 degrees. a. Option: Thermal-hanger shield inserts may be used. Include steel weight- distribution plate for pipe NPS 4 (DN100) and larger if pipe is installed on rollers. 4. Shield Dimensions for Pipe: Not less than the following: a. NPS 1/4 to NPS 3-1/2 (DN8 to DN90): 12 inches (305 mm) long and 0.048 inch (1.22 mm) thick. b. NPS 4 (DN100): 12 inches (305 mm) long and 0.06 inch (1.52 mm) thick. c. NPS 5 and NPS 6 (DN125 and DN150): 18 inches (457 mm) long and 0.06 inch (1.52 mm) thick. d. NPS 8 to NPS 14 (DN200 to DN350): 24 inches (610 mm) long and 0.075 inch (1.91 mm) thick. e. NPS 16 to NPS 24 (DN400 to DN600): 24 inches (610 mm) long and 0.105 inch (2.67 mm) thick. 5. Pipes NPS 8 (DN200) and Larger: Include wood inserts. 6. Insert Material: Length at least as long as protective shield. 7. Thermal-Hanger Shields: Install with insulation same thickness as piping insulation. 3.03 EQUIPMENT SUPPORTS A. Fabricate structural-steel stands to suspend equipment from structure above or to support equipment above floor. B. Grouting: Place grout under supports for equipment and make smooth bearing surface. 3.04 METAL FABRICATION A. Cut, drill, and fit miscellaneous metal fabrications for heavy-duty steel trapezes and equipment supports. B. Fit exposed connections together to form hairline joints. Field-weld connections that cannot be shop-welded because of shipping size limitations. Hangers and Supports for HVAC Piping and Equipment 23 05 29 - 9 DTN18104 – Lake Lewisville WTP/RWPS Improvements C. Field Welding: Comply with AWS D1.1 procedures for shielded metal arc welding, appearance and quality of welds, and methods used in correcting welding work, and with the following: 1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals. 2. Obtain fusion without undercut or overlap. 3. Remove welding flux immediately. 4. Finish welds at exposed connections so no roughness shows after finishing and contours of welded surfaces match adjacent contours. 3.05 ADJUSTING A. Hanger Adjustment: Adjust hangers to distribute loads equally on attachments and to achieve indicated slope of pipe. 3.06 PAINTING A. Touching Up: Clean field welds and abraded areas of shop paint. Paint exposed areas immediately after erecting hangers and supports. Use same materials as used for shop painting. Comply with SSPC-PA 1 requirements for touching up field-painted surfaces. 1. Apply paint by brush or spray to provide a minimum dry film thickness of 2.0 mils (0.05 mm). END OF SECTION Identification for HVAC Piping and Equipment 23 05 53 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 05 53 IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes the following mechanical identification materials and their installation: 1. Equipment nameplates. 2. Equipment markers. 3. Equipment signs. 4. Access panel and door markers. 5. Pipe markers. 6. Duct markers. 7. Stencils. 8. Warning tags. 1.03 SUBMITTALS A. Product Data: For each type of product indicated. B. Samples: For color, letter style, and graphic representation required for each identification material and device. 1.04 QUALITY ASSURANCE A. ASME Compliance: Comply with ASME A13.1, “Scheme for the Identification of Piping Systems,” for letter size, length of color field, colors, and viewing angles of identification devices for piping. 1.05 COORDINATION A. Coordinate installation of identifying devices with completion of covering and painting of surfaces where devices are to be applied. B. Coordinate installation of identifying devices with location of access panels and doors. C. Install identifying devices before installing acoustical ceilings and similar concealment. 2.00 PRODUCTS 2.01 EQUIPMENT IDENTIFICATION DEVICES A. Equipment Nameplates: Metal, with data engraved or stamped, for permanent attachment on equipment. Identification for HVAC Piping and Equipment 23 05 53 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1. Data: a. Manufacturer, product name, model number, and serial number. b. Capacity, operating and power characteristics, and essential data. c. Labels of tested compliances. 2. Location: Accessible and visible. 3. Fasteners: As required to mount on equipment. B. Equipment Markers: Engraved, color-coded laminated plastic. Include contact-type, permanent adhesive. 1. Terminology: Match schedules as closely as possible. 2. Data: a. Name and plan number. b. Equipment service. c. Design capacity. d. Other design parameters such as pressure drop, entering and leaving conditions, and speed. 3. Size: 2-1/2 by 4 inches (64 by 100 mm) for control devices, dampers, and valves; 4-1/2 by 6 inches (115 by 150 mm) for equipment. C. Equipment Signs: ASTM D709, Type I, cellulose, paper-base, phenolic-resin-laminate engraving stock; Grade ES-2, black surface, black phenolic core, with white melamine subcore, unless otherwise indicated. Fabricate in sizes required for message. Provide holes for mechanical fastening. 1. Data: Instructions for operation of equipment and for safety procedures. 2. Engraving: Manufacturer’s standard letter style, of sizes and with terms to match equipment identification. 3. Thickness: 1/16 inch (1.6 mm) for units up to 20 sq. in. (130 sq. cm) or 8 inches (200 mm) in length, and 1/8 inch (3.2 mm) for larger units. 4. Fasteners: Self-tapping, stainless-steel screws or contact-type, permanent adhesive. D. Access Panel and Door Markers: 1/16-inch (1.6-mm) thick, engraved laminated plastic, with abbreviated terms and numbers corresponding to identification. Provide 1/8-inch (3.2-mm) center hole for attachment. 1. Fasteners: Self-tapping, stainless-steel screws or contact-type, permanent adhesive. 2.02 PIPING IDENTIFICATION DEVICES A. Manufactured Pipe Markers, General: Preprinted, color-coded, with lettering indicating service, and showing direction of flow. 1. Colors: Comply with ASME A13.1, unless otherwise indicated. Identification for HVAC Piping and Equipment 23 05 53 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. Lettering: Use piping system terms indicated and abbreviate only as necessary for each application length. 3. Pipes with OD, Including Insulation, Less than 6 inches (150 mm): Full-band pipe markers extending 360 degrees around pipe at each location. 4. Pipes with OD, Including Insulation, 6 inches (150 mm) and Larger: Either full-band or strip-type pipe markers at least three times letter height and of length required for label. 5. Arrows: Integral with piping system service lettering to accommodate both directions; or as separate unit on each pipe marker to indicate direction of flow. B. Pretensioned Pipe Markers: Precoiled semi-rigid plastic formed to cover full circumference of pipe and to attach to pipe without adhesive. C. Shaped Pipe Markers: Preformed semi-rigid plastic formed to partially cover circumference of pipe and to attach to pipe with mechanical fasteners that do not penetrate insulation vapor barrier. 2.03 DUCT IDENTIFICATION DEVICES A. Duct Markers: Engraved, color-coded laminated plastic. Include direction and quantity of airflow and duct service (such as supply, return, and exhaust). Include contact-type, permanent adhesive. 2.04 STENCILS A. Stencils: Prepared with letter sizes according to ASME A13.1 for piping; minimum letter height of 1-1/4 inches (32 mm) for ducts; and minimum letter height of 3/4 inch (19 mm) for access panel and door markers, equipment markers, equipment signs, and similar operational instructions. 1. Stencil Paint: Exterior, gloss, alkyd enamel or acrylic enamel black, unless otherwise indicated. Paint may be in pressurized spray-can form. 2. Identification Paint: Exterior, alkyd enamel or acrylic enamel in colors according to ASME A13.1, unless otherwise indicated. 2.05 WARNING TAGS A. Warning Tags: Preprinted or partially preprinted, accident-prevention tags; of plasticized card stock with matte finish suitable for writing. 1. Size: Approximately 4 by 7 inches (100 by 178 mm). 2. Fasteners: Brass grommet and wire. 3. Nomenclature: Large-size primary caption such as DANGER, CAUTION, or DO NOT OPERATE. 4. Color: Yellow background with black lettering. Identification for HVAC Piping and Equipment 23 05 53 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.00 EXECUTION 3.01 APPLICATIONS, GENERAL A. Products specified are for applications referenced in other Division 23 Sections. If more than single-type material, device, or label is specified for listed applications, selection is Installer’s option. 3.02 EQUIPMENT IDENTIFICATION A. Install and permanently fasten equipment nameplates on each major item of mechanical equipment that does not have nameplate or has nameplate that is damaged or located where not easily visible. Locate nameplates where accessible and visible. B. Install equipment markers with permanent adhesive on or near each major item of mechanical equipment. Data required for markers may be included on signs, and markers may be omitted if both are indicated. 1. Letter Size: Minimum 1/4 inch (6.4 mm) for name of units if viewing distance is less than 24 inches (600 mm), 1/2 inch (13 mm) for viewing distances up to 72 inches (1830 mm), and proportionately larger lettering for greater viewing distances. Include secondary lettering 2/3 to 3/4 the size of principal lettering. 2. Data: Distinguish among multiple units, indicate operational requirements, indicate safety and emergency precautions, warn of hazards and improper operations, and identify units. 3. Locate markers where accessible and visible. Include markers for the following general categories of equipment: a. Fuel-burning units, including boilers, furnaces, heaters, stills, and absorption units. b. Pumps, compressors, chillers, condensers, and similar motor-driven units. c. Heat exchangers, coils, evaporators, cooling towers, heat recovery units, and similar equipment. d. Fans, blowers, primary balancing dampers, and mixing boxes. e. Packaged HVAC central-station and zone-type units. f. Strainers, filters, humidifiers, water-treatment systems, and similar equipment. C. Install equipment signs with screws or permanent adhesive on or near each major item of mechanical equipment. Locate signs where accessible and visible. 1. Identify mechanical equipment with equipment markers in the following color codes: a. Green: For cooling equipment and components. b. Yellow: For heating equipment and components. c. Green and Yellow: For combination cooling and heating equipment and components. d. Brown: For energy-reclamation equipment and components. Identification for HVAC Piping and Equipment 23 05 53 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. Letter Size: Minimum 1/4 inch (6.4 mm) for name of units if viewing distance is less than 24 inches (600 mm), 1/2 inch (13 mm) for viewing distances up to 72 inches (1830 mm), and proportionately larger lettering for greater viewing distances. Include secondary lettering 2/3 to 3/4 the size of principal lettering. 3. Data: Distinguish among multiple units, indicate operational requirements, indicate safety and emergency precautions, warn of hazards and improper operations, and identify units. D. Install access panel markers with screws on equipment access panels. 3.03 PIPING IDENTIFICATION A. Install manufactured pipe markers indicating service on each piping system. Install with flow indication arrows showing direction of flow. 1. Pipes with OD, Including Insulation, Less Than 6 Inches (150 mm): Pretensioned pipe markers. Use size to ensure a tight fit. 2. Pipes with OD, Including Insulation, 6 Inches (150 mm) and Larger: Shaped pipe markers. Use size to match pipe and secure with fasteners. B. Locate pipe markers and color bands where piping is exposed in finished spaces; machine rooms; accessible maintenance spaces such as shafts, tunnels, and plenums; and exterior nonconcealed locations as follows: 1. Near each valve and control device. 2. Near each branch connection, excluding short takeoffs for fixtures and terminal units. Where flow pattern is not obvious, mark each pipe at branch. 3. Near penetrations through walls, floors, ceilings, and nonaccessible enclosures. 4. At access doors, manholes, and similar access points that permit view of concealed piping. 5. Near major equipment items and other points of origination and termination. 6. Spaced at maximum intervals of 50 feet (15 m) along each run. Reduce intervals to 25 feet (7.6 m) in areas of congested piping and equipment. 7. On piping above removable acoustical ceilings. Omit intermediately spaced markers. 3.04 DUCT IDENTIFICATION A. Install duct markers with permanent adhesive on air ducts in the following color codes: 1. Green: For cold-air supply ducts. 2. Yellow: For hot-air supply ducts. 3. Blue: For exhaust-, outside-, relief-, return-, and mixed-air ducts. 4. ASME A13.1 Colors and Designs: For hazardous material exhaust. Identification for HVAC Piping and Equipment 23 05 53 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements 5. Letter Size: Minimum 1/4 inch (6.4 mm) for name of units if viewing distance is less than 24 inches (600 mm), 1/2 inch (13 mm) for viewing distances up to 72 inches (1830 mm), and proportionately larger lettering for greater viewing distances. Include secondary lettering 2/3 to 3/4 the size of principal lettering. B. Stenciled Duct Marker Option: Stenciled markers, showing service and direction of flow, may be provided instead of laminated-plastic duct markers, at Installer’s option, if lettering larger than 1 inch (25 mm) high is needed for proper identification because of distance from normal location of required identification. C. Locate markers near points where ducts enter into concealed spaces and at maximum intervals of 50 feet (15 m) in each space where ducts are exposed or concealed by removable ceiling system. 3.05 WARNING-TAG INSTALLATION A. Write required message on, and attach warning tags to, equipment and other items where required. 3.06 ADJUSTING A. Relocate mechanical identification materials and devices that have become visually blocked by other work. 3.07 CLEANING A. Clean faces of mechanical identification devices and glass frames of valve schedules. END OF SECTION Testing, Adjusting, and Balancing for HVAC 23 05 93 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC 1.00 GENERAL 1.01 SUMMARY A. This Section includes TAB to produce design objectives for the following: 1. Air Systems: a. Constant-volume air systems. 2. HVAC equipment quantitative-performance settings. 3. Kitchen hood airflow balancing. 4. Existing systems TAB. 5. Verifying that automatic control devices are functioning properly. 6. Reporting results of activities and procedures specified in this Section. 1.02 SUBMITTALS A. Strategies and Procedures Plan: Within 30 days from Contractor’s Notice to Proceed, submit four copies of TAB strategies and step-by-step procedures as specified in Part 3 “Preparation” Article. Include a complete set of report forms intended for use on this Project. B. Certified TAB Reports: Submit two copies of reports prepared, as specified in this Section, on approved forms certified by TAB firm. C. Warranties specified in this Section. 1.03 QUALITY ASSURANCE A. TAB Firm Qualifications: Engage a TAB firm certified by either AABC or NEBB. B. Certification of TAB Reports: Certify TAB field data reports. This certification includes the following: 1. Review field data reports to validate accuracy of data and to prepare certified TAB reports. 2. Certify that TAB team complied with approved TAB plan and the procedures specified and referenced in this Specification. C. TAB Report Forms: Use standard forms from AABC’s “National Standards for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems” or NEBB’s “Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems,” as applicable. 1.04 PROJECT CONDITIONS A. Partial Owner Occupancy: Owner may occupy completed areas of building before Substantial Completion. Cooperate with Owner during TAB operations to minimize conflicts with Owner’s operations. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1.05 COORDINATION A. Coordinate the efforts of factory-authorized service representatives for systems and equipment, HVAC controls installers, and other mechanics to operate HVAC systems and equipment to support and assist TAB activities. B. Perform TAB after leakage and pressure tests on air distribution systems have been satisfactorily completed. 1.06 WARRANTY A. National Project Performance Guarantee: If AABC, provide a guarantee on AABC’s “National Standards for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems” forms stating that AABC will assist in completing requirements of the Contract Documents if TAB firm fails to comply with the Contract Documents. Guarantee includes the following provisions: 1. The certified TAB firm has tested and balanced systems according to the Contract Documents. 2. Systems are balanced to optimum performance capabilities within design and installation limits. B. Special Guarantee: If NEBB, provide a guarantee on NEBB forms stating that NEBB will assist in completing requirements of the Contract Documents if TAB firm fails to comply with the Contract Documents. Guarantee shall include the following provisions: 1. The certified TAB firm has tested and balanced systems according to the Contract Documents. 2. Systems are balanced to optimum performance capabilities within design and installation limits. 2.00 PRODUCTS (NOT APPLICABLE) 3.00 EXECUTION 3.01 EXAMINATION A. Examine the Contract Documents to become familiar with Project requirements and to discover conditions in systems’ designs that may preclude proper TAB of systems and equipment. 1. Verify that balancing devices, such as test ports, gage cocks, thermometer wells, flow- control devices, balancing valves and fittings, and manual volume dampers, are required by the Contract Documents. Verify that quantities and locations of these balancing devices are accessible and appropriate for effective balancing and for efficient system and equipment operation. B. Examine approved submittal data of HVAC systems and equipment. C. Examine Project Record Documents described in Division 01. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Examine design data, including HVAC system descriptions, statements of design assumptions for environmental conditions and systems’ output, and statements of philosophies and assumptions about HVAC system and equipment controls. E. Examine equipment performance data including fan curves. Relate performance data to Project conditions and requirements, including system effects that can create undesired or unpredicted conditions that cause reduced capacities in all or part of a system. Calculate system effect factors to reduce performance ratings of HVAC equipment when installed under conditions different from those presented when the equipment was performance tested at the factory. To calculate system effects for air systems, use tables and charts found in AMCA 201, “Fans and Systems,” Sections 7 through 10; or in SMACNA’s “HVAC Systems--Duct Design,” Sections 5 and 6. Compare this data with the design data and installed conditions. F. Examine system and equipment installations to verify that they are complete and that testing, cleaning, adjusting, and commissioning specified in individual Sections have been performed. G. Examine system and equipment test reports. H. Examine HVAC system and equipment installations to verify that indicated balancing devices, such as balancing valves and fittings, and manual volume dampers, are properly installed, and that their locations are accessible and appropriate for effective balancing and for efficient system and equipment operation. I. Examine systems for functional deficiencies that cannot be corrected by adjusting and balancing. J. Examine HVAC equipment to ensure that clean filters have been installed, bearings are greased, belts are aligned and tight, and equipment with functioning controls is ready for operation. K. Examine terminal units, such as variable-air-volume boxes, to verify that they are accessible and their controls are connected and functioning. L. Examine plenum ceilings used for supply air to verify that they are airtight. Verify that pipe penetrations and other holes are sealed. M. Examine heat-transfer coils for correct piping connections and for clean and straight fins. N. Examine equipment for installation and for properly operating safety interlocks and controls. O. Examine automatic temperature system components to verify the following: 1. Dampers, valves, and other controlled devices are operated by the intended controller. 2. Dampers and valves are in the position indicated by the controller. 3. Integrity of valves and dampers for free and full operation and for tightness of fully closed and fully open positions. This includes dampers in multizone units, mixing boxes, and variable-air-volume terminals. 4. Automatic modulating and shutoff valves, including two-way valves and three-way mixing and diverting valves, are properly connected. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 5. Thermostats and humidistats are located to avoid adverse effects of sunlight, drafts, and cold walls. 6. Sensors are located to sense only the intended conditions. 7. Sequence of operation for control modes is according to the Contract Documents. 8. Controller set points are set at indicated values. 9. Interlocked systems are operating. 10. Changeover from heating to cooling mode occurs according to indicated values. P. Report deficiencies discovered before and during performance of TAB procedures. Observe and record system reactions to changes in conditions. Record default set points if different from indicated values. 3.02 PREPARATION A. Prepare a TAB plan that includes strategies and step-by-step procedures. B. Complete system readiness checks and prepare system readiness reports. Verify the following: 1. Permanent electrical power wiring is complete. 2. Automatic temperature-control systems are operational. 3. Equipment and duct access doors are securely closed. 4. Balance, smoke, and fire dampers are open. 5. Ceilings are installed in critical areas where air-pattern adjustments are required and access to balancing devices is provided. 6. Windows and doors can be closed so indicated conditions for system operations can be met. 3.03 GENERAL PROCEDURES FOR TESTING AND BALANCING A. Perform testing and balancing procedures on each system according to the procedures contained in AABC’s “National Standards for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems” or NEBB’s “Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems,” as applicable, and this Section. B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary to allow adequate performance of procedures. After testing and balancing, close probe holes and patch insulation with new materials identical to those removed. Restore vapor barrier and finish according to insulation Specifications for this Project. C. Mark equipment and balancing device settings with paint or other suitable, permanent identification material, including damper-control positions, valve position indicators, fan- speed-control levers, and similar controls and devices, to show final settings. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.04 GENERAL PROCEDURES FOR BALANCING AIR SYSTEMS A. Prepare test reports for both fans and outlets. Obtain manufacturer’s outlet factors and recommended testing procedures. Crosscheck the summation of required outlet volumes with required fan volumes. B. Prepare schematic diagrams of systems’ “as-built” duct layouts. C. For variable-air-volume systems, develop a plan to simulate diversity. D. Determine the best locations in main and branch ducts for accurate duct airflow measurements. E. Check airflow patterns from the outside-air louvers and dampers and the return- and exhaust-air dampers, through the supply-fan discharge and mixing dampers. F. Locate start-stop and disconnect switches, electrical interlocks, and motor starters. G. Verify that motor starters are equipped with properly sized thermal protection. H. Check dampers for proper position to achieve desired airflow path. I. Check for airflow blockages. J. Check condensate drains for proper connections and functioning. K. Check for proper sealing of air-handling unit components. L. Check for proper sealing of air duct system. 3.05 PROCEDURES FOR CONSTANT-VOLUME AIR SYSTEMS A. Adjust fans to deliver total indicated airflows within the maximum allowable fan speed listed by fan manufacturer. 1. Measure fan static pressures to determine actual static pressure as follows: a. Measure outlet static pressure as far downstream from the fan as practicable and upstream from restrictions in ducts such as elbows and transitions. b. Measure static pressure directly at the fan outlet or through the flexible connection. c. Measure inlet static pressure of single-inlet fans in the inlet duct as near the fan as possible, upstream from flexible connection and downstream from duct restrictions. d. Measure inlet static pressure of double-inlet fans through the wall of the plenum that houses the fan. 2. Measure static pressure across each component that makes up an air-handling unit, rooftop unit, and other air-handling and -treating equipment. a. Simulate dirty filter operation and record the point at which maintenance personnel must change filters. 3. Measure static pressures entering and leaving other devices such as sound traps, heat recovery equipment, and air washers, under final balanced conditions. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements 4. Compare design data with installed conditions to determine variations in design static pressures versus actual static pressures. Compare actual system effect factors with calculated system effect factors to identify where variations occur. Recommend corrective action to align design and actual conditions. 5. Obtain approval from Owners Representative for adjustment of fan speed higher or lower than indicated speed. Make required adjustments to pulley sizes, motor sizes, and electrical connections to accommodate fan-speed changes at no additional cost. 6. Do not make fan-speed adjustments that result in motor overload. Consult equipment manufacturers about fan-speed safety factors. Modulate dampers and measure fan- motor amperage to ensure that no overload will occur. Measure amperage in full cooling, full heating, economizer, and any other operating modes to determine the maximum required brake horsepower. B. Adjust volume dampers for main duct, submain ducts, and major branch ducts to indicated airflows within specified tolerances. 1. Measure static pressure at a point downstream from the balancing damper and adjust volume dampers until the proper static pressure is achieved. a. Where sufficient space in submain and branch ducts is unavailable for Pitot-tube traverse measurements, measure airflow at terminal outlets and inlets and calculate the total airflow for that zone. 2. Remeasure each submain and branch duct after all have been adjusted. Continue to adjust submain and branch ducts to indicated airflows within specified tolerances. C. Measure terminal outlets and inlets without making adjustments. 1. Measure terminal outlets using a direct-reading hood or outlet manufacturer’s written instructions and calculating factors. D. Adjust terminal outlets and inlets for each space to indicated airflows within specified tolerances of indicated values. Make adjustments using volume dampers rather than extractors and the dampers at air terminals. 1. Adjust each outlet in same room or space to within specified tolerances of indicated quantities without generating noise levels above the limitations prescribed by the Contract Documents. 2. Adjust patterns of adjustable outlets for proper distribution without drafts. 3.06 PROCEDURES FOR MOTORS A. Motors, 1/2 HP and Larger: Test at final balanced conditions and record the following data: 1. Manufacturer, model, and serial numbers. 2. Motor horsepower rating. 3. Motor rpm. 4. Efficiency rating. 5. Nameplate and measured voltage, each phase. 6. Nameplate and measured amperage, each phase. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements 7. Starter thermal-protection-element rating. B. Motors Driven by Variable-Frequency Controllers: Test for proper operation at speeds varying from minimum to maximum. Test the manual bypass for the controller to prove proper operation. Record observations, including controller manufacturer, model and serial numbers, and nameplate data. 3.07 PROCEDURES FOR CONDENSING UNITS A. Verify proper rotation of fans. B. Measure entering- and leaving-air temperatures. C. Record compressor data. 3.08 PROCEDURES FOR HEAT-TRANSFER COILS A. Electric-Heating Coils: Measure the following data for each coil: 1. Nameplate data. 2. Airflow. 3. Entering- and leaving-air temperature at full load. 4. Voltage and amperage input of each phase at full load and at each incremental stage. 5. Calculated kilowatt at full load. 6. Fuse or circuit-breaker rating for overload protection. B. Refrigerant Coils: Measure the following data for each coil: 1. Dry-bulb temperature of entering and leaving air. 2. Wet-bulb temperature of entering and leaving air. 3. Airflow. 4. Air pressure drop. 5. Refrigerant suction pressure and temperature. 3.09 PROCEDURES FOR TEMPERATURE MEASUREMENTS A. During TAB, report the need for adjustment in temperature regulation within the automatic temperature-control system. B. Measure indoor wet- and dry-bulb temperatures every other hour for a period of two successive 8-hour days, in each separately controlled zone, to prove correctness of final temperature settings. Measure when the building or zone is occupied. C. Measure outside-air, wet- and dry-bulb temperatures. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.10 PROCEDURES FOR COMMERCIAL KITCHEN HOODS A. Measure, adjust, and record the airflow of each kitchen hood. For kitchen hoods designed with integral makeup air, measure and adjust the exhaust and makeup airflow. Measure airflow by duct Pitot-tube traverse. If a duct Pitot-tube traverse is not possible, provide an explanation in the report of the reason(s) why and also the reason why the method used was chosen. 1. Install welded test ports in the sides of the exhaust duct for the duct Pitot-tube traverse. Install each test port with a threaded cap that is liquid tight. B. After balancing is complete, do the following: 1. Measure and record the static pressure at the hood exhaust-duct connection. 2. Measure and record the hood face velocity. Make measurements at multiple points across the face of the hood. Perform measurements at a maximum of 12 inches (300 mm) between points and between any point and the perimeter. Calculate the average of the measurements recorded. Verify that the hood average face velocity complies with the Contract Documents and governing codes. 3. Check the hood for capture and containment of smoke using a smoke emitting device. Observe the smoke pattern. Make adjustments to room airflow patterns to achieve optimum results. C. Visually inspect the hood exhaust duct throughout its entire length in compliance with authorities having jurisdiction. Begin at the hood connection and end at the point it discharges outdoors. Report findings. 1. Check duct slopes as required. 2. Verify that duct access is installed as required. 3. Verify that point of termination is as required. 4. Verify that duct air velocity is within the range required. 5. Verify that duct is within a fire-rated enclosure. D. Report deficiencies. 3.11 PROCEDURES FOR TESTING, ADJUSTING, AND BALANCING EXISTING SYSTEMS A. Perform a preconstruction inspection of existing equipment that is to remain and be reused. 1. Measure and record the operating speed, airflow, and static pressure of each fan. 2. Measure motor voltage and amperage. Compare the values to motor nameplate information. 3. Check the refrigerant charge. 4. Check the condition of filters. 5. Check the condition of coils. 6. Check the operation of the drain pan and condensate drain trap. 7. Check bearings and other lubricated parts for proper lubrication. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 9 DTN18104 – Lake Lewisville WTP/RWPS Improvements 8. Report on the operating condition of the equipment and the results of the measurements taken. Report deficiencies. B. Before performing testing and balancing of existing systems, inspect existing equipment that is to remain and be reused to verify that existing equipment has been cleaned and refurbished. 1. New filters are installed. 2. Coils are clean and fins combed. 3. Drain pans are clean. 4. Fans are clean. 5. Bearings and other parts are properly lubricated. 6. Deficiencies noted in the preconstruction report are corrected. C. Perform testing and balancing of existing systems to the extent that existing systems are affected by the renovation work. 1. Compare the indicated airflow of the renovated work to the measured fan airflows and determine the new fan, speed, filter, and coil face velocity. 2. Verify that the indicated airflows of the renovated work result in filter and coil face velocities and fan speeds that are within the acceptable limits defined by equipment manufacturer. 3. If calculations increase or decrease the airflow flow rates by more than 5 percent, make equipment adjustments to achieve the calculated airflow rates. If 5 percent or less, equipment adjustments are not required. 4. Air balance each air outlet. 3.12 TEMPERATURE-CONTROL VERIFICATION A. Verify that controllers are calibrated and commissioned. B. Check transmitter and controller locations and note conditions that would adversely affect control functions. C. Record controller settings and note variances between set points and actual measurements. D. Check the operation of limiting controllers (i.e., high- and low-temperature controllers). E. Check free travel and proper operation of control devices such as damper and valve operators. F. Check the sequence of operation of control devices. Note air pressures and device positions and correlate with airflow measurements. Note the speed of response to input changes. G. Check the interaction of electrically operated switch transducers. H. Check the interaction of interlock and lockout systems. I. Check main control supply-air pressure and observe compressor and dryer operations. J. Record voltages of power supply and controller output. Determine whether the system operates on a grounded or nongrounded power supply. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 10 DTN18104 – Lake Lewisville WTP/RWPS Improvements K. Note operation of electric actuators using spring return for proper fail-safe operations. 3.13 TOLERANCES A. Set HVAC system airflow rates within the following tolerances: 1. Supply, Return, and Exhaust Fans and Equipment with Fans: Plus 5 to plus 10 percent. 2. Air Outlets and Inlets: 0 to minus 10 percent. 3.14 FINAL REPORT A. General: Typewritten, or computer printout in letter-quality font, on standard bond paper, in three-ring binder, tabulated and divided into sections by tested and balanced systems. B. Include a certification sheet in front of binder signed and sealed by the certified testing and balancing engineer. 1. Include a list of instruments used for procedures, along with proof of calibration. C. Final Report Contents: In addition to certified field report data, include the following: 1. Pump curves. 2. Fan curves. 3. Manufacturers’ test data. 4. Field test reports prepared by system and equipment installers. 5. Other information relative to equipment performance, but do not include Shop Drawings and Product Data. D. General Report Data: In addition to form titles and entries, include the following data in the final report, as applicable: 1. Title page. 2. Name and address of TAB firm. 3. Project name. 4. Project location. 5. Architect/Engineer’s name and address. 6. Engineer’s name and address. 7. Contractor’s name and address. 8. Report date. 9. Signature of TAB firm who certifies the report. 10. Table of Contents with the total number of pages defined for each section of the report. Number each page in the report. 11. Summary of contents including the following: a. Indicated versus final performance. b. Notable characteristics of systems. Testing, Adjusting, and Balancing for HVAC 23 05 93 - 11 DTN18104 – Lake Lewisville WTP/RWPS Improvements c. Description of system operation sequence if it varies from the Contract Documents. 12. Nomenclature sheets for each item of equipment. 13. Data for terminal units, including manufacturer, type size, and fittings. 14. Notes to explain why certain final data in the body of reports varies from indicated values. 15. Test conditions for fans and pump performance forms including the following: a. Settings for outside-, return-, and exhaust-air dampers. b. Conditions of filters. c. Cooling coil, wet- and dry-bulb conditions. d. Face and bypass damper settings at coils. e. Fan drive settings including settings and percentage of maximum pitch diameter. f. Inlet vane settings for variable-air-volume systems. g. Settings for supply-air, static-pressure controller. h. Other system operating conditions that affect performance. E. System Diagrams: Include schematic layouts of air distribution systems. Present each system with single-line diagram and include the following: 1. Quantities of outside, supply, return, and exhaust airflows. 2. Duct, outlet, and inlet sizes. 3. Terminal units. 4. Balancing stations. 5. Position of balancing devices. 3.15 ADDITIONAL TESTS A. Within 90 days of completing TAB, perform additional testing and balancing to verify that balanced conditions are being maintained throughout and to correct unusual conditions. B. Seasonal Periods: If initial TAB procedures were not performed during near-peak summer and winter conditions, perform additional testing, inspecting, and adjusting during near- peak summer and winter conditions. END OF SECTION Duct Insulation 23 07 13 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 07 13 DUCT INSULATION 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes semi-rigid and flexible duct, plenum, and breeching insulation; insulating cements; field-applied jackets; accessories and attachments; and sealing compounds. 1.03 SUBMITTALS A. Product Data: Identify thermal conductivity, thickness, and jackets (both factory and field applied, if any), for each type of product indicated. B. Material Test Reports: From a qualified testing agency acceptable to authorities having jurisdiction indicating, interpreting, and certifying test results for compliance of insulation materials, sealers, attachments, cements, and jackets with requirements indicated. Include dates of tests. C. Installer Certificates: Signed by the Contractor certifying that installers comply with requirements. 1.04 QUALITY ASSURANCE A. Installer Qualifications: Skilled mechanics who have successfully completed an apprenticeship program or another craft training program certified by the U.S. Department of Labor, Bureau of Apprenticeship and Training. B. Fire-Test-Response Characteristics: As determined by testing materials identical to those specified in this Section according to ASTM E84, by a testing and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and sealer and cement material containers with appropriate markings of applicable testing and inspecting agency. 1. Insulation Installed Indoors: Flame-spread rating of 25 or less, and smoke-developed rating of 50 or less. 2. Insulation Installed Outdoors: Flame-spread rating of 75 or less, and smoke-developed rating of 150 or less. 1.05 DELIVERY, STORAGE, AND HANDLING A. Packaging: Ship insulation materials in containers marked by manufacturer with appropriate ASTM specification designation, type and grade, and maximum use temperature. Duct Insulation 23 07 13 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1.06 COORDINATION A. Coordinate clearance requirements with duct Installer for insulation application. 1.07 SCHEDULING A. Schedule insulation application after testing duct systems. Insulation application may begin on segments of ducts that have satisfactory test results. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Mineral-Fiber Insulation: a. CertainTeed Manson. b. Knauf FiberGlass GmbH. c. Owens-Corning Fiberglas Corp. d. Schuller International, Inc. 2. Fire-Rated Insulation: a. 3m. b. CertainTeed Manson. c. Thermal Ceramics. d. Unifrax Corporation. 2.02 INSULATION MATERIALS A. Mineral-Fiber Board Thermal Insulation: Glass fibers bonded with a thermosetting resin. Comply with ASTM C612, Type IB, without facing and with all-service jacket manufactured from kraft paper, reinforcing scrim, aluminum foil, and vinyl film. (ASTM C612, Type III for operating temperatures higher than 850 F (454 C)). B. Mineral-Fiber Blanket Thermal Insulation: 0.75 lb./ft 3, glass fibers bonded with a thermosetting resin. Comply with ASTM C553, Type II, without facing and with all-service jacket manufactured from kraft paper, reinforcing scrim, aluminum foil, and vinyl film. (ASTM C553, Type V for operating temperatures higher than 850 F (454 C)). 2.03 FIRE-RATED INSULATION SYSTEMS A. Fire-Rated Blanket: High-temperature, flexible, blanket insulation with FSK jacket that is tested and certified to provide a 2-hour fire rating by an NRTL acceptable to authorities having jurisdiction. 2.04 FIELD-APPLIED JACKETS A. General: ASTM C921, Type 1, unless otherwise indicated. Duct Insulation 23 07 13 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Foil and Paper Jacket: Laminated, glass-fiber-reinforced, flame-retardant kraft paper and aluminum foil. 2.05 ACCESSORIES AND ATTACHMENTS A. Glass Cloth and Tape: Comply with MIL-C-20079H, Type I for cloth and Type II for tape. Woven glass-fiber fabrics, plain weave, presized a minimum of 8 oz./sq. yd. (270 g/sq. m). 1. Tape Width: 4 inches (100 mm). B. Wire: 0.080-inch (2.0-mm), nickel-copper alloy; 0.062-inch (1.6-mm), soft-annealed, stainless steel; or 0.062-inch (1.6-mm), soft-annealed, galvanized steel. C. Self-Adhesive Anchor Pins and Speed Washers: Galvanized steel plate, pin, and washer manufactured for attachment to duct and plenum with adhesive. Pin length sufficient for insulation thickness indicated. 2.06 VAPOR RETARDERS A. Mastics: Materials recommended by insulation material manufacturer that are compatible with insulation materials, jackets, and substrates. 3.00 EXECUTION 3.01 EXAMINATION A. Examine substrates and conditions for compliance with requirements for installation and other conditions affecting performance of insulation application. B. Proceed with installation only after unsatisfactory conditions have been corrected. 3.02 PREPARATION A. Surface Preparation: Clean and dry surfaces to receive insulation. Remove materials that will adversely affect insulation application. 3.03 GENERAL APPLICATION REQUIREMENTS A. Apply insulation materials, accessories, and finishes according to the manufacturer’s written instructions; with smooth, straight, and even surfaces; and free of voids throughout the length of ducts and fittings. B. Refer to schedules at the end of this Section for materials, forms, jackets, and thicknesses required for each duct system. C. Use accessories compatible with insulation materials and suitable for the service. Use accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state. D. Apply multiple layers of insulation with longitudinal and end seams staggered. E. Seal joints and seams with vapor-retarder mastic on insulation indicated to receive a vapor retarder. F. Keep insulation materials dry during application and finishing. Duct Insulation 23 07 13 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements G. Apply insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by the insulation material manufacturer. H. Apply insulation with the least number of joints practical. I. Apply insulation over fittings and specialties, with continuous thermal and vapor-retarder integrity, unless otherwise indicated. J. Hangers and Anchors: Where vapor retarder is indicated, seal penetrations in insulation at hangers, supports, anchors, and other projections with vapor-retarder mastic. Apply insulation continuously through hangers and around anchor attachments. K. Insulation Terminations: For insulation application where vapor retarders are indicated, seal ends with a compound recommended by the insulation material manufacturer to maintain vapor retarder. L. Apply insulation with integral jackets as follows: 1. Pull jacket tight and smooth. 2. Joints and Seams: Cover with tape and vapor retarder as recommended by insulation material manufacturer to maintain vapor seal. 3. Vapor-Retarder Mastics: Where vapor retarders are indicated, apply mastic on seams and joints and at ends adjacent to duct flanges and fittings. M. Cut insulation according to manufacturer’s written instructions to prevent compressing insulation to less than 75 percent of its nominal thickness. N. Install vapor-retarder mastic on ducts and plenums scheduled to receive vapor retarders. 1. Ducts with Vapor Retarders: Overlap insulation facing at seams and seal with vapor- retarder mastic and pressure-sensitive tape having same facing as insulation. Repair punctures, tears, and penetrations with tape or mastic to maintain vapor-retarder seal. 2. Ducts without Vapor Retarders: Overlap insulation facing at seams and secure with outward clinching staples and pressure-sensitive tape having same facing as insulation. O. Roof Penetrations: Apply insulation for interior applications to a point even with top of roof flashing. 1. Seal penetrations with vapor-retarder mastic. 2. Apply insulation for exterior applications tightly joined to interior insulation ends. 3. Seal insulation to roof flashing with vapor-retarder mastic. P. Interior Wall and Partition Penetrations: Apply insulation continuously through walls and partitions, except fire-rated walls and partitions. Q. Fire-Rated Wall and Partition Penetrations: Terminate insulation at fire/smoke damper sleeves for fire-rated wall and partition penetrations. R. Floor Penetrations: Terminate insulation at underside of floor assembly and at floor support at top of floor. 1. For insulation indicated to have vapor retarders, taper termination and seal insulation ends with vapor-retarder mastic. Duct Insulation 23 07 13 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.04 MINERAL-FIBER INSULATION APPLICATION A. Blanket Applications for Ducts and Plenums: Secure blanket insulation with adhesive and anchor pins and speed washers. 1. Apply adhesives according to manufacturer’s recommended coverage rates per square foot, for 100 percent coverage of duct and plenum surfaces. 2. Apply adhesive to entire circumference of ducts and to all surfaces of fittings and transitions. 3. Install anchor pins and speed washers on sides and bottom of horizontal ducts and sides of vertical ducts as follows: a. On duct sides with dimensions 18 inches (450 mm) and smaller, along longitudinal centerline of duct. Space 3 inches (75 mm) maximum from insulation end joints, and 16 inches (400 mm) o.c. b. On duct sides with dimensions larger than 18 inches (450 mm). Space 16 inches (400 mm) o.c. each way, and 3 inches (75 mm) maximum from insulation joints. Apply additional pins and clips to hold insulation tightly against surface at cross bracing. c. Anchor pins may be omitted from top surface of horizontal, rectangular ducts and plenums. d. Do not overcompress insulation during installation. 4. Impale insulation over anchors and attach speed washers. 5. Cut excess portion of pins extending beyond speed washers or bend parallel with insulation surface. Cover exposed pins and washers with tape matching insulation facing. 6. Create a facing lap for longitudinal seams and end joints with insulation by removing 2 inches (50 mm) from one edge and one end of insulation segment. Secure laps to adjacent insulation segment with 1/2-inch (13-mm) staples, 1 inch (25 mm) o.c., and cover with pressure-sensitive tape having same facing as insulation. 7. Overlap unfaced blankets a minimum of 2 inches (50 mm) on longitudinal seams and end joints. Secure with steel band at end joints and spaced a maximum of 18 inches (450 mm) o.c. 8. Apply insulation on rectangular duct elbows and transitions with a full insulation segment for each surface. Apply insulation on round and flat-oval duct elbows with individually mitered gores cut to fit the elbow. 9. Insulate duct stiffeners, hangers, and flanges that protrude beyond the insulation surface with 6-inch (150-mm) wide strips of the same material used to insulate duct. Secure on alternating sides of stiffener, hanger, and flange with anchor pins spaced 6 inches (150 mm) o.c. 10. Apply vapor-retarder mastic to open joints, breaks, and punctures for insulation indicated to receive vapor retarder. Duct Insulation 23 07 13 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Board Applications for Ducts and Plenums: Secure board insulation with adhesive and anchor pins and speed washers. 1. Apply adhesives according to manufacturer’s recommended coverage rates per square foot, for 100 percent coverage of duct and plenum surfaces. 2. Apply adhesive to entire circumference of ducts and to all surfaces of fittings and transitions. 3. Space anchor pins as follows: a. On duct sides with dimensions 18 inches (450 mm) and smaller, along longitudinal centerline of duct. Space 3 inches (75 mm) maximum from insulation end joints, and 16 inches (400 mm) o.c. b. On duct sides with dimensions larger than 18 inches (450 mm). Space 16 inches (400 mm) o.c. each way, and 3 inches (75 mm) maximum from insulation joints. Apply additional pins and clips to hold insulation tightly against surface at cross bracing. c. Anchor pins may be omitted from top surface of horizontal, rectangular ducts and plenums. d. Do not overcompress insulation during installation. 4. Cut excess portion of pins extending beyond speed washers or bend parallel with insulation surface. Cover exposed pins and washers with tape matching insulation facing. 5. Create a facing lap for longitudinal seams and end joints with insulation by removing 2 inches (50 mm) from one edge and one end of insulation segment. Secure laps to adjacent insulation segment with 1/2-inch (13-mm) staples, 1 inch (25 mm) o.c., and cover with pressure-sensitive tape having same facing as insulation. 6. Apply insulation on rectangular duct elbows and transitions with a full insulation segment for each surface. Groove and score insulation to fit as closely as possible to outside and inside radius of elbows. Apply insulation on round and flat-oval duct elbows with individually mitered gores cut to fit the elbow. 7. Insulate duct stiffeners, hangers, and flanges that protrude beyond the insulation surface with 6-inch (150-mm) wide strips of the same material used to insulate duct. Secure on alternating sides of stiffener, hanger, and flange with anchor pins spaced 6 inches (150 mm) o.c. 8. Apply vapor-retarder mastic to open joints, breaks, and punctures for insulation indicated to receive vapor retarder. 3.05 FIRE-RATED INSULATION SYSTEM INSTALLATION 1. Where fire-rated insulation system is indicated, secure system to ducts and duct hangers and supports to maintain a continuous fire rating. 2. Insulate duct access panels and doors to achieve same fire rating as duct. 3. Install firestopping at penetrations through fire-rated assemblies. Fire-stop systems are specified in Section 078413 "Penetration Firestopping." Duct Insulation 23 07 13 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.06 FIELD-APPLIED JACKET APPLICATION A. Apply glass-cloth jacket, where indicated, directly over bare insulation or insulation with factory-applied jackets. 1. Apply jacket smooth and tight to surface with 2-inch (50-mm) overlap at seams and joints. 2. Embed glass cloth between two 0.062-inch (1.6-mm) thick coats of jacket manufacturer’s recommended adhesive. 3. Completely encapsulate insulation with jacket, leaving no exposed raw insulation. 3.07 FINISHES A. Glass-Cloth Jacketed Insulation: Paint insulation finished with glass-cloth jacket as specified in Division 09. B. Flexible Elastomeric Thermal Insulation: After adhesive has fully cured, apply two coats of insulation manufacturer’s recommended protective coating. C. Color: Final color as selected by Architect/Engineer. Vary first and second coats to allow visual inspection of the completed Work. 3.08 DUCT SYSTEM APPLICATIONS A. Insulation materials and thicknesses are specified in schedules at the end of this Section. B. Materials and thicknesses for systems listed below are specified in schedules at the end of this Section. C. Insulate the following plenums and duct systems: 1. Indoor concealed supply-, return-, and outside-air ductwork. 2. Indoor exposed supply-, return-, and outside-air ductwork. 3. Outdoor exposed supply and return ductwork. 4. Indoor exposed range-hood exhaust ductwork. 5. Indoor concealed range-hood exhaust ductwork. D. Items Not Insulated: Unless otherwise indicated, do not apply insulation to the following systems, materials, and equipment: 1. Factory-insulated flexible ducts. 2. Factory-insulated plenums, casings, terminal boxes, and filter boxes and sections. 3. Flexible connectors. 4. Vibration-control devices. 5. Testing agency labels and stamps. 6. Nameplates and data plates. Duct Insulation 23 07 13 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.09 INDOOR DUCT AND PLENUM APPLICATION SCHEDULE A. Service: Round and rectangular, supply-air ducts, concealed. 1. Material: Mineral-fiber blanket. 2. Thickness: 2 inches (50mm). 3. Number of Layers: One. 4. Field-Applied Jacket: None. 5. Vapor Retarder Required: Yes. B. Service: Round and rectangular, return-air ducts, concealed. 1. Material: Mineral-fiber blanket. No insulation is required if duct is located in a return air plenum. 2. Thickness: 2 inches (50 mm). 3. Number of Layers: One. 4. Field-Applied Jacket: None. 5. Vapor Retarder Required: Yes. C. Service: Round and rectangular, outside-air ducts, concealed. 1. Material: Mineral-fiber blanket. 2. Thickness: 2 inches (50mm). 3. Number of Layers: One. 4. Field-Applied Jacket: None. 5. Vapor Retarder Required: Yes. D. Service: Round and rectangular, supply-air ducts, exposed. 1. Material: Mineral-fiber board. 2. Thickness: 1-1/2 inch (38 mm). 3. Number of Layers: One. 4. Field-Applied Jacket: Glass cloth. 5. Vapor Retarder Required: Yes. E. Service: Round and rectangular, return-air ducts, exposed. 1. Material: Mineral-fiber board. 2. Thickness: 1-1/2 inch (38 mm). 3. Number of Layers: One. 4. Field-Applied Jacket: Glass cloth. 5. Vapor Retarder Required: Yes. Duct Insulation 23 07 13 - 9 DTN18104 – Lake Lewisville WTP/RWPS Improvements F. Service: Round and rectangular, outside-air ducts, exposed. 1. Material: Mineral-fiber board. 2. Thickness: 1-1/2 inches (38 mm). 3. Number of Layers: One. 4. Field-Applied Jacket: Glass cloth. 5. Vapor Retarder Required: Yes. G. Service: Type I, Commercial, Kitchen Hood Exhaust Duct and Plenum Insulation: Fire-rated blanket; thickness as required to achieve 2-hour fire rating. END OF SECTION HVAC Piping Insulation 23 07 19 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 07 19 HVAC PIPING INSULATION 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes preformed, rigid and flexible pipe insulation; insulating cements; field- applied jackets; accessories and attachments; and sealing compounds. 1.03 SUBMITTALS A. Product Data: Identify thermal conductivity, thickness, and jackets (both factory and field applied, if any), for each type of product indicated. B. Material Test Reports: From a qualified testing agency acceptable to authorities having jurisdiction indicating, interpreting, and certifying test results for compliance of insulation materials, sealers, attachments, cements, and jackets with requirements indicated. Include dates of tests. C. Installer Certificates: Signed by the Contractor certifying that installers comply with requirements. 1.04 QUALITY ASSURANCE A. Installer Qualifications: Skilled mechanics who have successfully completed an apprenticeship program or another craft training program certified by the U.S. Department of Labor, Bureau of Apprenticeship and Training. B. Fire-Test-Response Characteristics: As determined by testing materials identical to those specified in this Section according to ASTM E84, by a testing and inspecting agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and sealer and cement material containers with appropriate markings of applicable testing and inspecting agency. 1. Insulation Installed Indoors: Flame-spread rating of 25 or less, and smoke-developed rating of 50 or less. 2. Insulation Installed Outdoors: Flame-spread rating of 75 or less, and smoke-developed rating of 150 or less. 1.05 DELIVERY, STORAGE, AND HANDLING A. Packaging: Ship insulation materials in containers marked by manufacturer with appropriate ASTM specification designation, type and grade, and maximum use temperature. HVAC Piping Insulation 23 07 19 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1.06 COORDINATION A. Coordinate size and location of supports, hangers, and insulation shields specified in Section 23 05 29 “Hangers and Supports for HVAC Piping and Equipment.” B. Coordinate clearance requirements with piping Installer for insulation application. C. Coordinate installation and testing of heat tracing. 1.07 SCHEDULING A. Schedule insulation application after testing piping systems and, where required, after installing and testing heat-trace tape. Insulation application may begin on segments of piping that have satisfactory test results. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Flexible Elastomeric Thermal Insulation: a. Armstrong World Industries, Inc. b. Rubatex Corp. 2.02 INSULATION MATERIALS A. General: Insulation materials shall have a thermal conductivity, k, not exceeding 0.27 BTU per inch/h · ft2 · degrees F. B. Mineral-Fiber Insulation: Glass fibers bonded with a thermosetting resin complying with the following: 1. Preformed Pipe Insulation: Comply with ASTM C547, Type I, with factory-applied, all- purpose, vapor-retarder jacket (ASTM C547, Type II for operating temperatures higher than 850 F). 2. Blanket Insulation: Comply with ASTM C553, Type II, without facing (ASTM C533, Type V for operating temperatures higher than 850 F). 3. Fire-Resistant Adhesive: Comply with MIL-A-3316C in the following classes and grades: a. Class 1, Grade A for bonding glass cloth and tape to unfaced glass-fiber insulation, for sealing edges of glass-fiber insulation, and for bonding lagging cloth to unfaced glass-fiber insulation. b. Class 2, Grade A for bonding glass-fiber insulation to metal surfaces. 4. Vapor-Retarder Mastics: Fire- and water-resistant, vapor-retarder mastic for indoor applications. Comply with MIL-C-19565C, Type II. C. Flexible Elastomeric Thermal Insulation: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTM C534, Type I for tubular materials and Type II for sheet materials. HVAC Piping Insulation 23 07 19 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1. Adhesive: As recommended by insulation material manufacturer. 2. Ultraviolet-Protective Coating: As recommended by insulation manufacturer. 2.03 FIELD-APPLIED JACKETS A. General: ASTM C921, Type 1, unless otherwise indicated. B. Foil and Paper Jacket: Laminated, glass-fiber-reinforced, flame-retardant kraft paper and aluminum foil. C. PVC Jacket: High-impact, ultraviolet-resistant PVC; 20 mils (0.5 mm) thick; roll stock ready for shop or field cutting and forming. 1. Adhesive: As recommended by insulation material manufacturer. 2. PVC Jacket Color: Color-code piping jackets based on materials contained within the piping system. D. Heavy PVC Fitting Covers: Factory-fabricated fitting covers manufactured from 30-mil (0.75- mm) thick, high-impact, ultraviolet-resistant PVC. 1. Shapes: 45- and 90-degree, short- and long-radius elbows, tees, valves, flanges, reducers, end caps, soil-pipe hubs, traps, mechanical joints, and P-trap and supply covers for lavatories for the disabled. 2. Adhesive: As recommended by insulation material manufacturer. E. Standard PVC Fitting Covers: Factory-fabricated fitting covers manufactured from 20-mil (0.5 mm) thick, high-impact, ultraviolet-resistant PVC. 1. Shapes: 45- and 90-degree, short- and long-radius elbows, tees, valves, flanges, reducers, end caps, soil-pipe hubs, traps, mechanical joints, and P-trap and supply covers for lavatories for the disabled. 2. Adhesive: As recommended by insulation material manufacturer. F. Aluminum Jacket: Aluminum roll stock, ready for shop or field cutting and forming to indicated sizes. Comply with ASTM B209 (ASTM B209M), 3003 alloy, H-14 temper. 1. Finish and Thickness: Smooth finish, 0.010 inch (0.25 mm) thick. 2. Finish and Thickness: Corrugated finish, 0.010 inch (0.25 mm) thick. 3. Finish and Thickness: Stucco-embossed finish, 0.016 inch (0.40 mm) thick. 4. Finish and Thickness: Painted finish, 0.016 inch (0.40 mm) thick. 5. Moisture Barrier: 1-mil (0.025-mm) thick, heat-bonded polyethylene and kraft paper. 6. Elbows: Preformed, 45- and 90-degree, short- and long-radius elbows; same material, finish, and thickness as jacket. G. Stainless-Steel Jacket: ASTM A666, Type 304 or 316; 0.10 inch (2.5 mm) thick; and roll stock ready for shop or field cutting and forming to indicated sizes. 1. Moisture Barrier: 1-mil (0.025-mm) thick, heat-bonded polyethylene and kraft paper. 2. Elbows: Gore type, for 45- and 90-degree elbows in same material, finish, and thickness as jacket. HVAC Piping Insulation 23 07 19 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. Jacket Bands: Stainless steel, Type 304, 3/4 inch (19 mm) wide. 2.04 ACCESSORIES AND ATTACHMENTS A. Glass Cloth and Tape: Comply with MIL-C-20079H, Type I for cloth and Type II for tape. Woven glass-fiber fabrics, plain weave, presized a minimum of 8 oz./sq. yd. (270 g/sq. m). 1. Tape Width: 4 inches (100 mm). B. Bands: 3/4 inch (19 mm) wide, in one of the following materials compatible with jacket: 1. Stainless Steel: ASTM A666, Type 304; 0.020 inch (0.5 mm) thick. 2. Galvanized Steel: 0.005 inch (0.13 mm) thick. 3. Aluminum: 0.007 inch (0.18 mm) thick. 4. Brass: 0.010 inch (0.25 mm) thick. 5. Nickel-Copper Alloy: 0.005 inch (0.13 mm) thick. C. Wire: 0.080-inch (2.0-mm), nickel-copper alloy; 0.062-inch (1.6-mm), soft-annealed, stainless steel; or 0.062-inch (1.6-mm), soft-annealed, galvanized steel. 2.05 VAPOR RETARDERS A. Mastics: Materials recommended by insulation material manufacturer that are compatible with insulation materials, jackets, and substrates. 3.00 EXECUTION 3.01 EXAMINATION A. Examine substrates and conditions for compliance with requirements for installation and other conditions affecting performance of insulation application. B. Proceed with installation only after unsatisfactory conditions have been corrected. 3.02 PREPARATION A. Surface Preparation: Clean and dry pipe and fitting surfaces. Remove materials that will adversely affect insulation application. 3.03 GENERAL APPLICATION REQUIREMENTS A. Apply insulation materials, accessories, and finishes according to the manufacturer’s written instructions; with smooth, straight, and even surfaces; free of voids throughout the length of piping, including fittings, valves, and specialties. B. Refer to schedules at the end of this Section for materials, forms, jackets, and thicknesses required for each piping system. C. Use accessories compatible with insulation materials and suitable for the service. Use accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state. D. Apply insulation with longitudinal seams at top and bottom of horizontal pipe runs. HVAC Piping Insulation 23 07 19 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements E. Apply multiple layers of insulation with longitudinal and end seams staggered. F. Do not weld brackets, clips, or other attachment devices to piping, fittings, and specialties. G. Seal joints and seams with vapor-retarder mastic on insulation indicated to receive a vapor retarder. H. Keep insulation materials dry during application and finishing. I. Apply insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by the insulation material manufacturer. J. Apply insulation with the least number of joints practical. K. Apply insulation over fittings, valves, and specialties, with continuous thermal and vapor- retarder integrity, unless otherwise indicated. Refer to special instructions for applying insulation over fittings, valves, and specialties. L. Hangers and Anchors: Where vapor retarder is indicated, seal penetrations in insulation at hangers, supports, anchors, and other projections with vapor-retarder mastic. 1. Apply insulation continuously through hangers and around anchor attachments. 2. For insulation application where vapor retarders are indicated, extend insulation on anchor legs at least 12 inches (300 mm) from point of attachment to pipe and taper insulation ends. Seal tapered ends with a compound recommended by the insulation material manufacturer to maintain vapor retarder. 3. Install insert materials and apply insulation to tightly join the insert. Seal insulation to insulation inserts with adhesive or sealing compound recommended by the insulation material manufacturer. 4. Cover inserts with jacket material matching adjacent pipe insulation. Install shields over jacket, arranged to protect the jacket from tear or puncture by the hanger, support, and shield. M. Insulation Terminations: For insulation application where vapor retarders are indicated, taper insulation ends. Seal tapered ends with a compound recommended by the insulation material manufacturer to maintain vapor retarder. N. Apply adhesives and mastics at the manufacturer’s recommended coverage rate. O. Apply insulation with integral jackets as follows: 1. Pull jacket tight and smooth. 2. Circumferential Joints: Cover with 3-inch (75-mm) wide strips, of same material as insulation jacket. Secure strips with adhesive and outward clinching staples along both edges of strip and spaced 4 inches (100 mm) o.c. 3. Longitudinal Seams: Overlap jacket seams at least 1-1/2 inches (40 mm). Apply insulation with longitudinal seams at bottom of pipe. Clean and dry surface to receive self-sealing lap. Staple laps with outward clinching staples along edge at 4 inches (100 mm) o.c. a. Exception: Do not staple longitudinal laps on insulation having a vapor retarder. HVAC Piping Insulation 23 07 19 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements 4. Vapor-Retarder Mastics: Where vapor retarders are indicated, apply mastic on seams and joints and at ends adjacent to flanges, unions, valves, and fittings. 5. At penetrations in jackets for thermometers and pressure gages, fill and seal voids with vapor-retarder mastic. P. Roof Penetrations: Apply insulation for interior applications to a point even with top of roof flashing. 1. Seal penetrations with vapor-retarder mastic. 2. Apply insulation for exterior applications tightly joined to interior insulation ends. 3. Extend metal jacket of exterior insulation outside roof flashing at least 2 inches (50 mm) below top of roof flashing. 4. Seal metal jacket to roof flashing with vapor-retarder mastic. Q. Exterior Wall Penetrations: For penetrations of below-grade exterior walls, terminate insulation flush with mechanical sleeve seal. Seal terminations with vapor-retarder mastic. R. Interior Wall and Partition Penetrations: Apply insulation continuously through walls and floors. S. Fire-Rated Wall and Partition Penetrations: Apply insulation continuously through penetrations of fire-rated walls and partitions. 1. Firestopping and fire-resistive joint sealers are specified in Division 07. T. Floor Penetrations: Apply insulation continuously through floor assembly. 1. For insulation with vapor retarders, seal insulation with vapor-retarder mastic where floor supports penetrate vapor retarder. 3.04 FLEXIBLE ELASTOMERIC THERMAL INSULATION APPLICATION A. Apply insulation to straight pipes and tubes as follows: 1. Follow manufacturer’s written instructions for applying insulation. 2. Seal longitudinal seams and end joints with manufacturer’s recommended adhesive. Cement to avoid openings in insulation that will allow passage of air to the pipe surface. B. Apply insulation to flanges as follows: 1. Apply pipe insulation to outer diameter of pipe flange. 2. Make width of insulation segment the same as overall width of the flange and bolts, plus twice the thickness of the pipe insulation. 3. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with cut sections of sheet insulation of the same thickness as pipe insulation. 4. Secure insulation to flanges and seal seams with manufacturer’s recommended adhesive. Cement to avoid openings in insulation that will allow passage of air to the pipe surface. HVAC Piping Insulation 23 07 19 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements C. Apply insulation to fittings and elbows as follows: 1. Apply mitered sections of pipe insulation. 2. Secure insulation materials and seal seams with manufacturer’s recommended adhesive. Cement to avoid openings in insulation that will allow passage of air to the pipe surface. D. Apply insulation to valves and specialties as follows: 1. Apply preformed valve covers manufactured of the same material as pipe insulation and attached according to the manufacturer’s written instructions. 2. Apply cut segments of pipe and sheet insulation to valve body. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation. For check valves, fabricate removable sections of insulation arranged to allow access to strainer basket. 3. Apply insulation to flanges as specified for flange insulation application. 4. Secure insulation to valves and specialties and seal seams with manufacturer’s recommended adhesive. Cement to avoid openings in insulation that will allow passage of air to the pipe surface. 3.05 FIELD-APPLIED JACKET APPLICATION A. Apply glass-cloth jacket, where indicated, directly over bare insulation or insulation with factory-applied jackets. 1. Apply jacket smooth and tight to surface with 2-inch (50-mm) overlap at seams and joints. 2. Embed glass cloth between two 0.062-inch (1.6-mm) thick coats of jacket manufacturer’s recommended adhesive. 3. Completely encapsulate insulation with jacket, leaving no exposed raw insulation. B. Foil and Paper Jackets: Apply foil and paper jackets where indicated. 1. Draw jacket material smooth and tight. 2. Apply lap or joint strips with the same material as jacket. 3. Secure jacket to insulation with manufacturer’s recommended adhesive. 4. Apply jackets with 1-1/2-inch (40-mm) laps at longitudinal seams and 3-inch (75-mm) wide joint strips at end joints. 5. Seal openings, punctures, and breaks in vapor-retarder jackets and exposed insulation with vapor-retarder mastic. C. Apply PVC jacket where indicated, with 1-inch (25-mm) overlap at longitudinal seams and end joints. Seal with manufacturer’s recommended adhesive. D. Apply metal jacket where indicated, with 2-inch (50-mm) overlap at longitudinal seams and end joints. Overlap longitudinal seams arranged to shed water. Seal end joints with weatherproof sealant recommended by insulation manufacturer. Secure jacket with stainless-steel bands 12 inches (300 mm) o.c. and at end joints. HVAC Piping Insulation 23 07 19 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.06 FINISHES A. Glass-Cloth Jacketed Insulation: Paint insulation finished with glass-cloth jacket as specified in Division 09. B. Flexible Elastomeric Thermal Insulation: After adhesive has fully cured, apply two coats of the insulation manufacturer’s recommended protective coating. C. Color: Final color as selected by Architect/Engineer. Vary first and second coats to allow visual inspection of the completed Work. 3.07 PIPING SYSTEM APPLICATIONS A. Insulation materials and thicknesses are specified in schedules at the end of this Section. B. Items Not Insulated: Unless otherwise indicated, do not apply insulation to the following systems, materials, and equipment: 1. Flexible connectors. 2. Vibration-control devices. 3. Fire-suppression piping. 4. Drainage piping located in crawl spaces, unless otherwise indicated. 5. Below-grade piping, unless otherwise indicated. 6. Chrome-plated pipes and fittings, unless potential for personnel injury. 7. Air chambers, unions, strainers, check valves, plug valves, and flow regulators. 3.08 FIELD QUALITY CONTROL A. Inspection: Engage a qualified inspection agency to perform the following field quality- control inspections, after installing insulation materials, jackets, and finishes, to determine compliance with requirements: 1. Inspect fittings and valves randomly selected by Architect/Engineer. 2. Remove fitting covers from 20 elbows or 1 percent of elbows, whichever is less, for various pipe sizes. 3. Remove fitting covers from 20 valves or 1 percent of valves, whichever is less, for various pipe sizes. B. Insulation applications will be considered defective if sample inspection reveals noncompliance with requirements. Remove defective Work and replace with new materials according to these Specifications. C. Reinstall insulation and covers on fittings and valves uncovered for inspection according to these Specifications. 3.09 INSULATION APPLICATION SCHEDULE, GENERAL A. Refer to insulation application schedules for required insulation materials, vapor retarders, and field-applied jackets. HVAC Piping Insulation 23 07 19 - 9 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Application schedules identify piping system and indicate pipe size ranges and material, thickness, and jacket requirements. 3.10 INTERIOR INSULATION APPLICATION SCHEDULE A. Service: A/C condensate drain piping. 1. Operating Temperature: 35 to 75 F (2 to 38 C). 2. Insulation Material: Flexible elastomeric. 3. Insulation Thickness: 1/2-inch (13-mm) thickness for all pipe sizes. 4. Field-Applied Jacket: None. 5. Vapor Retarder Required: Yes. 6. Finish: None. B. Service: Refrigerant suction and hot-gas piping. 1. Operating Temperature: 35 to 50 F (2 to 10 C). 2. Insulation Material: Flexible elastomeric. 3. Insulation Thickness: Apply the following insulation thicknesses: a. 1-inch (25-mm) Diameter Pipe and Smaller: 1-inch (25-mm) thickness. b. 1-1/4-inch (32-mm) Diameter Pipe and Larger: 1-1/2-inch (40-mm) thickness. 4. Field-Applied Jacket: None. 5. Vapor Retarder Required: None. 6. Finish: None. 3.11 EXTERIOR INSULATION APPLICATION SCHEDULE A. This application schedule is for aboveground insulation outside the building. Piping below ground requiring insulation will be provided as part of a preinsulated double wall piping system specified elsewhere. B. Service: A/Condensate drain piping. 1. Operating Temperature: 35 to 75 F (2 to 24 C). 2. Insulation Material: Flexible elastomeric. 3. Insulation Thickness: 1/2-inch (13-mm) thickness for all pipe sizes. 4. Field-Applied Jacket: None. 5. Vapor Retarder Required: Yes. 6. Finish: Weatherproof adhesive. C. Service: Refrigerant suction and hot-gas piping. 1. Operating Temperature: 35 to 50 F (2 to 10 C). 2. Insulation Material: Flexible elastomeric. HVAC Piping Insulation 23 07 19 - 10 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. Insulation Thickness: Apply the following insulation thicknesses: a. 1-inch (25-mm) Diameter Pipe and Smaller: 1-inch (25-mm) thickness. b. 1-1/4-inch (32-mm) Diameter Pipe and Larger: 1-1/2-inch (40-mm) thickness. 4. Field-Applied Jacket: Aluminum. 5. Vapor Retarder Required: Yes. 6. Finish: Weatherproof adhesive. END OF SECTION Refrigerant Piping 23 23 00 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 23 00 REFRIGERANT PIPING 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes refrigerant piping used for air-conditioning applications. 1.03 SUBMITTALS A. Product Data: For each type of valve and refrigerant piping specialty indicated. Include pressure drop, based on manufacturer’s test data, for thermostatic expansion valves, solenoid valves, and pressure-regulating valves. B. Shop Drawings: 1. Show layout of refrigerant piping and specialties, including pipe, tube, and fitting sizes, flow capacities, valve arrangements and locations, slopes of horizontal runs, oil traps, double risers, wall and floor penetrations, and equipment connection details. Show interface and spatial relationship between piping and equipment. 2. Refrigerant piping indicated is schematic only. Size piping and design the actual piping layout, including oil traps, double risers, specialties, and pipe and tube sizes, to ensure proper operation and compliance with warranties of connected equipment. C. Field Test Reports: Indicate and interpret test results for compliance with performance requirements. D. Maintenance Data: For refrigerant valves and piping specialties to include in maintenance manuals specified in Division 01. 1.04 QUALITY ASSURANCE A. ASHRAE Standard: Comply with ASHRAE 15, “Safety Code for Mechanical Refrigeration.” B. ASME Standard: Comply with ASME B31.5, “Refrigeration Piping.” C. UL Standard: Provide products complying with UL 207, “Refrigerant-Containing Components and Accessories, Nonelectrical”; or UL 429, “Electrically Operated Valves.” 1.05 COORDINATION A. Coordinate layout and installation of refrigerant piping and suspension system components with other construction, including light fixtures, HVAC equipment, fire-suppression-system components, and partition assemblies. B. Coordinate pipe sleeve installations for foundation wall penetrations. C. Coordinate installation of roof curbs, equipment supports, and roof penetrations. Refrigerant Piping 23 23 00 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Coordinate pipe sleeve installations for penetrations in exterior walls and floor assemblies. Coordinate with requirements for firestopping specified in Division 07 for materials and methods for sealing pipe penetrations through fire and smoke barriers. E. Coordinate pipe fitting pressure classes with products specified in related Sections. 1.06 PRODUCT STORAGE AND HANDLING A. Store piping with end caps in place to ensure that piping interior and exterior are clean when installed. 1.07 EXTRA MATERIALS A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Refrigeration Oil Test Kits: Two each, containing everything required to conduct one test. 2. Refrigerant: Two containers each, with 20 lb. (9 kg) of refrigerant. 3. Filter-Dryer Cartridges: Three of each type. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Refrigerants: a. Allied Signal, Inc./Fluorine Products; Genetron Refrigerants. b. DuPont Company; Fluorochemicals Div. c. Elf Atochem North America, Inc.; Fluorocarbon Div. d. ICI Americas Inc./ICI KLEA; Fluorochemicals Bus. 2. Refrigerant Valves and Specialties: a. Climate & Industrial Controls Group; Parker-Hannifin Corp.; Refrigeration & Air Conditioning Division. b. Danfoss Electronics, Inc. c. Emerson Electric Company; Alco Controls Div. d. Henry Valve Company. e. Sporlan Valve Company. 2.02 PERFORMANCE REQUIREMENTS A. Line Test Pressure for Refrigerant R-134a: 1. Suction Lines for Air-Conditioning Applications: 115 psig (793 kPa). Refrigerant Piping 23 23 00 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. Suction Lines for Heat-Pump Applications: 225 psig (1551 kPa). 3. Hot-Gas and Liquid Lines: 225 psig (1551 kPa). B. Line Test Pressure for R-410A 1. Suction lines for air-conditioning applications: 230 psig. 2. Suction lines for heat-pump applications: 380 psig. 3. Hot-gas and liquid lines: 535 psig. 2.03 COPPER TUBE AND FITTINGS A. Copper Tube: ASTM B280, Type ACR. B. Wrought-Copper Fittings: ASME B16.22. C. Wrought-Copper Unions: ASME B16.22. D. Solder Filler Metals: ASTM B 32. Use 95-5 tin antimony or alloy HB solder to join copper socket fittings on copper pipe. E. Brazing Filler Metals: AWS A5.8, Classification BAg-1 (silver). F. Flexible Connectors: 1. Body: Tin-bronze bellows with woven, flexible, tinned-bronze-wire-reinforced protective jacket. 2. End Connections: Socket ends. 3. Offset Performance: Capable of minimum 3/4-inch misalignment in minimum 7-inch- long assembly. 4. Working Pressure Rating: Factory test at minimum 500 psig (3450 kPa). 5. Maximum Operating Temperature: 250 deg F (121 deg C). 2.04 VALVES A. Diaphragm Packless Valves: 1. Body and Bonnet: Forged brass or cast bronze; globe design with straight-through or angle pattern. 2. Diaphragm: Phosphor bronze and stainless steel with stainless-steel spring. 3. Operator: Rising stem and hand wheel. 4. Seat: Nylon. 5. End Connections: Socket, union, or flanged. 6. Working Pressure Rating: 500 psig (3450 kPa). 7. Maximum Operating Temperature: 275 deg F (135 deg C). B. Packed-Angle Valves: 1. Body and Bonnet: Forged brass or cast bronze. 2. Packing: Molded stem, back seating, and replaceable under pressure. Refrigerant Piping 23 23 00 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. Operator: Rising stem. 4. Seat: Nonrotating, self-aligning polytetrafluoroethylene. 5. Seal Cap: Forged-brass or valox hex cap. 6. End Connections: Socket, union, threaded, or flanged. 7. Working Pressure Rating: 500 psig (3450 kPa). 8. Maximum Operating Temperature: 275 deg F (135 deg C). C. Check Valves: 1. Body: Ductile iron, forged brass, or cast bronze; globe pattern. 2. Bonnet: Bolted ductile iron, forged brass, or cast bronze; or brass hex plug. 3. Piston: Removable polytetrafluoroethylene seat. 4. Closing Spring: Stainless steel. 5. Manual Opening Stem: Seal cap, plated-steel stem, and graphite seal. 6. End Connections: Socket, union, threaded, or flanged. 7. Maximum Opening Pressure: 0.50 psig (3.4 kPa). 8. Working Pressure Rating: 500 psig (3450 kPa). 9. Maximum Operating Temperature: 275 deg F (135 deg C). D. Service Valves: 1. Body: Forged brass with brass cap including key end to remove core. 2. Core: Removable ball-type check valve with stainless-steel spring. 3. Seat: Polytetrafluoroethylene. 4. End Connections: Copper spring. 5. Working Pressure Rating: 500 psig (3450 kPa). E. Solenoid Valves: Comply with AHRI 760 and UL 429; listed and labeled by a National Recognized Testing Laboratory (NRTL). 1. Body and Bonnet: Plated steel. 2. Solenoid Tube, Plunger, Closing Spring, and Seat Orifice: Stainless steel. 3. Seat: Polytetrafluoroethylene. 4. End Connections: Threaded. 5. Electrical: Molded, watertight coil in NEMA 250 enclosure of type required by location with 1/2-inch (16-GRC) conduit adapter, and 24-V AC coil. 6. Working Pressure Rating: 400 psig (2760 kPa). 7. Maximum Operating Temperature: 240 deg F (116 deg C). Refrigerant Piping 23 23 00 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements F. Safety Relief Valves: Comply with 2010 ASME Boiler and Pressure Vessel Code; listed and labeled by an NRTL. 1. Body and Bonnet: Ductile iron and steel, with neoprene O-ring seal. 2. Piston, Closing Spring, and Seat Insert: Stainless steel. 3. Seat: Polytetrafluoroethylene. 4. End Connections: Threaded. 5. Working Pressure Rating: 400 psig (2760 kPa). 6. Maximum Operating Temperature: 240 deg F (116 deg C). G. Thermostatic Expansion Valves: Comply with AHRI 750. 1. Body, Bonnet, and Seal Cap: Forged brass or steel. 2. Diaphragm, Piston, Closing Spring, and Seat Insert: Stainless steel. 3. Packing and Gaskets: Non-asbestos. 4. Capillary and Bulb: Copper tubing filled with refrigerant charge. 5. Suction Temperature: 40 deg F (4.4 deg C). 6. Superheat: Adjustable. 7. Reverse-flow option (for heat-pump applications). 8. End Connections: Socket, flare, or threaded union. 9. Working Pressure Rating: 700 psig (4820 kPa). H. Hot-Gas Bypass Valves: Comply with UL 429; listed and labeled by an NRTL. 1. Body, Bonnet, and Seal Cap: Ductile iron or steel. 2. Diaphragm, Piston, Closing Spring, and Seat Insert: Stainless steel. 3. Packing and Gaskets: Non-asbestos. 4. Solenoid Tube, Plunger, Closing Spring, and Seat Orifice: Stainless steel. 5. Seat: Polytetrafluoroethylene. 6. Equalizer: External. 7. Electrical: Molded, watertight coil in NEMA 250 enclosure of type required by location with 1/2-inch (16-GRC) conduit adapter and 24-V AC coil. 8. End Connections: Socket. 9. Set Pressure: 30 psig (207 kPa). 10. Throttling Range: Maximum 5 psig (34 kPa). 11. Working Pressure Rating: 500 psig (3450 kPa). 12. Maximum Operating Temperature: 240 deg F (116 deg C). Refrigerant Piping 23 23 00 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.05 REFRIGERANT PIPING SPECIALITIES A. Straight-Type Strainers: 1. Body: Welded steel with corrosion-resistant coating. 2. Screen: 100-mesh stainless steel. 3. End Connections: Socket or flare. 4. Working Pressure Rating: 500 psig (3450 kPa). 5. Maximum Operating Temperature: 275 deg F (135 deg C). B. Angle-Type Strainers: 1. Body: Forged brass or cast bronze. 2. Drain Plug: Brass hex plug. 3. Screen: 100-mesh monel. 4. End Connections: Socket or flare. 5. Working Pressure Rating: 500 psig (3450 kPa). 6. Maximum Operating Temperature: 275 deg F (135 deg C). C. Moisture/Liquid Indicators: 1. Body: Forged brass. 2. Window: Replaceable, clear, fused glass window with indicating element protected by filter screen. 3. Indicator: Color coded to show moisture content in parts per million (ppm). 4. Minimum Moisture Indicator Sensitivity: Indicate moisture above 60 ppm. 5. End Connections: Socket or flare. 6. Working Pressure Rating: 500 psig (3450 kPa). 7. Maximum Operating Temperature: 240 deg F (116 deg C). D. Replaceable-Core Filter Dryers: Comply with AHRI 730. 1. Body and Cover: Painted-steel shell with ductile-iron cover, stainless-steel screws, and neoprene gaskets. 2. Filter Media: 10 micron, pleated with integral end rings; stainless-steel support. 3. Desiccant Media: Activated alumina. 4. Designed for reverse flow (for heat-pump applications). 5. End Connections: Socket. 6. Access Ports: NPS 1/4 (DN 8) connections at entering and leaving sides for pressure differential measurement. 7. Maximum Pressure Loss: 2 psig (14 kPa). 8. Rated Flow: 10 tons (35.2 kW). Refrigerant Piping 23 23 00 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements 9. Working Pressure Rating: 500 psig (3450 kPa). 10. Maximum Operating Temperature: 240 deg F (116 deg C). E. Permanent Filter Dryers: Comply with AHRI 730. 1. Body and Cover: Painted-steel shell. 2. Filter Media: 10 micron, pleated with integral end rings; stainless-steel support. 3. Desiccant Media: Activated alumina. 4. Designed for reverse flow (for heat-pump applications). 5. End Connections: Socket. 6. Access Ports: NPS 1/4 (DN 8) connections at entering and leaving sides for pressure differential measurement. 7. Maximum Pressure Loss: 2 psig (14 kPa). 8. Rated Flow: 10 tons 35.2 (kW). 9. Working Pressure Rating: 500 psig (3450 kPa). 10. Maximum Operating Temperature: 240 deg F (116 deg C). F. Mufflers: 1. Body: Welded steel with corrosion-resistant coating. 2. End Connections: Socket or flare. 3. Working Pressure Rating: 500 psig (3450 kPa). 4. Maximum Operating Temperature: 275 deg F (135 deg C). G. Liquid Accumulators: Comply with AHRI 495. 1. Body: Welded steel with corrosion-resistant coating. 2. End Connections: Socket or threaded. 3. Working Pressure Rating: 500 psig (3450 kPa). 4. Maximum Operating Temperature: 275 deg F (135 deg C). 2.06 RECEIVERS A. Receivers: Comply with AHRI 495. 1. Comply with 2010 ASME Boiler and Pressure Vessel Code; listed and labeled by an NRTL. 2. Comply with UL 207; listed and labeled by an NRTL. 3. Body: Welded steel with corrosion-resistant coating. 4. Tappings: Inlet, outlet, liquid level indicator, and safety relief valve. 5. End Connections: Socket or threaded. 6. Working Pressure Rating: 500 psig (3450 kPa). 7. Maximum Operating Temperature: 275 deg F (135 deg C). Refrigerant Piping 23 23 00 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.07 REFRIGERANTS A. ASHRAE 34, R-134a: Tetrafluoroethane. B. ASHRAE 34, R-410A: Pentafluoroethane/Difluoromethane. 3.00 EXECUTION 3.01 PIPING APPLICATIONS A. Aboveground, within Building: Type ACR drawn-copper tubing and wrought-copper fittings with brazed or soldered joints. B. Belowground: Type ACR annealed-copper tubing and wrought-copper fittings with brazed or soldered joints. 3.02 VALVE APPLICATIONS A. Install diaphragm packless or packed-angle valves in suction and discharge lines of compressor, for gage taps at hot-gas bypass regulators, on each side of strainers. B. Install service valves for gage taps at inlet and outlet of hot-gas bypass valves and strainers if they are not an integral part of valves and strainers. C. Install check valves in compressor discharge lines and in condenser liquid lines on multiple condenser systems. D. Install a liquid accumulator at the compressor suction connection. E. Install packed-angle valve in liquid line between receiver shutoff valve and thermostatic expansion valve for system charging. F. Install diaphragm packless or packed-angle valves on each side of strainers and dryers, in liquid and suction lines at evaporators, and elsewhere as indicated. G. Install a full-sized, three-valve bypass around each dryer. H. Install solenoid valves upstream from each expansion valve and hot-gas bypass valve. 1. Install solenoid valves in horizontal lines with coil at top. 2. Electrical wiring for solenoid valves is specified in Division 26 Sections. Coordinate electrical requirements and connections. I. Install thermostatic expansion valves as close as possible to evaporator. 1. If refrigerant distributors are used, install them directly on expansion-valve outlet. 2. Install valve so diaphragm case is warmer than bulb. 3. Secure bulb to clean, straight, horizontal section of suction line using two bulb straps. Do not mount bulb in a trap or at bottom of the line. Verify proper location for bulb with valve manufacturer. 4. If external equalizer lines are required, make connection where it will reflect suction-line pressure at bulb location. Refrigerant Piping 23 23 00 - 9 DTN18104 – Lake Lewisville WTP/RWPS Improvements J. Install pressure-regulating and pressure relief valves as required by ASHRAE 15. Pipe pressure relief valve discharge to outside. 3.03 SPECIALTY APPLICATIONS A. Install liquid indicators in liquid line leaving condenser, in liquid line leaving receiver, and on leaving side of liquid solenoid valves. B. Install strainers immediately upstream from each automatic valve, including expansion valves, solenoid valves, hot-gas bypass valves, and compressor suction valves. C. Install strainers in main liquid line where multiple expansion valves with integral strainers are used. D. Install moisture-liquid indicators in liquid lines between filter-dryers and thermostatic expansion valves and in liquid line to receiver. E. Install pressure relief valves on ASME receivers; pipe discharge to outdoors. F. Install replaceable-core filter-dryers in vertical liquid line adjacent to receivers and before each solenoid valve. G. Install permanent filter-dryers before each solenoid valve in low-temperature systems and in systems using hermetic compressors. H. Install receivers, sized to accommodate pump-down charge, on systems 5 tons (17.5 kW) and larger and on systems with long piping runs. I. Install flexible connectors at or near compressors and fan coils or air handlers where piping configuration does not absorb vibration. 3.04 PIPING INSTALLATION A. Install refrigerant piping according to ASHRAE 15. B. Basic piping installation requirements are specified in Division 23 Section “Basic Mechanical Materials and Methods.” C. Install piping as short and direct as possible, with a minimum number of joints, elbows, and fittings. D. Arrange piping to allow inspection and service of compressor and other equipment. Install valves and specialties in accessible locations to allow for service and inspection. E. Install piping with adequate clearance between pipe and adjacent walls and hangers or between pipes for insulation installation. Use sleeves through floors, walls, or ceilings, sized to permit installation of full-thickness insulation. F. Belowground, install copper tubing in protective conduit. Vent conduit outdoors. G. Install copper tubing in rigid or flexible conduit in locations where copper tubing will be exposed to mechanical injury. H. Slope refrigerant piping as follows: 1. Install horizontal hot-gas discharge piping with a uniform slope downward away from compressor. Refrigerant Piping 23 23 00 - 10 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. Install horizontal suction lines with a uniform slope downward to compressor. 3. Install traps and double risers to entrain oil in vertical runs. 4. Liquid lines may be installed level. I. Install bypass around moisture-liquid indicators in lines larger than NPS 2 (DN 50). J. Install unions to allow removal of solenoid valves, pressure-regulating valves, and expansion valves and at connections to compressors and evaporators. K. When brazing, remove solenoid-valve coils and sight glasses; also remove valve stems, seats, and packing, and accessible internal parts of refrigerant specialties. Do not apply heat near expansion valve bulb. L. Hanger, support, and anchor products are specified in Section 23 05 09 “Hangers and Supports for HVAC Piping and Equipment.” M. Install the following pipe attachments: 1. Adjustable steel clevis hangers for individual horizontal runs less than 20 feet (6.0 m) long. 2. Roller hangers and spring hangers for individual horizontal runs 20 feet (6.0 m) or longer. 3. Pipe rollers for multiple horizontal runs 20 feet (6.0 m) or longer, supported by a trapeze. 4. Spring hangers to support vertical runs. N. Install hangers for copper tubing with the following maximum spacing and minimum rod sizes: 1. NPS 1/2 (DN 15): Maximum span, 60 inches (1500 mm); minimum rod size, 1/4 inch (6.4 mm). 2. NPS 5/8 (DN 18): Maximum span, 60 inches (1500 mm); minimum rod size, 1/4 inch (6.4 mm). 3. NPS 1 (DN 25): Maximum span, 72 inches (1800 mm); minimum rod size, 1/4 inch (6.4 mm). 4. NPS 1-1/4 (DN 32): Maximum span, 96 inches (2400 mm); minimum rod size, 3/8 inch (9.5 mm). 5. NPS 1-1/2 (DN 40): Maximum span, 96 inches (2400 mm); minimum rod size, 3/8 inch (9.5 mm). 6. NPS 2 (DN 50): Maximum span, 96 inches (2400 mm); minimum rod size, 3/8 inch (9.5 mm). 7. NPS 2-1/2 (DN 65): Maximum span, 108 inches (2700 mm); minimum rod size, 3/8 inch (9.5 mm). 8. NPS 3 (DN 80): Maximum span, 10 feet (3 m); minimum rod size, 3/8 inch (9.5 mm). 9. NPS 4 (DN 100): Maximum span, 12 feet (3.7 m); minimum rod size, 1/2 inch (13 mm). O. Support vertical runs at each floor. Refrigerant Piping 23 23 00 - 11 DTN18104 – Lake Lewisville WTP/RWPS Improvements P. Install piping in concealed locations unless otherwise indicated and except in equipment rooms and service areas. Q. 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. R. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal. S. Install piping free of sags and bends. T. Install fittings for changes in direction and branch connections. U. Select system components with pressure rating equal to or greater than system operating pressure. V. Identify refrigerant piping and valves according to Section 23 05 53 "Identification for HVAC Piping and Equipment." 3.05 PIPE JOINT CONSTRUCTION A. Braze or solder joints according to Division 23 Section “Basic Mechanical Materials and Methods.” B. Fill pipe and fittings with an inert gas (nitrogen or carbon dioxide) during brazing to prevent scale formation. C. Ream ends of pipes and tubes and remove burrs. D. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly. 3.06 FIELD QUALITY CONTROL A. Test and inspect refrigerant piping according to ASME B31.5, Chapter VI. 1. Test refrigerant piping, specialties, and receivers. Isolate compressor, condenser, evaporator, and safety devices from test pressure. 2. Test high- and low-pressure side piping of each system at not less than the lower of the design pressure or the setting of pressure relief device protecting high and low side of system. a. System shall maintain test pressure at the manifold gage throughout duration of test. b. Test joints and fittings by brushing a small amount of soap and glycerine solution over joint. c. Fill system with nitrogen to raise a test pressure of 150 psig (1035 kPa) or higher as required by authorities having jurisdiction. d. Remake leaking joints using new materials, and retest until satisfactory results are achieved. 3.07 ADJUSTING A. Adjust thermostatic expansion valve to obtain proper evaporator superheat requirements. Refrigerant Piping 23 23 00 - 12 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Adjust high- and low-pressure switch settings to avoid short cycling in response to fluctuating suction pressure. C. Adjust set-point temperature of the conditioned air or chilled-water controllers to the system design temperature. D. Perform the following adjustments before operating the refrigeration system, according to manufacturer’s written instructions: 1. Open shutoff valves in condenser water circuit. 2. Check compressor oil level above center of sight glass. 3. Open compressor suction and discharge valves. 4. Open refrigerant valves, except bypass valves that are used for other purposes. 5. Check compressor-motor alignment, and lubricate motors and bearings. 3.08 CLEANING A. Replace core of filter-dryer after system has been adjusted and design flow rates and pressures are established. 3.09 SYSTEM CHARGING A. Charge system using the following procedures: 1. Install core in filter-dryer after leak test but before evacuation. 2. Evacuate entire refrigerant system with a vacuum pump to a vacuum of 500 micrometers (67 Pa). If vacuum holds for 12 hours, system is ready for charging. 3. Break vacuum with refrigerant gas, allowing pressure to build up to 2 psig (14 kPa). 4. Charge system with a new filter-dryer core in charging line. Provide full-operating charge. END OF SECTION Metal Ducts 23 31 13 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 31 13 METAL DUCTS 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes metal ducts for supply, return, outside, and exhaust air-distribution systems in pressure classes from minus 2- to plus 10-inch wg (minus 500- to plus 2500-Pa). Metal ducts include the following: 1. Rectangular ducts and fittings. 2. Single-wall, round spiral-seam ducts and formed fittings. 1.03 DEFINITIONS A. FRP: Fiberglass-reinforced plastic. B. NUSIG: National Uniform Seismic Installation Guidelines. 1.04 SUBMITTALS A. Field Quality-Control Test Reports. 1.05 QUALITY ASSURANCE A. NFPA Compliance: 1. NFPA 90A, “Installation of Air Conditioning and Ventilating Systems.” 2. NFPA 90B, “Installation of Warm Air Heating and Air Conditioning Systems.” B. Comply with NFPA 96, “Ventilation Control and Fire Protection of Commercial Cooking Operations,” Ch. 3, “Duct System,” for range hood ducts, unless otherwise indicated. 2.00 PRODUCTS 2.01 MANUFACTURERS A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the manufacturers specified. Metal Ducts 23 31 13 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.02 SHEET METAL MATERIALS A. Comply with SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible” for acceptable materials, material thicknesses, and duct construction methods, unless otherwise indicated. Sheet metal materials shall be free of pitting, seam marks, roller marks, stains, discolorations, and other imperfections. B. Galvanized Sheet Steel: Lock-forming quality; complying with ASTM A653/A653M and having G60 (Z180) coating designation; ducts shall have mill-phosphatized finish for surfaces exposed to view. C. PVC-Coated Galvanized Steel: Acceptable by authorities having jurisdiction for use in fabricating ducts with UL 181, Class 1 listing. Lock-forming-quality, galvanized sheet steel complying with ASTM A653/A653M and having G60 (Z180) coating designation. Factory- applied PVC coatings shall be 4 mils (0.10 mm) thick on sheet metal surfaces of ducts and fittings exposed to corrosive conditions and 2 mils (0.05 mm) thick on opposite surfaces. D. Carbon-Steel Sheets: ASTM A366/A366M, cold-rolled sheets; commercial quality; with oiled, matte finish for exposed ducts. E. Stainless Steel: ASTM A480/A480M, Type 316, and having a No. 2Dfinish for concealed ducts and a No. 2D for exposed ducts. F. Aluminum Sheets: ASTM B209 (ASTM B209M), alloy 3003, temper H14; with mill finish for concealed ducts and standard, one-side bright finish for exposed ducts. G. Reinforcement Shapes and Plates: Galvanized-steel reinforcement where installed on galvanized sheet metal ducts. H. Tie Rods: Galvanized steel, 1/4-inch (6-mm) minimum diameter for lengths 36 inches (900 mm) or less; 3/8-inch (10-mm) minimum diameter for lengths longer than 36 inches (900 mm). 2.03 SEALANT MATERIALS A. Joint and Seam Sealants, General: The term “sealant” is not limited to materials of adhesive or mastic nature but includes tapes and combinations of open-weave fabric strips and mastics. B. Joint and Seam Tape: 2 inches (50 mm) wide; glass-fiber-reinforced fabric. C. Tape Sealing System: Woven-fiber tape impregnated with gypsum mineral compound and modified acrylic/silicone activator to react exothermically with tape to form hard, durable, airtight seal. D. Water-Based Joint and Seam Sealant: Flexible, adhesive sealant, resistant to UV light when cured, UL 723 listed, and complying with NFPA requirements for Class 1 ducts. E. Solvent-Based Joint and Seam Sealant: One-part, nonsag, solvent-release-curing, polymerized butyl sealant formulated with a minimum of 75 percent solids. F. Flanged Joint Mastic: One-part, acid-curing, silicone, elastomeric joint sealant complying with ASTM C920, Type S, Grade NS, Class 25, Use O. G. Flange Gaskets: Butyl rubber or EPDM polymer with polyisobutylene plasticizer. Metal Ducts 23 31 13 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.04 HANGERS AND SUPPORTS A. Building Attachments: Concrete inserts, powder-actuated fasteners, or structural-steel fasteners appropriate for construction materials to which hangers are being attached. 1. Use powder-actuated concrete fasteners for standard-weight aggregate concretes or for slabs more than 4 inches (100 mm) thick. 2. Exception: Do not use powder-actuated concrete fasteners for lightweight-aggregate concretes or for slabs less than 4 inches (100 mm) thick. B. Hanger Materials: Galvanized sheet steel or threaded steel rod. 1. Hangers Installed in Corrosive Atmospheres: Electrogalvanized, all-thread rods or galvanized rods with threads painted with zinc-chromate primer after installation. 2. Strap and Rod Sizes: Comply with SMACNA’s “HVAC Duct Construction Standards-- Metal and Flexible” for steel sheet width and thickness and for steel rod diameters. 3. Galvanized-steel straps attached to aluminum ducts shall have contact surfaces painted with zinc-chromate primer. C. Duct Attachments: Sheet metal screws, blind rivets, or self-tapping metal screws; compatible with duct materials. D. Trapeze and Riser Supports: Steel shapes complying with ASTM A36/A36M. 1. Supports for Galvanized-Steel Ducts: Galvanized-steel shapes and plates. 2. Supports for Stainless-Steel Ducts: Stainless-steel support materials. 3. Supports for Aluminum Ducts: Aluminum support materials unless materials are electrolytically separated from ducts. 2.05 RECTANGULAR DUCT FABRICATION A. Fabricate ducts, elbows, transitions, offsets, branch connections, and other construction according to SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible” and complying with requirements for metal thickness, reinforcing types and intervals, tie-rod applications, and joint types and intervals. 1. Lengths: Fabricate rectangular ducts in lengths appropriate to reinforcement and rigidity class required for pressure class. 2. Deflection: Duct systems shall not exceed deflection limits according to SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible.” B. Transverse Joints: Prefabricated slide-on joints and components constructed using manufacturer’s guidelines for material thickness, reinforcement size and spacing, and joint reinforcement. 1. Manufacturers: a. Ductmate Industries, Inc. b. Nexus Inc. c. Ward Industries, Inc. Metal Ducts 23 31 13 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements C. Formed-On Flanges: Construct according to SMACNA’s “HVAC Duct Construction Standards- -Metal and Flexible,” Figure 1-4, using corner, bolt, cleat, and gasket details. 1. Manufacturers: a. Ductmate Industries, Inc. b. Lockformer. 2. Duct Size: Maximum 30 inches (750 mm) wide and up to 2-inch wg (500-Pa) pressure class. 3. Longitudinal Seams: Pittsburgh lock sealed with noncuring polymer sealant. D. Cross Breaking or Cross Beading: Cross break or cross bead duct sides 19 inches (480 mm) and larger and 0.0359 inch (0.9 mm) thick or less, with more than 10 sq. ft. (0.93 sq. m) of nonbraced panel area unless ducts are lined. 2.06 ROUND AND FLAT-OVAL DUCT AND FITTING FABRICATION A. Diameter as applied to flat-oval ducts in this Article is the diameter of a round duct with a circumference equal to the perimeter of a given size of flat-oval duct. B. Round, Longitudinal- and Spiral Lock - Seam Ducts: Fabricate supply ducts of galvanized steel according to SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible.” C. Flat-Oval, Longitudinal- and Spiral Lock - Seam Ducts: Fabricate supply ducts according to SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible.” Fabricate ducts larger than 72 inches (1830 mm) in diameter with butt-welded longitudinal seams. 1. Manufacturers: a. McGill AirFlow Corporation. b. SEMCO Incorporated. D. Duct Joints: 1. Ducts up to 20 Inches (500 mm) in Diameter: Interior, center-beaded slip coupling, sealed before and after fastening, attached with sheet metal screws. 2. Ducts 21 to 72 Inches (535 to 1830 mm) in Diameter: Three-piece, gasketed, flanged joint consisting of two internal flanges with sealant and one external closure band with gasket. 3. Ducts Larger Than 72 Inches (1830 mm) in Diameter: Companion angle flanged joints per SMACNA “HVAC Duct Construction Standards--Metal and Flexible,” Figure 3-2. 4. Round Ducts: Prefabricated connection system consisting of double-lipped, EPDM rubber gasket. Manufacture ducts according to connection system manufacturer’s tolerances. a. Manufacturers: 1). Ductmate Industries, Inc. 2). Lindab Inc. Metal Ducts 23 31 13 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements E. 90-Degree Tees and Laterals and Conical Tees: Fabricate to comply with SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible,” with metal thicknesses specified for longitudinal-seam straight ducts. F. Diverging-Flow Fittings: Fabricate with reduced entrance to branch taps and with no excess material projecting from fitting onto branch tap entrance. G. Fabricate elbows using die-formed, gored, pleated, or mitered construction. Bend radius of die-formed, gored, and pleated elbows shall be 1-1/2 times duct diameter. Unless elbow construction type is indicated, fabricate elbows as follows: 1. Mitered-Elbow Radius and Number of Pieces: Welded construction complying with SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible,” unless otherwise indicated. 2. Round Mitered Elbows: Welded construction with the following metal thickness for pressure classes from minus 2- to plus 2-inch wg (minus 500- to plus 500-Pa): a. Ducts 3 to 36 Inches (75 to 915 mm) in Diameter: 0.034 inch (0.85 mm). b. Ducts 37 to 50 Inches (940 to 1270 mm) in Diameter: 0.040 inch (1.0 mm). c. Ducts 52 to 60 Inches (1320 to 1525 mm) in Diameter: 0.052 inch (1.3 mm). d. Ducts 62 to 84 Inches (1575 to 2130 mm) in Diameter: 0.064 inch (1.6 mm). 3. Round Mitered Elbows: Welded construction with the following metal thickness for pressure classes from 2- to 10-inch wg (500- to 2500-Pa): a. Ducts 3 to 26 Inches (75 to 660 mm) in Diameter: 0.034 inch (0.85 mm). b. Ducts 27 to 50 Inches (685 to 1270 mm) in Diameter: 0.040 inch (1.0 mm). c. Ducts 52 to 60 Inches (1320 to 1525 mm) in Diameter: 0.052 inch (1.3 mm). d. Ducts 62 to 84 Inches (1575 to 2130 mm) in Diameter: 0.064 inch (1.6 mm). 4. 90-Degree, Two-Piece, Mitered Elbows: Use only for supply systems or for material- handling Class A or B exhaust systems and only where space restrictions do not permit using radius elbows. Fabricate with single-thickness turning vanes. 5. Round Elbows 8 Inches (200 mm) and Less in Diameter: Fabricate die-formed elbows for 45- and 90-degree elbows and pleated elbows for 30, 45, 60, and 90 degrees only. Fabricate nonstandard bend-angle configurations or nonstandard diameter elbows with gored construction. 6. Round Elbows 9 through 14 Inches (225 through 355 mm) in Diameter: Fabricate gored or pleated elbows for 30, 45, 60, and 90 degrees unless space restrictions require mitered elbows. Fabricate nonstandard bend-angle configurations or nonstandard diameter elbows with gored construction. 7. Round Elbows Larger Than 14 Inches (355 mm) in Diameter and All Flat-Oval Elbows: Fabricate gored elbows unless space restrictions require mitered elbows. 8. Die-Formed Elbows for Sizes through 8 Inches (200 mm) in Diameter and All Pressures 0.040 inch (1.0 mm) thick with two-piece welded construction. 9. Round Gored-Elbow Metal Thickness: Same as non-elbow fittings specified above. Metal Ducts 23 31 13 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements 10. Pleated Elbows for Sizes through 14 Inches (355 mm) in Diameter and Pressures through 10-Inch wg (2500-Pa): 0.022 inch (0.55 mm). H. PVC-Coated Elbows and Fittings: Fabricate elbows and fittings as follows: 1. Round Elbows 4 to 8 Inches (100 to 200 mm) in Diameter: Two-piece, die-stamped, with longitudinal seams spot welded, bonded, and painted with PVC aerosol spray. 2. Round Elbows 9 to 26 Inches (225 to 660 mm) in Diameter: Standing-seam construction. 3. Round Elbows 28 to 60 Inches (710 to 1525 mm) in Diameter: Standard gored construction, riveted and bonded. 4. Other Fittings: Riveted and bonded joints. 5. Couplings: Slip-joint construction with a minimum 2-inch (50-mm) insertion length. 3.00 EXECUTION 3.01 DUCT APPLICATIONS A. Static-Pressure Classes: Unless otherwise indicated, construct ducts according to the following: 1. Supply Ducts: 2-inch wg (500-Pa). 2. Return Ducts (Negative Pressure): 1-inch wg (250-Pa). 3. Exhaust Ducts (Negative Pressure): 2-inch wg (500-Pa). B. All ducts shall be galvanized steel except as follows: 1. Range Hood Exhaust Ducts: Comply with NFPA 96. a. Concealed: Carbon-steel sheet. b. Exposed: Type 304, stainless steel with finish to match kitchen equipment and range hood. c. Weld and flange seams and joints. 3.02 DUCT INSTALLATION A. Construct and install ducts according to SMACNA’s “HVAC Duct Construction Standards-- Metal and Flexible,” unless otherwise indicated. B. Install round and flat-oval ducts in lengths not less than 12 feet (3.7 m) unless interrupted by fittings. C. Install ducts with fewest possible joints. D. Install fabricated fittings for changes in directions, size, and shape and for connections. E. Install couplings tight to duct wall surface with a minimum of projections into duct. Secure couplings with sheet metal screws. Install screws at intervals of 12 inches (300 mm), with a minimum of three screws in each coupling. Metal Ducts 23 31 13 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements F. Install ducts, unless otherwise indicated, vertically and horizontally and parallel and perpendicular to building lines; avoid diagonal runs. G. Install ducts close to walls, overhead construction, columns, and other structural and permanent enclosure elements of building. H. Install ducts with a clearance of 1 inch (25 mm), plus allowance for insulation thickness. I. Conceal ducts from view in finished spaces. Do not encase horizontal runs in solid partitions unless specifically indicated. J. Coordinate layout with suspended ceiling, fire- and smoke-control dampers, lighting layouts, and similar finished work. K. Seal all joints and seams. Apply sealant to male end connectors before insertion, and afterward to cover entire joint and sheet metal screws. L. Electrical Equipment Spaces: Route ducts to avoid passing through transformer vaults and electrical equipment spaces and enclosures. M. Non-Fire-Rated Partition Penetrations: Where ducts pass through interior partitions and exterior walls and are exposed to view, conceal spaces between construction openings and ducts or duct insulation with sheet metal flanges of same metal thickness as ducts. Overlap openings on four sides by at least 1-1/2 inches (38 mm). N. Fire-Rated Partition Penetrations: Where ducts pass through interior partitions and exterior walls, install appropriately rated fire dampers, sleeves, and firestopping sealant. Fire and smoke dampers are specified in Section 23 33 00 “Air Duct Accessories.” Firestopping materials and installation methods are specified in Division 07 Section. O. Protect duct interiors from the elements and foreign materials until building is enclosed. Follow SMACNA’s “Duct Cleanliness for New Construction.” P. Paint interiors of metal ducts, that do not have duct liner, for 24 inches (600 mm) upstream of registers and grilles. Apply one coat of flat, black, latex finish coat over a compatible galvanized-steel primer. Paint materials and application requirements are specified in Division 09 painting Sections. 3.03 RANGE HOOD EXHAUST DUCTS, SPECIAL INSTALLATION REQUIREMENTS A. Install ducts to allow for thermal expansion through 2000 F (1110 C) temperature range. B. Install ducts without dips or traps that may collect residues unless traps have continuous or automatic residue removal. C. Install access openings at each change in direction and at intervals defined by NFPA 96; locate on sides of duct a minimum of 1-1/2 inches (38 mm) from bottom; and fit with grease-tight covers of same material as duct. D. Do not penetrate fire-rated assemblies except as permitted by applicable building codes. 3.04 SEAM AND JOINT SEALING A. Seal duct seams and joints according to SMACNA’s “HVAC Duct Construction Standards-- Metal and Flexible” for duct pressure class indicated. Metal Ducts 23 31 13 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.05 HANGING AND SUPPORTING A. Support horizontal ducts within 24 inches (600 mm) of each elbow and within 48 inches (1200 mm) of each branch intersection. B. Support vertical ducts at maximum intervals of 16 feet (5 m) and at each floor. C. Install upper attachments to structures with an allowable load not exceeding one-fourth of failure (proof-test) load. 3.06 CONNECTIONS A. Make connections to equipment with flexible connectors according to Section 23 33 00 “Air Duct Accessories.” B. Comply with SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible” for branch, outlet and inlet, and terminal unit connections. 3.07 FIELD QUALITY CONTROL A. Perform the following field tests and inspections according to SMACNA’s “HVAC Air Duct Leakage Test Manual” and prepare test reports: 1. Disassemble, reassemble, and seal segments of systems to accommodate leakage testing and for compliance with test requirements. 2. Conduct tests at static pressures equal to maximum design pressure of system or section being tested. If pressure classes are not indicated, test entire system at maximum system design pressure. Do not pressurize systems above maximum design operating pressure. Give 7 days’ advance notice for testing. 3. Maximum Allowable Leakage: Comply with requirements for Leakage Class 3 for round and flat-oval ducts, Leakage Class 12 for rectangular ducts in pressure classes lower than and equal to 2-inch wg (500-Pa) (both positive and negative pressures), and Leakage Class 6 for pressure classes from 2- to 10-inch wg (500- to 2500-Pa). 4. Remake leaking joints and retest until leakage is equal to or less than maximum allowable. 3.08 CLEANING NEW SYSTEMS A. Mark position of dampers and air-directional mechanical devices before cleaning, and perform cleaning before air balancing. B. Use service openings, as required, for physical and mechanical entry and for inspection. 1. Create other openings to comply with duct standards. 2. Disconnect flexible ducts as needed for cleaning and inspection. 3. Remove and reinstall ceiling sections to gain access during the cleaning process. C. Vent vacuuming system to the outside. Include filtration to contain debris removed from HVAC systems, and locate exhaust down wind and away from air intakes and other points of entry into building. Metal Ducts 23 31 13 - 9 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Clean the following metal duct systems by removing surface contaminants and deposits: 1. Air outlets and inlets (registers, grilles, and diffusers). 2. Supply, return, and exhaust fans including fan housings, plenums (except ceiling supply and return plenums), scrolls, blades or vanes, shafts, baffles, dampers, and drive assemblies. 3. Air-handling unit internal surfaces and components including mixing box, coil section, air wash systems, spray eliminators, condensate drain pans, humidifiers and dehumidifiers, filters and filter sections, and condensate collectors and drains. 4. Coils and related components. 5. Return-air ducts, dampers, and actuators except in ceiling plenums and mechanical equipment rooms. 6. Supply-air ducts, dampers, actuators, and turning vanes. E. Mechanical Cleaning Methodology: 1. Clean metal duct systems using mechanical cleaning methods that extract contaminants from within duct systems and remove contaminants from building. 2. Use vacuum-collection devices that are operated continuously during cleaning. Connect vacuum device to downstream end of duct sections so areas being cleaned are under negative pressure. 3. Use mechanical agitation to dislodge debris adhered to interior duct surfaces without damaging integrity of metal ducts, duct liner, or duct accessories. 4. Clean fibrous-glass duct liner with HEPA vacuuming equipment; do not permit duct liner to get wet. 5. Clean coils and coil drain pans according to NADCA 1992. Keep drain pan operational. Rinse coils with clean water to remove latent residues and cleaning materials; comb and straighten fins. F. Cleanliness Verification: 1. Visually inspect metal ducts for contaminants. 2. Where contaminants are discovered, re-clean and reinspect ducts. END OF SECTION Air Duct Accessories 23 33 00 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 33 00 AIR DUCT ACCESSORIES 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes the following: 1. Backdraft dampers. 2. Manual-volume dampers. 3. Fire and smoke dampers. 4. Turning vanes. 5. Flexible ducts. 6. Flexible connectors. 7. Duct accessory hardware. 1.03 SUBMITTALS A. Product Data: For the following: 1. Backdraft dampers. 2. Manual-volume dampers. 3. Fire and smoke dampers. 4. Flexible ducts. B. Product Certificates: Submit certified test data on dynamic insertion loss; self-noise power levels; and airflow performance data, static-pressure loss, dimensions, and weights. 1.04 QUALITY ASSURANCE A. NFPA Compliance: Comply with the following NFPA standards: 1. NFPA 90A, “Standard for the Installation of Air-Conditioning and Ventilating Systems.” 2. NFPA 90B, “Standard for the Installation of Warm Air Heating and Air-Conditioning Systems.” 1.05 EXTRA MATERIALS A. Furnish extra materials described below that match products installed, are packaged with protective covering for storage, and are identified with labels describing contents. 1. Fusible Links: Furnish quantity equal to 10 percent of amount installed. Air Duct Accessories 23 33 00 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.00 PRODUCTS 2.01 SHEET METAL MATERIALS A. Galvanized, Sheet Steel: Lock-forming quality; ASTM A653/A653M, G90 (Z275) coating designation; mill-phosphatized finish for surfaces of ducts exposed to view. B. Carbon-Steel Sheets: ASTM A366/A366M, cold-rolled sheets, commercial quality, with oiled, exposed matte finish. C. Aluminum Sheets: ASTM B209 (ASTM B209M), Alloy 3003, Temper H14, sheet form; with standard, one-side bright finish for ducts exposed to view and mill finish for concealed ducts. D. Extruded Aluminum: ASTM B221 (ASTM B221M), Alloy 6063, Temper T6. E. Reinforcement Shapes and Plates: Galvanized steel reinforcement where installed on galvanized, sheet metal ducts; compatible materials for aluminum and stainless-steel ducts. F. Tie Rods: Galvanized steel, 1/4-inch (6-mm) minimum diameter for 36-inch (900-mm) length or less; 3/8-inch (10-mm) minimum diameter for lengths longer than 36 inches (900 mm). 2.02 BACKDRAFT DAMPERS A. Description: Suitable for horizontal or vertical installations. B. Frame: 0.052-inch (1.3-mm) thick, galvanized, sheet steel, with welded corners and mounting flange. C. Frame: 0.090-inch (2.3-mm) thick extruded aluminum, with mounting flange. D. Blades: 0.050-inch (1.2-mm) thick extended aluminum sheet. E. Blade Seals: Vinyl. F. Blade Axles: Nonferrous (for aluminum dampers). G. Blade Axles: Galvanized steel (for steel dampers). H. Tie Bars and Brackets: Aluminum (for aluminum dampers). I. Tie Bars and Brackets: Galvanized steel (for steel dampers). J. Return Spring: Adjustable tension. 2.03 MANUAL-VOLUME DAMPERS A. General: Factory fabricated with required hardware and accessories. Stiffen damper blades for stability. Include locking device to hold single-blade dampers in a fixed position without vibration. Close duct penetrations for damper components to seal duct consistent with pressure class. 1. Pressure Classifications of 3-inch wg (750 Pa) or Higher: End bearings or other seals for ducts with axles full length of damper blades and bearings at both ends of operating shaft. Air Duct Accessories 23 33 00 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Low-Leakage Volume Dampers: Multiple- or single-blade, parallel- or opposed-blade design as indicated, low-leakage rating, and suitable for horizontal or vertical applications. 1. Comply with AMCA 500-D testing for damper rating. 2. Low-leakage rating and bearing AMCA's Certified Ratings Seal for both air performance and air leakage. 3. Steel Frames: Hat-shaped, galvanized, sheet steel channels, minimum of 0.064 inch (1.62 mm) thick, with mitered and welded corners; frames with flanges where indicated for attaching to walls; and flangeless frames where indicated for installing in ducts. 4. Aluminum Frames: Hat-shaped, 0.10-inch- (2.5-mm-) thick, aluminum sheet channels; frames with flanges for attaching to walls and flangeless frames for installing in ducts 5. Roll-Formed Steel Blades: 0.064-inch (1.62-mm) thick, galvanized, sheet steel. 6. Roll-Formed Aluminum Blades: 0.10-inch (2.5-mm) thick aluminum sheet. 7. Blade Seals: Vinyl. 8. Blade Axles: Nonferrous (for aluminum dampers). 9. Blade Axles: Galvanized steel (for steel dampers). 10. Tie Bars and Brackets: Aluminum (for aluminum dampers). 11. Tie Bars and Brackets: Galvanized steel (for steel dampers). C. Jackshaft: 1-inch (25-mm) diameter, galvanized steel pipe rotating within a pipe-bearing assembly mounted on supports at each mullion and at each end of multiple-damper assemblies. 1. Length and Number of Mountings: Appropriate to connect linkage of each damper of a multiple-damper assembly. D. Damper Hardware: Zinc-plated, die-cast core with dial and handle made of 3/32-inch (2.4- mm) thick zinc-plated steel, and a 3/4-inch (19-mm) hexagon locking nut. Include center hole to suit damper operating-rod size. Include elevated platform for insulated duct mounting. 2.04 FIRE DAMPERS A. General: Labeled to UL 555. B. Fire Rating: 1. One and one-half hours for 2-hour walls. 2. Three hours for 4-hour walls. C. Frame: SMACNA Type A with blades in airstream; fabricated with roll-formed, 0.034-inch (0.85-mm) thick galvanized steel; with mitered and interlocking corners. D. Frame: SMACNA Type B with blades out of airstream; fabricated with roll-formed, 0.034- inch (0.85-mm) thick galvanized steel; with mitered and interlocking corners. Air Duct Accessories 23 33 00 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements E. Mounting Sleeve: Factory- or field-installed galvanized, sheet steel. 1. Minimum Thickness: 0.052 inch (1.3 mm) or 0.138 inch (3.5 mm) thick as indicated, and length to suit application. 2. Exceptions: Omit sleeve where damper frame width permits direct attachment of perimeter mounting angles on each side of wall or floor, and thickness of damper frame complies with sleeve requirements. F. Mounting Orientation: Vertical or horizontal as indicated. G. Blades: Roll-formed, interlocking, 0.034-inch (0.85-mm) thick, galvanized, sheet steel. In place of interlocking blades, use full-length, 0.034-inch (0.85-mm) thick, galvanized steel blade connectors. H. Horizontal Dampers: Include a blade lock and stainless-steel negator closure spring. I. Fusible Link: Replaceable, 165 or 212 F (74 or 100 C) rated as indicated. 2.05 TURNING VANES A. Fabricate to comply with SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible.” B. Manufactured Turning Vanes: Fabricate of 1-1/2-inch (38-mm) wide, curved blades set 3/4 inch (19 mm) o.c.; support with bars perpendicular to blades set 2 inches (50 mm) o.c.; and set into side strips suitable for mounting in ducts. C. Acoustic Turning Vanes: Fabricate of airfoil-shaped aluminum extrusions with perforated faces and fibrous-glass fill. 2.06 FLEXIBLE CONNECTORS A. General: Flame-retarded or noncombustible fabrics, coatings, and adhesives complying with UL 181, Class 1. B. Standard Metal-Edged Connectors: Factory fabricated with a strip of fabric 3-1/2 inches (89 mm) wide attached to two strips of 2-3/4-inch (70-mm) wide, 0.028-inch (0.7-mm) thick, galvanized, sheet steel or 0.032-inch (0.8-mm) aluminum sheets. Select metal compatible with connected ducts. C. Extra-Wide Metal-Edged Connectors: Factory fabricated with a strip of fabric 5-3/4 inches (146 mm) wide attached to two strips of 2-3/4-inch (70-mm) wide, 0.028-inch (0.7-mm) thick, galvanized, sheet steel or 0.032-inch (0.8-mm) aluminum sheets. Select metal compatible with connected ducts. D. Transverse Metal-Edged Connectors: Factory fabricated with a strip of fabric 3-1/2 inches (89 mm) wide attached to two strips of 4-3/8-inch (111-mm) wide, 0.028-inch (0.7-mm) thick, galvanized, sheet steel or 0.032-inch (0.8-mm) aluminum sheets. Select metal compatible with connected ducts. E. Conventional, Indoor System (minus 10 to plus 250 F) Flexible Connector Fabric: Glass fabric double coated with polychloroprene. 1. Minimum Weight: 26 oz./sq. yd. (880 g/sq. m). Air Duct Accessories 23 33 00 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. Tensile Strength: 480 lbf/inch (84 N/mm) in the warp, and 360 lbf/inch (63 N/mm) in the filling. F. Conventional, Outdoor System (minus 10 to plus 250 F) Flexible Connector Fabric: Glass fabric double coated with a synthetic-rubber, weatherproof coating resistant to the sun’s ultraviolet rays and ozone environment. 1. Minimum Weight: 26 oz./sq. yd. (880 g/sq. m). 2. Tensile Strength: 530 lbf/inch (93 N/mm) in the warp, and 440 lbf/inch (77 N/mm) in the filling. G. High-Temperature System (minus 25 to plus 500 F) Flexible Connectors: Glass fabric coated with silicone rubber and having a minimum weight of 16 oz./sq. yd. (542 g/sq. m) and tensile strength of 285 lbf/inch (50 N/mm) in the warp, and 185 lbf/inch (32 N/mm) in the filling. H. High-Corrosive-Environment System (minus 20 to plus 500 F) Flexible Connectors: Glass fabric coated with a chemical-resistant coating. 1. Minimum Weight: 14 oz./sq. yd. (474 g/sq. m). 2. Tensile Strength: 450 lbf/inch (79 N/mm) in the warp, and 340 lbf/inch (60 N/mm) in the filling. 2.07 FLEXIBLE DUCTS A. General: Comply with UL 181, Class 1. B. Flexible Ducts, Uninsulated: Spiral-wound steel spring with flameproof vinyl sheathing. C. Flexible Ducts, Uninsulated: Corrugated aluminum. D. Flexible Ducts, Insulated: Factory-fabricated, insulated, round duct, with an outer jacket enclosing 1-1/2-inch (38-mm) thick, glass-fiber insulation around a continuous inner liner. 1. Reinforcement: Steel-wire helix encapsulated in inner liner. 2. Outer Jacket: Glass-reinforced, silver Mylar with a continuous hanging tab, integral fibrous-glass tape, and nylon hanging cord. 3. Inner Liner: Polyethylene film. E. Pressure Rating: 6-inch wg (1500-Pa) positive, 1/2-inch wg (125-Pa) negative. 2.08 ACCESSORY HARDWARE A. Instrument Test Holes: Cast iron or cast aluminum to suit duct material, including screw cap and gasket. Size to allow insertion of pitot tube and other testing instruments, and length to suit duct insulation thickness. B. Splitter Damper Accessories: Zinc-plated damper blade bracket; 1/4-inch (6-mm), zinc- plated operating rod; and a duct-mounted, ball-joint bracket with flat rubber gasket and square-head set screw. C. Flexible Duct Clamps: Stainless-steel band with cadmium-plated hex screw to tighten band with a worm-gear action, in sizes 3 to 18 inches (75 to 450 mm) to suit duct size. Air Duct Accessories 23 33 00 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Adhesives: High strength, quick setting, neoprene based, waterproof, and resistant to gasoline and grease. 3.00 EXECUTION 3.01 INSTALLATION A. Install duct accessories according to applicable details shown in SMACNA’s “HVAC Duct Construction Standards--Metal and Flexible” for metal ducts and in NAIMA AH116, "Fibrous Glass Duct Construction Standards," for fibrous-glass ducts. B. Install duct accessories of materials suited to duct materials; use galvanized-steel accessories in galvanized-steel and fibrous-glass ducts, stainless-steel accessories in stainless-steel ducts, and aluminum accessories in aluminum ducts. C. Install volume dampers in lined duct; avoid damage to and erosion of duct liner. D. Provide test holes at fan inlet and outlet and elsewhere as indicated. E. Install fire and smoke dampers according to manufacturer’s UL-approved written instructions. 1. Install fusible links in fire dampers. 3.02 FIELD QUALITY CONTROL A. Tests and Inspections: 1. Adjust duct accessories for proper settings. 2. Operate dampers to verify full range of movement. 3. Operate fire, smoke, and combination fire and smoke dampers to verify full range of movement and verify that proper heat-response device is installed. 4. Inspect turning vanes for proper and secure installation. B. Final positioning of manual-volume dampers is specified in Section 23 05 93 “Testing, Adjusting, and Balancing for HVAC.” END OF SECTION HVAC Power Ventilators 23 34 23 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 34 23 HVAC POWER VENTILATORS 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes the following: B. Adjust list below to suit Project. 1. Centrifugal roof ventilators. 2. Centrifugal wall ventilators. 3. Ceiling-mounted ventilators. 4. Propeller fans. 1.03 PERFORMANCE REQUIREMENTS A. Project Altitude: Base air ratings on actual site elevations. 1.04 SUBMITTALS A. Product Data: Include rated capacities, furnished specialties, and accessories for each type of product indicated and include the following: 1. Certified fan performance curves with system operating conditions indicated. 2. Certified fan sound-power ratings. 3. Motor ratings and electrical characteristics, plus motor and electrical accessories. 4. Material gages and finishes, including color charts. 5. Dampers, including housings, linkages, and operators. B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. 1. Wiring Diagrams: Power, signal, and control wiring. Differentiate between manufacturer-installed and field-installed wiring. 2. Design Calculations: Calculate requirements for selecting vibration isolators and seismic restraints and for designing vibration isolation bases. 3. Vibration Isolation Base Details: Detail fabrication, including anchorages and attachments to structure and to supported equipment. Include auxiliary motor slides and rails, and base weights. HVAC Power Ventilators 23 34 23 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1.05 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. AMCA Compliance: Products shall comply with performance requirements and shall be licensed to use the AMCA-Certified Ratings Seal. C. NEMA Compliance: Motors and electrical accessories shall comply with NEMA standards. D. UL Standard: Power ventilators shall comply with UL 705. 1.06 DELIVERY, STORAGE, AND HANDLING A. Deliver fans as factory-assembled unit, to the extent allowable by shipping limitations, with protective crating and covering. B. Disassemble and reassemble units, as required for moving to final location, according to manufacturer’s written instructions. C. Lift and support units with manufacturer’s designated lifting or supporting points. 1.07 COORDINATION A. Coordinate size and location of structural-steel support members. B. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 03 Sections. C. Coordinate installation of roof curbs, equipment supports, and roof penetrations. These items are specified in Division 08 Sections. 1.08 EXTRA MATERIALS A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Belts: One set for each belt-driven unit. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Centrifugal Roof Ventilators: a. Aerovent; a Twin City Fan Company. b. Breidert Air Products, Inc. c. Captive-Aire Systems. d. Carnes Company HVAC. e. Cook, Loren Company. HVAC Power Ventilators 23 34 23 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements f. Greenheck Fan Corp. g. Hartzell Fan, Inc. h. ILG Industries, Inc./American Coolair Corp. i. JennFan; Div. of Breidert Air Products, Inc. j. PennBarry. 2. Centrifugal Wall Ventilators: a. Aerovent; a Twin City Fan Company. b. Breidert Air Products, Inc. c. Broan Mfg. Co., Inc. d. Carnes Company HVAC. e. Cook, Loren Company. f. Greenheck Fan Corp. 3. Ceiling-Mounting Ventilators: a. Breidert Air Products, Inc. b. Broan Mfg. Co., Inc. c. Carnes Company HVAC. d. Cook, Loren Company. e. Greenheck Fan Corp. 4. Propeller Fans: a. Aerovent; a Twin City Fan Company. b. Breidert Air Products, Inc. c. Carnes Company HVAC. d. Chicago Blower Corp. e. Cincinnati Fan & Ventilator Co. f. Cook, Loren Company. 2.02 CENTRIFUGAL ROOF VENTILATORS A. Description: Belt-driven or direct-driven centrifugal fans consisting of housing, wheel, fan shaft, bearings, motor and disconnect switch, drive assembly, curb base, and accessories. B. Housing: Removable, spun-aluminum, dome top and outlet baffle; square, one-piece, aluminum base with venturi inlet cone. C. Fan Wheels: Aluminum hub and wheel with backward-inclined blades. D. Belt-Driven Drive Assembly: Resiliently mounted to housing, with the following features: 1. Fan Shaft: Turned, ground, and polished steel; keyed to wheel hub. HVAC Power Ventilators 23 34 23 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. Shaft Bearings: Permanently lubricated, permanently sealed, self-aligning ball bearings. 3. Pulleys: Cast-iron, adjustable-pitch motor pulley. 4. Fan and motor isolated from exhaust airstream. E. Accessories: 1. Variable-Speed Controller: Solid-state control to reduce speed from 100 percent to less than 50 percent. 2. Disconnect Switch: Nonfusible type, with thermal-overload protection mounted inside fan housing, factory wired through an internal aluminum conduit. 3. Bird Screens: Removable, 1/2-inch (13-mm) mesh, aluminum or brass wire. 4. Dampers: Counterbalanced, parallel-blade, backdraft dampers mounted in curb base; factory set to close when fan stops. 5. Motorized Dampers: Parallel-blade dampers mounted in curb base with electric actuator; wired to close when fan stops. F. Roof Curbs: Galvanized steel; mitered and welded corners; 1-1/2-inch (40-mm) thick, rigid, fiberglass insulation adhered to inside walls; and 1-1/2-inch (40-mm) wood nailer. Size as required to suit roof opening and fan base. 1. Configuration: as recommended by manufacturer. 2. Overall Height: 12 inches (300 mm). 3. Metal Liner: Galvanized steel. 4. Hinged Subbase: Galvanized steel hinged arrangement permitting service and maintenance. 5. Mounting Pedestal: Galvanized steel with removable access panel. 6. Vented Curb: Unlined with louvered vents in vertical sides. 2.03 CENTRIFUGAL WALL VENTILATORS A. Description: Belt-driven or direct-driven centrifugal fans consisting of housing, wheel, fan shaft, bearings, motor and disconnect switch, drive assembly, and accessories. B. Housing: Heavy-gage, removable, spun-aluminum, dome top and outlet baffle; venturi inlet cone. C. Fan Wheel: Aluminum hub and wheel with backward-inclined blades. D. Belt-Driven Drive Assembly: Resiliently mounted to housing, with the following features: 1. Fan Shaft: Turned, ground, and polished steel; keyed to wheel hub. 2. Shaft Bearings: Permanently lubricated, permanently sealed, self-aligning ball bearings. 3. Pulleys: Cast-iron, adjustable-pitch motor pulley. 4. Fan and motor isolated from exhaust airstream. HVAC Power Ventilators 23 34 23 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements E. Accessories: 1. Variable-Speed Controller: Solid-state control to reduce speed from 100 percent to less than 50 percent. 2. Disconnect Switch: Nonfusible type, with thermal-overload protection mounted inside fan housing, factory wired through internal aluminum conduit. 3. Bird Screens: Removable, 1/2-inch (13-mm) mesh, aluminum or brass wire. 4. Wall Grille: Ring type for flush mounting. 5. Dampers: Counterbalanced, parallel-blade, backdraft dampers mounted in wall sleeve; factory set to close when fan stops. 6. Motorized Dampers: Parallel-blade dampers mounted in curb base with electric actuator; wired to close when fan stops. 2.04 CEILING-MOUNTING VENTILATORS A. Description: Centrifugal fans designed for installing in ceiling or wall or for concealed in-line applications. B. Housing: Steel, lined with acoustical insulation. C. Fan Wheel: Centrifugal wheels directly mounted on motor shaft. Fan shrouds, motor, and fan wheel shall be removable for service. D. Grille: Plastic, louvered grille with flange on intake and thumbscrew attachment to fan housing. E. Electrical Requirements: Junction box for electrical connection on housing and receptacle for motor plug-in. F. Accessories: 1. Variable-Speed Controller: Solid-state control to reduce speed from 100 percent to less than 50 percent. 2. Manual Starter Switch: Single-pole rocker switch assembly with cover and pilot light. 3. Time-Delay Switch: Assembly with single-pole rocker switch, timer, and cover plate. 4. Filter: Washable aluminum to fit between fan and grille. 5. Isolation: Rubber-in-shear vibration isolators. 6. Manufacturer’s standard roof jack or wall cap, and transition fittings. 2.05 PROPELLER FANS A. Description: Belt-driven or direct-driven propeller fans consisting of fan blades, hub, housing, orifice ring, motor, drive assembly, and accessories. B. Housing: Galvanized steel sheet with flanged edges and integral orifice ring with baked- enamel finish coat applied after assembly. C. Steel Fan Wheels: Formed-steel blades riveted to heavy-gage steel spider bolted to cast- iron hub. HVAC Power Ventilators 23 34 23 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Fan Wheel: Replaceable, cast-aluminum, airfoil blades fastened to cast-aluminum hub; factory set pitch angle of blades. E. Belt-Driven Drive Assembly: Resiliently mounted to housing, statically and dynamically balanced and selected for continuous operation at maximum rated fan speed and motor horsepower, with final alignment and belt adjustment made after installation. 1. Service Factor Based on Fan Motor: 1.4. 2. Fan Shaft: Turned, ground, and polished steel; keyed to wheel hub. 3. Shaft Bearings: Permanently lubricated, permanently sealed, self-aligning ball bearings. a. Ball-Bearing Rating Life: ABMA 9, L10 of 100,000 hours. 4. Pulleys: Cast iron with split, tapered bushing; dynamically balanced at factory. 5. Motor Pulleys: Adjustable pitch for use with motors through 5 HP; fixed pitch for use with motors larger than 5 HP. Select pulley so pitch adjustment is at the middle of adjustment range at fan design conditions. 6. Belts: Oil resistant, nonsparking, and nonstatic; matched sets for multiple belt drives. 7. Belt Guards: Fabricate of steel for motors mounted on outside of fan cabinet. F. Accessories: 1. Gravity Shutters: Aluminum blades in aluminum frame; interlocked blades with nylon bearings. 2. Motor-Side Back Guard: Galvanized steel, complying with OSHA specifications, removable for maintenance. 3. Wall Sleeve: Galvanized steel to match fan and accessory size. 4. Weathershield Hood: Galvanized steel to match fan and accessory size. 5. Weathershield Front Guard: Galvanized steel with expanded metal screen. 6. Variable-Speed Controller: Solid-state control to reduce speed from 100 percent to less than 50 percent. 7. Disconnect Switch: Nonfusible type, with thermal-overload protection mounted inside fan housing, factory wired through an internal aluminum conduit. 2.06 MOTORS A. Refer to Division 23 Section “Common Motor Requirements for HVAC Equipment” for general requirements for factory-installed motors. B. Motor Construction: NEMA MG 1, general purpose, continuous duty, Design B. C. Enclosure Type: Open drip proof. 2.07 SOURCE QUALITY CONTROL A. Sound-Power Level Ratings: Comply with AMCA 301, “Methods for Calculating Fan Sound Ratings from Laboratory Test Data.” Factory test fans according to AMCA 300, “Reverberant Room Method for Sound Testing of Fans.” Label fans with the AMCA-Certified Ratings Seal. HVAC Power Ventilators 23 34 23 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Fan Performance Ratings: Establish flow rate, pressure, power, air density, speed of rotation, and efficiency by factory tests and ratings according to AMCA 210, “Laboratory Methods of Testing Fans for Rating.” 3.00 EXECUTION 3.01 INSTALLATION A. Install power ventilators level and plumb. B. Secure roof-mounting fans to roof curbs with cadmium-plated hardware. Refer to Division 07 Sections. C. Ceiling Units: Suspend units from structure; use steel wire or metal straps. D. Install units with clearances for service and maintenance. E. Label units according to requirements specified in Section 23 05 53 “Identification for HVAC Piping and Equipment.” 3.02 CONNECTIONS A. Duct installation and connection requirements are specified in other Division 23 Sections. Drawings indicate general arrangement of ducts and duct accessories. Make final duct connections with flexible connectors. Flexible connectors are specified in Section 23 33 00 “Air Duct Accessories.” B. Install ducts adjacent to power ventilators to allow service and maintenance. C. Ground equipment. D. Tighten electrical connectors and terminals according to manufacturer’s published torque- tightening values. If manufacturer’s torque values are not indicated, use those specified in UL 486A and UL 486B. 3.03 FIELD QUALITY CONTROL A. Equipment Startup Checks: 1. Verify that shipping, blocking, and bracing are removed. 2. Verify that unit is secure on mountings and supporting devices and that connections to ducts and electrical components are complete. Verify that proper thermal-overload protection is installed in motors, starters, and disconnect switches. 3. Verify that cleaning and adjusting are complete. 4. Disconnect fan drive from motor, verify proper motor rotation direction, and verify fan wheel free rotation and smooth bearing operation. Reconnect fan drive system, align and adjust belts, and install belt guards. 5. Verify lubrication for bearings and other moving parts. 6. Verify that manual and automatic volume control and fire and smoke dampers in connected ductwork systems are in fully open position. 7. Disable automatic temperature-control operators. HVAC Power Ventilators 23 34 23 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Starting Procedures: 1. Energize motor and adjust fan to indicated rpm. 2. Measure and record motor voltage and amperage. C. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation. Remove malfunctioning units, replace with new units, and retest. D. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. E. Shut unit down and reconnect automatic temperature-control operators. F. Refer to Section 23 05 93 “Testing, Adjusting, and Balancing for HVAC” for testing, adjusting, and balancing procedures. G. Replace fan and motor pulleys as required to achieve design airflow. H. Repair or replace malfunctioning units. Retest as specified above after repairs or replacements are made. 3.04 ADJUSTING A. Adjust damper linkages for proper damper operation. B. Adjust belt tension. C. Lubricate bearings. 3.05 CLEANING A. On completion of installation, internally clean fans according to manufacturer’s written instructions. Remove foreign material and construction debris. Vacuum fan wheel and cabinet. B. After completing system installation, including outlet fitting and devices, inspect exposed finish. Remove burrs, dirt, and construction debris and repair damaged finishes. END OF SECTION Air Outlets and Inlets 23 37 00 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 37 00 AIR OUTLETS AND INLETS 1.00 GENERALS 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes the following types of roof-mounting intake and relief ventilators: 1. Roof hoods. B. Related Sections include the following: 1. Section 08 90 00 “Louvers and Vents” for ventilator assemblies provided as part of the general construction. 2. Section 23 34 23 “HVAC Power Ventilators” for roof-mounting exhaust fans. 1.03 PERFORMANCE REQUIREMENTS A. Structural Performance: Intake and relief ventilators shall be capable of withstanding the effects of gravity loads, wind loads, and thermal movements without permanent deformation of components, noise or metal fatigue, or permanent damage to fasteners and anchors. 1.04 SUBMITTALS A. Product Data: For each type of product indicated. B. Coordination Drawings: Roof framing plans and other details, drawn to scale, on which the following items are shown and coordinated with each other, based on input from installers of the items involved: 1. Structural members to which roof curbs and ventilators will be attached. 2. Sizes and locations of roof openings. 1.05 QUALITY ASSURANCE A. Source Limitations: Obtain ventilators through one source from a single manufacturer where indicated to be of same type, design, or factory-applied color finish. B. Product Options: Drawings indicate size, profiles, and dimensional requirements of intake and relief ventilators and are based on the specific equipment indicated. Refer to Section 01 60 00 “Product Requirements.” 1. Do not modify intended aesthetic effects, as judged solely by Architect, except with Architect’s approval. If modifications are proposed, submit comprehensive explanatory data to Architect for review. Air Outlets and Inlets 23 37 00 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1.06 COORDINATION A. Coordinate installation of roof curbs and roof penetrations. These items are specified in Division 07. 2.00 PRODUCTS 2.01 MANUFACTURERS A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection: 1. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, manufacturers specified. 2.02 MATERIALS A. Aluminum Extrusions: ASTM B221 (ASTM B221M), Alloy 6063-T5 or T-52. B. Aluminum Sheet: ASTM B209 (ASTM B209M), Alloy 3003 or 5005 with temper as required for forming or as otherwise recommended by metal producer for required finish. C. Galvanized-Steel Sheet: ASTM A653/A653M, G90 (Z275) zinc coating, mill phosphatized. D. Fasteners: Same basic metal and alloy as fastened metal or 300 Series stainless steel, unless otherwise indicated. Do not use metals that are incompatible with joined materials. 1. Use types and sizes to suit unit installation conditions. E. Post-Installed Fasteners for Concrete and Masonry: Torque-controlled expansion anchors, made from stainless-steel components, with capability to sustain, without failure, a load equal to four times the loads imposed, for concrete, or six times the load imposed, for masonry, as determined by testing per ASTM E488, conducted by a qualified independent testing agency. F. Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D1187. 2.03 FABRICATION, GENERAL A. Factory or shop fabricate intake and relief ventilators to minimize field splicing and assembly. Disassemble units to the minimum extent as necessary for shipping and handling. Clearly mark units for reassembly and coordinated installation. B. Fabricate frames, including integral bases, to fit in openings of sizes indicated, with allowances made for fabrication and installation tolerances, adjoining material tolerances, and perimeter sealant joints. C. Fabricate units with closely fitted joints and exposed connections accurately located and secured. D. Fabricate supports, anchorages, and accessories required for complete assembly. E. Perform shop welding by AWS-certified procedures and personnel. Air Outlets and Inlets 23 37 00 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.04 ROOF HOODS A. Manufacturers: 1. Acme Engineering & Mfg. Corp. 2. Aerovent; a Twin City Fan company. 3. Carnes. 4. Greenheck. 5. JencoFan. 6. Loren Cook Company. 7. Penn Barry. B. Factory or shop fabricate according to SMACNA’s “HVAC Duct Construction Standards - Metal and Flexible,” Figures 5-6 and 5-7. C. Materials: Aluminum sheet, minimum 0.063-inch (1.6-mm) thick base and 0.050-inch (1.27- mm) thick hood; suitably reinforced. D. Roof Curbs: Galvanized-steel sheet; with mitered and welded corners; 1-1/2-inch (40-mm) thick, rigid fiberglass insulation adhered to inside walls; and 1-1/2-inch (40-mm) wood nailer. Size as required to fit roof opening and ventilator base. 1. Configuration: as recommended by manufacturer. 2. Overall Height: 12 inches (300 mm). E. Bird Screening: Aluminum, 1/2-inch (12.7-mm) square mesh, 0.063-inch (1.6-mm) wire. F. Galvanized-Steel Sheet Finish: 1. Surface Preparation: Clean surfaces of dirt, grease, and other contaminants. Clean welds, mechanical connections, and abraded areas and repair galvanizing according to ASTM A780. Apply a conversion coating suited to the organic coating to be applied over it. 2. Factory Priming for Field-Painted Finish: Where field painting after installation is indicated, apply an air-dried primer immediately after cleaning and pretreating. 3. Baked-Enamel Finish: Immediately after cleaning and pretreating, apply manufacturer’s standard finish consisting of prime coat and thermosetting topcoat, with a minimum dry film thickness of 1 mil (0.025 mm) for topcoat and an overall minimum dry film thickness of 2 mils (0.05 mm). a. Color and Gloss: As selected by Architect. 3.00 EXECUTION 3.01 INSTALLATION A. Install intake and relief ventilators level, plumb, and at indicated alignment with adjacent work. B. Install intake and relief ventilators with clearances for service and maintenance. Air Outlets and Inlets 23 37 00 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements C. Install perimeter reveals and openings of uniform width for sealants and joint fillers, as indicated. D. Install concealed gaskets, flashings, joint fillers, and insulation as installation progresses. Comply with Division 07 for sealants applied during installation. E. Label intake and relief ventilators according to requirements specified in Section 23 05 53 “Identification for HVAC Piping and Equipment.” F. Protect galvanized and nonferrous-metal surfaces from corrosion or galvanic action by applying a heavy coating of bituminous paint on surfaces that will be in contact with concrete, masonry, or dissimilar metals. G. Repair finishes damaged by cutting, welding, soldering, and grinding. Restore finishes so no evidence remains of corrective work. Return items that cannot be refinished in the field to the factory, make required alterations, and refinish entire unit or provide new units. 3.02 ADJUSTING A. Adjust damper linkages for proper damper operation. END OF SECTION Diffusers, Registers, and Grilles 23 37 13 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 37 13 DIFFUSERS, REGISTERS, AND GRILLES 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes duct-mounted diffusers, registers, and grilles. 1.03 DEFINITIONS A. Diffuser: Circular, square, or rectangular air distribution outlet, generally located in the ceiling and comprised of deflecting members discharging supply air in various directions and planes and arranged to promote mixing of primary air with secondary room air. B. Grille: A louvered or perforated covering for an opening in an air passage, which can be located in a sidewall, ceiling, or floor. C. Register: A combination grille and damper assembly over an air opening. 1.04 SUBMITTALS A. Product Data: For each model indicated, include the following: 1. Data Sheet: For each type of air outlet and inlet, and accessory furnished; indicate construction, finish, and mounting details. 2. Performance Data: Include throw and drop, static-pressure drop, and noise ratings for each type of air outlet and inlet. 1.05 QUALITY ASSURANCE A. Product Options: Drawings and schedules indicate specific requirements of diffusers, registers, and grilles and are based on the specific requirements of the systems indicated. Other manufacturers' products with equal performance characteristics may be considered. Refer to Division 01. B. NFPA Compliance: Install diffusers, registers, and grilles according to NFPA 90A “Standard for the Installation of Air-Conditioning and Ventilating Systems.” 2.00 PRODUCTS 2.01 MANUFACTURED UNITS A. Diffusers, registers, and grilles are scheduled on the Drawings. 2.02 SOURCE QUALITY CONTROL A. Testing: Test performance according to ASHRAE 70 “Method of Testing for Rating the Performance of Air Outlets and Inlets.” Diffusers, Registers, and Grilles 23 37 13 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.00 EXECUTION 3.01 EXAMINATION A. Examine areas where diffusers, registers, and grilles are to be installed for compliance with requirements for installation tolerances and other conditions affecting performance of equipment. Do not proceed with installation until unsatisfactory conditions have been corrected. 3.02 INSTALLATION A. Install diffusers, registers, and grilles level and plumb, according to manufacturer's written instructions, Coordination Drawings, original design, and referenced standards. B. Duct-Mounted Outlets and Inlets: Drawings indicate general arrangement of ducts, fittings, and accessories. Air outlet and inlet locations have been indicated to achieve design requirements for air volume, noise criteria, airflow pattern, throw, and pressure drop. Make final locations where indicated, as much as practicable. C. Install diffusers, registers, and grilles with airtight connection to ducts and to allow service and maintenance of dampers, air extractors, and fire dampers. 3.03 ADJUSTING A. After installation, adjust diffusers, registers, and grilles to air patterns indicated, or as directed, before starting air balancing. 3.04 CLEANING A. After installation of diffusers, registers, and grilles, inspect exposed finish. Clean exposed surfaces to remove burrs, dirt, and smudges. Replace diffusers, registers, and grilles that have damaged finishes. END OF SECTION Commercial-Kitchen Hoods 23 38 13 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 38 13 COMMERCIAL-KITCHEN HOODS 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes Type I commercial kitchen hood, kitchen hood exhaust fan, and kitchen hood fire-suppression system and accessories. 1.03 DEFINITIONS A. Listed Hood: A hood tested according to UL 710 by a testing agency acceptable to authorities having jurisdiction. B. Standard Hood: A hood that complies with design, construction, and performance criteria of applicable national and local codes. C. Type I Hood: A hood designed for grease exhaust applications. 1.04 SUBMITTALS A. Product Data: For the following: 1. Hoods. 2. Exhaust Fans. 3. Grease removal devices. 4. Fire-suppression systems. 5. Lighting fixtures. B. Shop Drawings: Signed and sealed by a qualified professional engineer. 1. Show plan view, elevation view, sections, roughing-in dimensions, service requirements, duct connection sizes, and attachments to other work. 2. Show cooking equipment plan and elevation to confirm minimum code-required overhang. 3. Indicate performance, exhaust and makeup air airflow and pressure loss, at actual Project-site elevation. 4. Indicate method of attaching hangers to building structure. 5. Show exhaust and makeup air ducts, and fittings connecting to hoods. 6. Show water-supply and drain piping. 7. Show control cabinets. 8. Show fire-protection piping, actuation devices, and manual control devices. Commercial-Kitchen Hoods 23 38 13 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 9. Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. 10. Design Calculations: Calculate requirements for selecting seismic restraints. 11. Wiring Diagrams: Power, signal, and control wiring. C. Piping Diagrams: Detail fire-suppression piping and components and differentiate between manufacturer-installed and field-installed piping. Include roughing-in requirements for drain connections. Show cooking equipment plan and elevation to illustrate fire- suppression nozzle locations. D. Welding Certificates. E. Field Test Reports. 1.05 QUALITY ASSURANCE A. Engineering Responsibility: Preparation of Shop Drawings and comprehensive engineering analysis by a qualified professional engineer. B. Welding: Qualify procedures and personnel according to AWS D1.1, “Structural Welding Code--Steel,” for hangers and supports; and AWS D9.1, “Sheet Metal Welding Code,” for joint and seam welding. C. 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. D. NSF Compliance: Fabricate hoods according to NSF 2, “Food Equipment.” E. SMACNA Compliance: 1. Comply with SMACNA’s “Kitchen Equipment Fabrication Guidelines,” Appendix 1, “Guidelines for Seismic Restraints of Kitchen Equipment.” 1.06 COORDINATION A. Coordinate equipment layout and installation with other Work, including light fixtures, HVAC equipment, and fire-suppression system components. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Commercial Kitchen Exhaust Fan and Hood: a. Aerolator Systems, Inc. b. Captive-Aire Systems. c. Cook, Loren Company. d. Greenheck. Commercial-Kitchen Hoods 23 38 13 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements e. Halton Company. f. LC Systems. 2. Wet-Chemical Fire-Suppression Systems: a. Ansul Incorporated; a Tyco International Ltd. Company. b. Badger Fire Protection, Inc. c. Fenwall Safety Systems, Inc.; Div. of Kidde Technologies, Inc. d. Pyro Chem, Inc. 2.02 HOOD MATERIALS A. Stainless-Steel Sheet: ASTM A666, Type 304. 1. Minimum Thickness: 0.03 inch (0.8 mm). 2. General: Comply with SSINA’s “Finishes for Stainless Steel” for recommendations for applying and designating finishes. 3. Remove tool and die marks and stretch lines or blend into finish. Grind and polish surfaces to produce uniform, directionally textured, polished finish indicated, free of cross scratches. Run grain with long dimension of each piece. 4. Concealed Stainless-Steel Surfaces: ASTM A480/A480M, No. 2B finish (bright, cold- rolled, unpolished finish). 5. Exposed Surfaces: ASTM A480/A480M, No. 3 finish (intermediate polished surface). 6. When polishing is completed, passivate and rinse surfaces. Remove embedded foreign matter and leave surfaces chemically clean. B. Carbon-Steel Sheets: ASTM A366/A366M, cold-rolled sheets; commercial quality; with oiled, exposed matte finish. C. Galvanized Steel Sheet: Lock-forming quality; ASTM A653/A653M, G90 (Z275) coating designation; mill-phosphatized finish for surfaces of ducts exposed to view. 1. Minimum Thickness: 0.03 inch (0.8 mm). D. Zinc-Coated Steel Shapes: ASTM A36/A36M, zinc coated according to ASTM A123/A123M requirements. E. Sealant: ASTM C920; Type S, Grade NS, Class 25, Use NT. Elastomeric sealant shall be NSF certified for commercial kitchen hood application. Sealants, when cured and washed, shall comply with requirements in 21 CFR, Section 177.2600, for use in areas that come in contact with food. 1. Color: As selected by Architect from manufacturer’s full range. 2. Backer Rod: Closed-cell polyethylene, in diameter larger than joint width. F. Sound Dampening: NSF-certified, nonabsorbent, hard-drying, sound-deadening compound for permanent adhesion to metal in minimum 1/8-inch (3-mm) thickness that does not chip, flake, or blister. Commercial-Kitchen Hoods 23 38 13 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements G. Gaskets: NSF certified for end-use application indicated; of resilient rubber, neoprene, or PVC that is nontoxic, stable, odorless, nonabsorbent, and unaffected by exposure to foods and cleaning compounds, and passes testing according to UL 710. 2.03 TYPE I EXHAUST HOOD FABRICATION A. Weld all joints exposed to grease with continuous welds and make grease removal devices and makeup air diffusers easily accessible for cleaning. 1. Hood shall be listed and labeled, according to UL 710, by a testing agency acceptable to authorities having jurisdiction. 2. Include access panels as required for access to fire dampers and fusible links. 3. Exhaust-Duct Collars: Minimum 0.0625-inch (1.58-mm) thick stainless steel at least 3 inches (75 mm) long, continuously welded to top of hood and at corners. B. Hood Configuration: Exhaust and makeup air. 1. Makeup air shall be introduced through laminar-flow-type perforated metal panels on front of hood canopy. C. Hood Style: Wall-mounted canopy. D. Grease Removal Devices: Removable, stainless-steel, filter/baffle grease filters. Fabricate with minimum 0.0781-inch (1.98-mm) thick stainless steel for filter frame and removable collection cup and trough. Exposed surfaces shall be pitched to drain to collection cup. Filters/baffles shall comply with UL 1046, “Grease Filters for Exhaust Ducts.” E. Light Fixtures: UL-listed, surface-mounted, fluorescent fixtures and lamps with lenses sealed vaportight. Wiring shall be installed in stainless-steel conduit on hood exterior. Number and location of fixtures shall provide a minimum of 70 fc (753 lx) on cooking surface below hood. 1. Switches shall be mounted on wall adjacent to hood. 2. Fluorescent Lighting Fixtures: Comply with UL 1570. 3. Incandescent Lighting Fixtures: Comply with UL 1571. F. Wet-Chemical Fire-Suppression System: Preengineered distribution piping designed for automatic detection and release or manual release of fire-suppression agent by hood operator. Fire-suppression system shall be listed and labeled by a testing agency acceptable to authorities having jurisdiction. 1. Steel Pipe, NPS 2 (DN 50) and Smaller: ASTM A53/A53M, Type S, Grade A, Schedule 40, plain ends. 2. Malleable-Iron Threaded Fittings: ASME B16.3, Classes 150 and 300. 3. Pipe Covers: Chrome-plated aluminum tubing. 4. Piping, fusible links and release mechanism, tank containing the suppression agent, and controls shall be factory installed. Controls shall be in stainless-steel control cabinet mounted on wall. Furnish manual pull station for wall mounting adjacent to hood. Exposed piping shall be covered with stainless-steel sleeves. Exposed fittings shall be chrome plated. Commercial-Kitchen Hoods 23 38 13 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 5. Liquid Extinguishing Agent: Noncorrosive, low-pH liquid. 6. Furnish an electric-operated, gas shutoff valve with clearly marked open and closed indicator for field installation. 7. Fire-suppression system controls shall be integrated with controls for fans, lights, and fuel supply and located in a single cabinet for each group of hoods immediately adjacent. 8. Wiring shall have color-coded, numbered terminal blocks and grounding bar. Spare terminals for fire alarm, optional wiring to start fan with fire alarm, red pilot light to indicate fan operation, and control switches shall all be factory wired in control cabinet with relays or starters. G. Hood Controls: Single, wall-mounting control cabinet shall control groups of adjacent hoods and shall be fabricated of stainless steel. 1. Exhaust Fan: On-off switches shall start and stop the exhaust fan. Interlock exhaust fan with makeup air supply fan to operate simultaneously. Interlock exhaust fan with fire- suppression system to operate fan during fire-suppression-agent release and to remain in operation until manually stopped. Motor starters shall comply with Section 26 29 13 “Enclosed Controllers.” 3.00 EXECUTION 3.01 EXAMINATION A. Examine substrates and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting installation. B. Examine roughing-in for piping systems to verify actual locations of piping connections before equipment installation. C. Proceed with installation only after unsatisfactory conditions have been corrected. 3.02 INSTALLATION A. Install hoods level and plumb. B. Complete field assembly of hoods where required. 1. Make closed butt and contact joints that do not require filler. 2. Grind field welds on stainless-steel equipment smooth, and polish to match adjacent finish. Comply with welding requirements in Part 2 “General Hood Fabrication” Article. C. Install hoods and associated services with clearances and access for maintaining, cleaning, and servicing hoods, grease removal devices, and fire-suppression systems according to manufacturer’s written instructions and requirements of authorities having jurisdiction. D. Securely anchor and attach items and accessories to walls, floors, or bases with stainless- steel fasteners, unless otherwise indicated. E. Install hoods to operate free from vibration. Commercial-Kitchen Hoods 23 38 13 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements F. Install trim strips and similar items requiring fasteners in a bed of sealant. Fasten with stainless-steel fasteners at 48 inches (1200 mm) o.c. maximum. G. Install sealant in joints between equipment and abutting surfaces with continuous joint backing, unless otherwise indicated. Provide airtight, watertight, vermin-proof, sanitary joints. H. Install lamps, with maximum recommended wattage, in equipment with integral lighting. 3.03 CONNECTIONS A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate general arrangement of piping, fittings, and specialties. B. Install piping adjacent to machine with clearance to allow service and maintenance. C. Duct Connections: Comply with applicable requirements in Section 23 33 00 “Air Duct Accessories” for flexible connectors on makeup air supply duct. Weld exhaust-duct connections. D. Fire-Suppression Piping: Install piping connections for remote-mounted suppression systems according to NFPA 17, “Wet Chemical Extinguishing Systems.” E. Ground equipment. F. Tighten electrical connectors and terminals according to manufacturer’s published torque- tightening values. If manufacturer’s torque values are not indicated, use those specified in UL 486A and UL 486B. 3.04 FIELD QUALITY CONTROL A. Testing: See Section 23 05 93 “Testing, Adjusting, and Balancing for HVAC.” B. Manufacturer’s Field Service: Engage a factory-authorized service representative to inspect field-assembled components and equipment installation, including piping and electrical connections. Report results in writing. 1. Test each equipment item for proper operation. Repair or replace equipment that is defective, including units that operate below required capacity or that operate with excessive noise or vibration. 2. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. 3. Test motors and rotating equipment for proper rotation and lubricate moving parts according to manufacturer’s written instructions. 4. Test liquid-carrying and water, drain, and gas components for leaks. Repair or replace leaking components. C. Remove malfunctioning units, replace with new units, and retest as specified above. 3.05 ADJUSTING A. Set initial temperatures, and calibrate sensors. B. Set field-adjustable switches. Commercial-Kitchen Hoods 23 38 13 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.06 CLEANING A. Remove protective coverings and clean and sanitize hoods and associated services, both inside and out, according to manufacturer’s written instructions. B. Remove paint splatters and other spots, dirt, and debris. Repair damaged finish to match original finish. 3.07 DEMONSTRATION A. Engage a factory-authorized service representative to train Owner’s maintenance personnel to adjust, operate, and maintain hoods. Refer to Division 01. END OF SECTION Rooftop Air Conditioners 23 74 09 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 74 09 ROOFTOP AIR CONDITIONERS 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes the following rooftop air conditioners: 1. Cooling and heating units 7-1/2 to 20 tons (26 to 70 kW). 1.03 DEFINITIONS A. DDC: Direct-digital controls. 1.04 SUBMITTALS A. Product Data: Include manufacturer’s technical data for each model indicated, including rated capacities, dimensions, required clearances, characteristics, furnished specialties, and accessories. B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. Prepare the following by or under the supervision of a qualified professional engineer: 1. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions. 2. Detailed description of equipment anchorage devices on which the certification is based and their installation requirements. C. Field Quality-Control Test Reports. D. Operation and Maintenance Data: Include emergency, operation, and maintenance manuals. E. Warranties: Special warranties specified in this Section. 1.05 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. Fabricate and label refrigeration system to comply with ASHRAE 15, “Safety Standard for Refrigeration Systems.” C. Energy-Efficiency Ratio: Equal to or greater than prescribed by ASHRAE 90.1, “Energy Efficient Design of New Buildings except Low-Rise Residential Buildings” and International Energy Conservation Code, whichever is greater.” Rooftop Air Conditioners 23 74 09 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Coefficient of Performance: Equal to or greater than prescribed by ASHRAE 90.1, “Energy Efficient Design of New Buildings except Low-Rise Residential Buildings” and International Energy Conservation Code, whichever is greater.” E. ARI Certification: Units shall be ARI certified and listed. F. ARI Compliance for Units with Capacities Less Than 135,000 BTUH (39.6 kW): Rate rooftop air-conditioner capacity according to ARI 210/240, “Unitary Air-Conditioning and Air-Source Heat Pump Equipment.” 1. Sound Power Level Ratings: Comply with ARI 270, “Sound Rating of Outdoor Unitary Equipment.” G. ARI Compliance for Units with Capacities 135,000 BTUH (39.6 kW) and More: Rate rooftop air-conditioner capacity according to ARI 340/360, “Commercial and Industrial Unitary Air- Conditioning and Heat Pump Equipment.” 1. Sound Power Level Ratings: Comply with ARI 270, “Sound Rating of Outdoor Unitary Equipment.” 1.06 COORDINATION A. Coordinate installation of roof curbs, equipment supports, and roof penetrations. These items are specified in Section 07 72 00 “Roof Accessories.” 1.07 WARRANTY A. Special Warranty: Manufacturer’s standard form in which manufacturer agrees to replace components of rooftop air conditioners that fail in materials or workmanship within specified warranty period. 1.08 EXTRA MATERIALS A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Fan Belts: One set for each belt-drive fan. 2. Filters: One set of filters for each unit. 2.00 PRODUCTS 2.01 MANUFACTURERS 1. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified. 2.02 ROOFTOP AIR CONDITIONERS 7-1/2 TO 20 TONS (26 TO 70 KW) A. Manufacturers: 1. AAON, Inc. 2. Addison Products Company. 3. Carrier Corp. Rooftop Air Conditioners 23 74 09 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 4. Lennox Industries Inc. 5. McQuay International. 6. Trane Company (The); North American Commercial Group. 7. YORK International Corporation. B. Description: Factory assembled and tested; designed for exterior installation; consisting of compressor, indoor and outside refrigerant coils, indoor fan and outside coil fan, refrigeration and temperature controls, filters, and dampers. C. Casing: Galvanized-steel construction with enamel paint finish, removable panels or access doors with neoprene gaskets for inspection and access to internal parts, minimum 1/2-inch (13-mm) thick thermal insulation, knockouts for electrical and piping connections, exterior condensate drain connection, and lifting lugs. D. Indoor Fan: Forward curved, centrifugal, belt driven with adjustable motor sheaves, grease- lubricated ball bearings, and motor. E. Outside Coil Fan: Propeller type, directly driven by permanently lubricated motor. F. Refrigerant Coils: Aluminum-plate fin and seamless copper tube in steel casing with equalizing-type vertical distributor. G. Compressor(s): Two hermetic scroll compressors with integral vibration isolators, internal overcurrent and overtemperature protection, internal pressure relief, and crankcase heater(s). H. Refrigeration System: 1. Compressor(s). 2. Outside coil and fan. 3. Indoor coil and fan. 4. Expansion valves with replaceable thermostatic elements. 5. Refrigerant dryers. 6. High-pressure switches. 7. Low-pressure switches. 8. Thermostats for coil freeze-up protection during low-ambient temperature operation or loss of air. 9. Low-ambient switch. 10. Charge of refrigerant. I. Filters: 2-inch (50-mm) thick, pleated, throwaway filters in filter rack. J. Electric Heat: Helix-wound, nickel-chrome, electric-resistance elements, factory wired for single-point wiring connection; with time delay for element staging, and overcurrent and overheat protective devices. K. Economizer: Return- and outside-air dampers with neoprene seals, outside-air filter, and hood. Rooftop Air Conditioners 23 74 09 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1. Damper Motor: Fully modulating spring return with adjustable minimum position. 2. Control: Electronic-control system uses mixed-air and outside-air temperature to adjust mixing dampers. 3. Relief Damper: Gravity actuated with bird screen and hood. L. Power Connection: Provide for single connection of power to unit with unit-mounted disconnect switch accessible from outside unit and control-circuit transformer with built-in circuit breaker. M. Unit Controls: Solid-state control board and components contain at least the following features: 1. Indoor fan on/off delay. 2. Default control to ensure proper operation after power interruption. 3. Service relay output. 4. Unit diagnostics and diagnostic code storage. 5. Field-adjustable control parameters. 6. Dehumidification control with dehumidistat. 7. Economizer control. 8. Electric heat staging. 9. Gas valve delay between first- and second-stage firing. 10. Indoor-air quality control with carbon dioxide sensor. 11. Low-ambient control, allowing operation down to 0 F (minus 18 C). 12. Minimum run time. 13. Night setback mode. 14. Return-air temperature limit. 15. Smoke alarm with smoke detector installed in supply and return air. 16. Low-refrigerant pressure control. 17. Digital display of outside temperature, supply-air temperature, return-air temperature, economizer damper position, indoor-air quality, and control parameters. N. Thermostat: Programmable, electronic; with heating setback and cooling setup with 7-day programming; and the following: 1. Touch sensitive keyboard. 2. Automatic switching. 3. Degrees F readout. 4. LED indicators. 5. Hour/day programming. 6. Manual override capability. Rooftop Air Conditioners 23 74 09 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 7. Time and operational mode readout. 8. Status indicator. 9. Battery backup. 10. Subbase with manual system switch (on-heat-auto-cool) and fan switch (auto-on). 11. Fan-proving switch to lock out unit if fan fails. 12. Dirty-filter switch. O. Optional Accessories: 1. Cold-Weather Kit: Electric heater maintains temperature in gas burner compartment. 2. Service Outlets: Two, 115-V, ground-fault, circuit-interrupter type. 3. PVC condensate drain trap. 4. Dirty-filter switch. 5. Coil guards of painted, galvanized-steel wire. P. Roof Curb: Steel with corrosion-protection coating, gasketing, and factory-installed wood nailer; complying with NRCA standards; minimum height of 14 inches (350 mm). Q. Isolation Curb: Rigid upper and lower steel structure with vibration isolation springs having 2-inch (50-mm) static deflection and vertical and horizontal restraints; with elastomeric waterproof membrane. 2.03 MOTORS A. General requirements for motors are specified in Section 23 05 13 “Common Motor Requirements for HVAC.” B. Motor Sizes: Minimum size as indicated; if not indicated, large enough so driven load will not require motor to operate in service factor range above 1.0. C. Controllers, electrical devices, and wiring are specified in Division 26 Sections. 3.00 EXECUTION 3.01 INSTALLATION A. Install units level and plumb, maintaining manufacturer’s recommended clearances. Install according to ARI Guideline B. B. Curb Support: Install roof curb on roof structure, level and secure, according to NRCA’s “Low-Slope Membrane Roofing Construction Details Manual,” Illustration “Raised Curb Detail for Rooftop Air Handling Units and Ducts.” Install and secure rooftop air conditioners on curbs and coordinate roof penetrations and flashing with roof construction. Secure units to curb support with anchor bolts. 3.02 CONNECTIONS A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate general arrangement of piping, fittings, and specialties. Rooftop Air Conditioners 23 74 09 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Install piping adjacent to machine to allow service and maintenance. C. Duct installation requirements are specified in other Division 23 Sections. Drawings indicate the general arrangement of ducts. The following are specific connection requirements: 1. Install ducts to termination in roof curb. 2. Remove roof decking only as required for passage of ducts. Do not cut out decking under entire roof curb. 3. Terminate return-air duct through roof structure and insulate space between roof and bottom of unit with 2-inch (50-mm) thick, acoustic duct liner. 4. Install normal-weight, 3000 psi (20.7 MPa), compressive strength (28-day) concrete mix inside roof curb, 4 inches (100 mm) thick. Concrete, formwork, and reinforcement are specified in Division 03. D. Electrical System Connections: Comply with applicable requirements in Division 26 Sections for power wiring, switches, and motor controls. E. Ground equipment according to Division 26. F. Tighten electrical connectors and terminals according to manufacturer’s published torque- tightening values. If manufacturer’s torque values are not indicated, use those specified in UL 486A and UL 486B. 3.03 FIELD QUALITY CONTROL A. Perform the following field quality-control tests and inspections and prepare test reports: 1. After installing rooftop air conditioners and after electrical circuitry has been energized, test units for compliance with requirements. 2. Inspect for and remove shipping bolts, blocks, and tie-down straps. 3. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation. 4. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. B. Remove malfunctioning units, replace with new units, and retest as specified above. 3.04 STARTUP SERVICE A. Complete installation and startup checks according to manufacturer’s written instructions and do the following: 1. Inspect for visible damage to unit casing. 2. Inspect for visible damage to furnace combustion chamber. 3. Inspect for visible damage to compressor, air-cooled outside coil, and fans. 4. Inspect internal insulation. 5. Verify that labels are clearly visible. 6. Verify that clearances have been provided for servicing. Rooftop Air Conditioners 23 74 09 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements 7. Verify that controls are connected and operable. 8. Verify that filters are installed. 9. Clean outside coil and inspect for construction debris. 10. Adjust vibration isolators. 11. Inspect operation of barometric dampers. 12. Lubricate bearings on fan. 13. Inspect fan-wheel rotation for movement in correct direction without vibration and binding. 14. Adjust fan belts to proper alignment and tension. 15. Start unit according to manufacturer’s written instructions. a. Start refrigeration system in summer only. b. Complete startup sheets and attach copy with Contractor’s startup report. 16. Inspect and record performance of interlocks and protective devices; verify sequences. 17. Operate unit for an initial period as recommended or required by manufacturer. 18. Perform the following operations for both minimum and maximum firing and adjust burner for peak efficiency. Adjust pilot to stable flame. a. Measure combustion-air temperature at inlet to combustion chamber. b. Measure flue-gas temperature at furnace discharge. c. Perform flue-gas analysis. Measure and record flue-gas carbon dioxide and oxygen concentration. d. Measure supply-air temperature and volume when burner is at maximum firing rate and when burner is off. Calculate useful heat to supply air. 19. Calibrate thermostats. 20. Adjust and inspect high-temperature limits. 21. Inspect outside-air dampers for proper stroke and interlock with return-air dampers. 22. Start refrigeration system and measure and record the following: a. Coil leaving-air, dry- and wet-bulb temperatures. b. Coil entering-air, dry- and wet-bulb temperatures. c. Outside-air, dry-bulb temperature. d. Outside-air-coil, discharge-air, dry-bulb temperature. 23. Inspect controls for correct sequencing of heating, mixing dampers, refrigeration, and normal and emergency shutdown. 24. Measure and record the following minimum and maximum airflows. Plot fan volumes on fan curve. a. Supply-air volume. Rooftop Air Conditioners 23 74 09 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements b. Return-air volume. c. Relief-air volume. d. Outside-air intake volume. 25. Simulate maximum cooling demand and inspect the following: a. Compressor refrigerant suction and hot-gas pressures. b. Short circuiting of air through outside coil or from outside coil to outside-air intake. 26. Verify operation of remote panel, including pilot-light operation and failure modes. Inspect the following: a. High-limit heat exchanger. b. Warm-up for morning cycle. c. Freezestat operation. d. Economizer to limited outside-air changeover. e. Alarms. 27. After startup and performance testing, change filters, vacuum heat exchanger and cooling and outside coils, lubricate bearings, adjust belt tension, and inspect operation of power vents. 3.05 ADJUSTING A. Adjust initial temperature and humidity set points. B. Set field-adjustable switches and circuit-breaker trip ranges as indicated. C. Occupancy Adjustments: When requested within 12 months of date of Substantial Completion, provide on-site assistance in adjusting system to suit actual occupied conditions. Provide up to two visits to site outside normal occupancy hours for this purpose, without additional cost. END OF SECTION Make-Up Air Systems 23 74 33 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 74 33 MAKE-UP AIR SYSTEMS 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions apply to this Section. 1.02 SUMMARY A. This Section includes the following equipment: 1. Make-up air systems (MUA) for kitchen hood exhaust. 1.03 SUBMITTALS A. Product Data: Include manufacturer’s technical data for each model indicated, including rated capacities, dimensions, required clearances, characteristics, furnished specialties, and accessories. B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. C. Wiring Diagrams: Power, signal, and control wiring. D. Factory & Field Quality-Control Test Reports. E. Operation and Maintenance Data: Include emergency, operation, and maintenance manuals. F. Warranties: Special warranties specified in this Section. 1.04 QUALITY ASSURANCE A. Product Options: Drawings indicate size, profiles, and dimensional requirements of MUA. These are based on the Basis of Design system. 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. Energy-Efficiency Ratio: Equal to or greater than prescribed by ASHRAE 90.1, “Energy Efficient Design of New Buildings except Low-Rise Residential Buildings” and International Energy Conservation Code, whichever is greater.” D. Coefficient of Performance: Equal to or greater than prescribed by ASHRAE 90.1, “Energy Efficient Design of New Buildings except Low-Rise Residential Buildings” and International Energy Conservation Code, whichever is greater.” E. ARI Certification: Units shall be ARI certified and listed. F. ARI Compliance: Make-Up Air Systems 23 74 33 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 1. Sound Power Level Ratings: Comply with ARI 270, “Sound Rating of Outdoor Unitary Equipment.” 1.05 COORDINATION A. Coordinate location of installation of equipment supports. 1.06 WARRANTY A. Special Warranty: Manufacturer’s standard form in which manufacturer agrees to replace components of MUA that fails in materials or workmanship within specified warranty period. 1.07 EXTRA MATERIALS A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Fan Belts: One set for each belt-drive fan. 2. Filters: One set of filters for each unit. 2.00 PRODUCTS 2.01 MAKE-UP AIR SYSTEMS (MUA) A. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified below with no exceptions. 1. CaptiveAire. 2. Daikin. 3. Mitsubishi. 4. Aaon. 5. Carrier. 6. Trane. B. Description: Factory assembled and tested; designed for exterior installation; consisting of outside fan, filters, and dampers. C. Base and Cabinet: 1. The unit shall be constructioned with heavy duty minimum 20 gauge G-90 galvanized steel. Gasketed access doors shall be minimum 20 gauge steel with 2-inch (R-13) closed cell foam insulation and a 24 gauge galvanized steel liner. Standard outer panels will be insulated with 2-inch (R-13) insulation with a 24 gauge galvanized steel interior liner. The underside of the base panel shall be insulated with 3/8-inch closed cell foam insulation. Base pan of the unit shall have no openings or penetrations. The design of the cabinet shall allow access to the electrical control panel without impairing unit operation. 2. Cabinet shall be designed for vertical or horizontal supply air duct connection. Make-Up Air Systems 23 74 33 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. Galvanized-steel rails for mounting on wall. 4. Service access doors shall also be mounted with stainless steel hinges and equipped with 1/4 turn cam operated adjustable compression type latches. 5. Provide perforated-metal liner knockouts for electrical and piping connections, exterior condensate drain connections, and lifting lugs. Knockouts shall be thru unit sidewall. 6. Paint Finish: polyester urethane powder coat with primer. 7. Maximum Cabinet Leakage: 1 percent of the total supply-air flow at a pressure rating equal to the fan shut-off pressure. D. Supply Fan Section: 1. The standard fan assembly shall be a plenum fan assembly mounted on rubber vibration isolation. The shaft is direct driven and connected to a nominal 1725 RPM open drip proof motor with sealed ball bearings. The bearings on both the blower shaft and motor are permanently lubricated. The fan shall be powder-coated steel or aluminum with aluminum blades. The supply fan shall be on a slide out deck for removal from the cabinet to service or inspect. Fans shall be statically and dynamically balanced to provide efficient operation. 2. The supply fan motor shall be premium efficiency, ODP, and externally protected (manual reset). E. Filters: 2-inch (50-mm) thick, fiberglass, pleated, MERV-8, throwaway filters in filter rack. F. Power Connection: The unit shall be designed for electrical power entry through the side of the cabinet. The starter/control panel shall include a programmable logic controller and a complete modular, integrated motor control system mounted on din rails. All safety and operating controls shall be factory mounted. The system shall also include all relays, fan contactors, and power distribution. The 24-volt control circuit shall include a transformer and low voltage terminal strip for interface with a control system. G. A factory installed clogged filter indicator shall be mounted to indicate dirty or clogged filters when the preset pressure differential across the filters is reached. The indicator shall be manual-reset and shall include contacts for remote annunciation. H. Service Lights and Switch: installed in each accessible location with weatherproof cover. Factory wire lights to the single-point electrical connection. I. Roof Curbs: Galvanized steel; mitered and welded corners; 1-1/2-inch (40-mm) thick, rigid, fiberglass insulation adhered to inside walls; and 1-1/2-inch (40-mm) wood nailer. Size as required to suit roof opening and fan base. 1. Configuration: as recommended by manufacturer. 2. Overall Height: 12 inches (300 mm). 3. Metal Liner: Galvanized steel. 4. Mounting Pedestal: Galvanized steel with removable access panel. Make-Up Air Systems 23 74 33 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.02 MOTORS A. General requirements for motors are specified in Section 23 05 13 “Common Motor Requirements for HVAC.” B. Motor Sizes: Minimum size as indicated; if not indicated, large enough so driven load will not require motor to operate in service factor range above 1.0. C. Controllers, electrical devices, and wiring are specified in Division 26 Sections. 3.00 EXECUTION 3.01 EXAMINATION A. Examine substrates, areas, and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance of the Work. B. Examine roughing-in for piping, ducts, and electrical systems to verify actual locations of connections before equipment installation. C. Examine equipment supports for suitable conditions where units will be installed. D. Proceed with installation only after unsatisfactory conditions have been corrected. 3.02 INSTALLATION A. Install units level and plumb, maintaining manufacturer’s recommended clearances. B. Unit Support: Install unit level on wall. Coordinate penetrations with pre-engineered metal building manufacturer. Secure units to structural support with anchor bolt. 3.03 CONNECTIONS A. Duct installation requirements are specified in other Division 23 Sections. Drawings indicate the general arrangement of ducts. Connect ducts to units with flexible duct connectors. B. Electrical System Connections: Comply with applicable requirements in Division 26 Sections for power wiring, switches, and motor controls. C. Ground equipment according to Division 26. D. Tighten electrical connectors and terminals according to manufacturer’s published torque- tightening values. If manufacturer’s torque values are not indicated, use those specified in UL 486A and UL 486B. 3.04 FIELD QUALITY CONTROL A. Manufacturer’s Field Service: Engage a factory-authorized service representative to inspect, test, and adjust field-assembled components and equipment installation, including connections, and to assist in field testing. Report results in writing. B. Remove malfunctioning units, replace with new units, and retest as specified above. Make-Up Air Systems 23 74 33 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.05 STARTUP SERVICE A. Engage a factory-authorized service representative to perform startup service. B. Complete installation and startup checks according to manufacturer’s written instructions and do the following: 1. Inspect for visible damage to unit casing. 2. Inspect for visible damage to fans. 3. Inspect internal insulation. 4. Verify that labels are clearly visible. 5. Verify that clearances have been provided for servicing. 6. Verify that controls are connected and operable. 7. Verify that filters are installed. 8. Adjust vibration isolators. 9. Lubricate bearings on fan. 10. Inspect fan-wheel rotation for movement in correct direction without vibration and binding. 11. Adjust fan belts to proper alignment and tension. 12. Start unit according to manufacturer’s written instructions. a. Complete startup sheets and attach copy with Contractor’s startup report. 13. Inspect and record performance of interlocks and protective devices; verify sequences. 14. Operate unit for an initial period as recommended or required by manufacturer. 15. Inspect outside-air dampers for proper stroke. 16. Inspect controls for emergency shutdown. 17. Verify Alarms. 18. After startup and performance testing, change filters, lubricate bearings, adjust belt tension, and inspect operation of power vents. 3.06 ADJUSTING A. Set field-adjustable switches and circuit-breaker trip ranges as indicated. B. Occupancy Adjustments: When requested within 12 months of date of Substantial Completion, provide on-site assistance in adjusting system to suit actual occupied conditions. Provide up to two visits to the Site outside normal occupancy hours for this purpose, without additional cost. END OF SECTION Wall Mount Air Conditioners 23 81 13 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 81 13 WALL MOUNT AIR-CONDITIONERS 1.00 GENERAL 1.01 SUMMARY A. This Section includes wall mount air conditioners and their accessories and controls, in the following configurations: 1. Vertical Wall Mount 1.02 SUBMITTALS A. Product Data: Include rated capacities, operating characteristics, furnished specialties, and accessories. B. Shop Drawings: Show installation details for wall penetrations. 1. Wiring Diagrams: Power, signal, and control wiring. 1.03 QUALITY ASSURANCE A. Product Options: Drawings indicate size, profiles, and dimensional requirements of packaged terminal air conditioners and are based on the specific system indicated. 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. Seasonal Energy-Efficiency Ratio: Equal to or greater than prescribed by ASHRAE/IESNA 90.1, “Energy Efficient Design of New Buildings except Low-Rise Residential Buildings.” D. Coefficient of Performance: Equal to or greater than prescribed by ASHRAE/IESNA 90.1, “Energy Efficient Design of New Buildings except Low-Rise Residential Buildings.” 1.04 COORDINATION A. Coordinate layout and installation of packaged terminal air conditioners and wall construction with other construction that penetrates walls or is supported by them. 1.05 WARRANTY A. Special Warranty: Manufacturer’s standard form in which manufacturer agrees to repair or replace components of packaged terminal air conditioners that fail in materials or workmanship within specified warranty period. B. Warranty Period for Sealed Refrigeration System: Manufacturer’s standard, but not less one year from date of Substantial Completion, including components and labor. Wall Mount Air Conditioners 23 81 13 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Bard Manufacturing Co. 2. Carrier Corp. 3. Marvair. 4. Trane Company (The); North American Commercial Group. 2.02 MANUFACTURED UNITS A. Description: Factory-assembled and tested, self-contained, wall mount air conditioner with electric refrigeration system and temperature controls; fully charged with refrigerant and filled with oil. 1. Power Supply: hard-wired chassis for 208/3 phase units. B. Cabinet: 0.052-inch (1.32-mm) thick, galvanized steel with removable front panel with concealed latches. 1. Mounting: Exterior wall. 2. Finish: Baked enamel. 3. Grilles: Extruded-aluminum supply and return grilles. 4. Wall Sleeves: Galvanized steel with polyester finish. C. Refrigeration System: Direct-expansion indoor coil with capillary restrictor, hermetically sealed scroll compressor with internal spring isolation, external isolation, permanent-split- capacitor motor, and overload protection. Include the following: 1. Outdoor coil and fan. D. Indoor Fan: Forward curved, centrifugal, with permanent-split-capacitor motor and positive-pressure ventilation damper with electric operator. 1. Motor Sizes: Minimum size as indicated. If not indicated, large enough so driven load will not require motor to operate in service factor range above 1.0. 2. Noise Rating: Quiet. 3. Electrical devices and connections are specified in Division 26 Sections. E. Filters: MERV 8 filters. F. Condensate Drain: Drain pan and piping to direct condensate as shown on plans. G. Outdoor Fan: Forward curved, centrifugal type driven by indoor fan motor. 1. Motor Sizes: Minimum size as indicated. If not indicated, large enough so driven load will not require motor to operate in service factor range above 1.0. 2. Noise Rating: Quiet. Wall Mount Air Conditioners 23 81 13 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. Electrical devices and connections are specified in Division 26 Sections. 2.03 CONTROLS A. Thermostat: Wall-mounted adjustable, programmable temperature controller. One stage cool fan switch. 2.04 SOURCE QUALITY CONTROL A. Sound-Power Level Ratings: Factory test to comply with ARI 270, “Sound Rating of Outdoor Unitary Equipment.” B. Unit Performance Ratings: Factory test to comply with ARI 310/380, “Packaged Terminal Air-Conditioners and Heat Pumps.” 3.00 EXECUTION 3.01 INSTALLATION A. Install units level and plumb, maintaining manufacturer’s recommended clearances and tolerances. B. Install wall sleeves in finished wall assembly; seal and weatherproof. C. Install wall sleeves to withstand, without damage to equipment and structure, seismic forces required by building code. 3.02 CONNECTIONS A. Electrical System Connections: Comply with applicable requirements in Division 26 Sections for power wiring, switches, and motor controls. B. Ground equipment according to Division 26. C. Tighten electrical connectors and terminals according to manufacturer’s published torque- tightening values. If manufacturer’s torque values are not indicated, use those specified in UL 486A and UL 486B. 3.03 FIELD QUALITY CONTROL A. Manufacturer’s Field Service: Engage a factory-authorized service representative to inspect, test, and adjust field-assembled components and equipment installation, including connections, and to assist in field testing. Report results in writing. B. Perform the following field tests and inspections and prepare test reports: 1. Inspect for and remove shipping bolts, blocks, and tie-down straps. 2. After installing packaged terminal air conditioners and after electrical circuitry has been energized, test for compliance with requirements. 3. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation. 4. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. Wall Mount Air Conditioners 23 81 13 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements C. Remove malfunctioning units, replace with new units, and retest as specified above. 3.04 STARTUP SERVICE A. Engage a factory-authorized service representative to perform startup service. B. After installation, verify the following: 1. Unit is level on base and is flashed in exterior wall. 2. Unit casing has no visible damage. 3. Compressor, air-cooled condenser coil, and fans have no visible damage. 4. Labels are clearly visible. 5. Controls are connected and operable. 6. Shipping bolts, blocks, and tie-down straps are removed. 7. Filters are installed and clean. 8. Drain pan and drain line are installed correctly. C. Verify that electrical wiring installation complies with manufacturer’s submittal and installation requirements in Division 26 Sections. D. Complete installation and startup checks according to manufacturer’s written instructions, including the following: 1. Lubricate bearings on fan. 2. Check fan-wheel rotation for correct direction without vibration and binding. E. After startup service and performance test, change filters. 3.05 ADJUSTING A. Adjust initial temperature and humidity set points. B. Set field-adjustable switches and circuit-breaker trip ranges as indicated. 3.06 DEMONSTRATION A. Engage a factory-authorized service representative to train Owner’s maintenance personnel to adjust, operate, and maintain packaged terminal air conditioners. END OF SECTION Variable Refrigerant Flow HVAC Systems 23 81 29 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 81 29 VARIABLE REFRIGERANT FLOW HVAC SYSTEMS 1.00 GENERAL 1.01 SYSTEM DESCRIPTION A. The system shall be a variable capacity, heat pump with heat recovery air conditioning system. B. The system shall consist of a heat recovery outdoor unit, heat recovery box capable of simultaneous heating and cooling, multiple indoor units, and manufacturer’s Direct Digital Controls system. Each indoor unit or group of indoor units shall be capable of operating in any mode independently of other indoor units or groups. System shall be capable of changing mode (cooling to heating, heating to cooling) with no interruption to system operation. To ensure owner comfort, each indoor unit or group of indoor units shall be independently controlled and capable of changing mode automatically when zone temperature strays 1.8 degrees F from set point for ten minutes. The sum of connected capacity of all indoor air handlers shall range from 50% to 130% of outdoor rated capacity. 1.02 SUBMITTALS A. Product Data: Include rated capacities, furnished specialties, and accessories for each type of product indicated and include the following: 1. Performance for each unit with system operating conditions indicated. 2. Motor ratings and electrical characteristics, plus motor and electrical accessories. 3. Material gages and finishes, including color charts. 4. Manufacturer’s equipment selection and piping software shall be used to determine pipe lengths and proper pipe diameters in advance of ordering materials. The contractor shall produce a document titled “Pre-con VRF Equipment & Piping” and submit this document to manufacturer’s start-up agent and engineer. B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. 1. Wiring Diagrams: Power, signal, and control wiring. Differentiate between manufacturer-installed and field-installed wiring. 2. Design Calculations: Calculate requirements for selecting vibration isolators and seismic restraints and for designing vibration isolation bases. C. Operations and maintenance manuals including commissioning documentation required by manufacturer. 1.03 QUALITY ASSURANCE A. The units shall be listed by Electrical Testing Laboratories (ETL) and bear the ETL label. B. All wiring shall be in accordance with the National Electrical Code (N.E.C.). Variable Refrigerant Flow HVAC Systems 23 81 29 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements C. The units shall be manufactured in a facility registered to ISO 9001 and ISO14001 which is a set of standards applying to environmental protection set by the International Standard Organization (ISO). D. All units must meet or exceed the 2010 Federal minimum efficiency requirements and the proposed ASHRAE 90.1 efficiency requirements for VRF systems. Efficiency shall be published in accordance with the DOE alternative test procedure, which is based on the Air- Conditioning, Heating, and Refrigeration Institute (AHRI) Standards 340/360, 1230 and ISO Standard 13256-1. E. A full charge of R-410A for the heat recovery outdoor unit only shall be provided in the heat recovery outdoor unit. F. Manufacturer shall have a minimum of twenty years of HVAC experience in the U.S. market. G. All manufacturer technical and service manuals must be readily available for download by any local contractor should emergency service be required. Registering and sign-in requirements which may delay emergency service reference are not allowed. 1.04 INSTALLER QUALIFICATIONS A. The VRF system shall be installed by a contractor with certifications and training from the VRF manufacturer for installing manufacturers’ VRF system. Additionally, contractor shall have completed a minimum of five (5) installations of manufacturers’ VRF system on completed projects. The mandatory contractor service and install training should be performed by the manufacturer. B. Provide with list of VRF installations including system description and client contact information. 1.05 DELIVERY, STORAGE AND HANDLING A. Unit shall be stored and handled according to the manufacturer’s recommendation. 1.06 CONTROLS A. The control system shall consist of a low voltage communication network of unitary built-in controllers with on-board communications and a web-based operator interface. A web controller with a network interface card shall gather data from this system and generate web pages accessible through a conventional web browser on each PC connected to the network. Operators shall be able to perform all normal operator functions through the web browser interface. B. System controls and control components shall be installed in accordance with the manufacturer’s written installation instructions. C. Furnish energy conservation features such as optimal start, night setback, request-based logic, and demand level adjustment of overall system capacity as specified in the sequence. D. System shall provide direct and reverse-acting on and off algorithms based on an input condition or group conditions to cycle a binary output or multiple binary outputs. E. Provide capability for system to include monitoring and use of occupant card access, lighting control and general equipment control. Variable Refrigerant Flow HVAC Systems 23 81 29 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements F. System shall be capable of email generation for remote alarm annunciation. G. Control system start-up shall be a required service to be completed by the manufacturer or a duly authorized, competent representative that has been factory trained in manufacturer controls system configuration and operation. The representative shall provide proof of certification indicating successful completion of class no more than two (2) years prior to system installation. This certification shall be included as part of the equipment and/or controls submittals. This service shall be equipment and system count dependent. 1.07 WARRANTY A. The system shall be designed by a certified designer, installed by a contractor that has successfully completed the manufacturer service course, and verified with a completed commissioning report submitted to and approved by the manufacturer’s service department. If completed, the parts and compressor will be warranted for a period of ten (10) years to the original owner. B. If, during this period, any part should fail to function properly due to defects in workmanship or material, it shall be replaced or repaired at the discretion of the manufacturer. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Daikin 2. Mitsubishi 3. LG 2.02 HEAT RECOVERY OUTDOOR UNIT A. The outdoor units shall be equipped with multiple circuit boards that interface to the manufacturer’s controls system and shall perform all functions necessary for operation. Each outdoor unit module shall be completely factory assembled, piped and wired and run tested at the factory. B. All units requiring a factory supplied twinning kits shall be piped together in the field, without the need for equalizing line(s). If an alternate manufacturer is selected, any additional material, cost, and labor to install additional lines shall be incurred by the contractor. C. Outdoor unit shall have a sound rating no higher than 60 dB(A) individually or 64 dB(A) twinned. Units shall have a sound rating no higher than 50 dB(A) individually or 53 dB(A) twinned while in night mode operation. If an alternate manufacturer is selected, any additional material, cost, and labor to meet published sound levels shall be incurred by the contractor. D. All refrigerant lines from the outdoor unit to the heat recovery box shall be insulated. Variable Refrigerant Flow HVAC Systems 23 81 29 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements E. Outdoor unit shall be able to connect to up to 50 indoor units depending upon model. F. The outdoor unit shall have an accumulator with refrigerant level sensors and controls. G. The outdoor unit shall have a high pressure safety switch, over-current protection, crankcase heater and DC bus protection. H. The outdoor unit shall have the ability to operate with a maximum height difference of 164 feet and have total refrigerant tubing length of 1804-2625 feet. The greatest length is not to exceed 541 feet between outdoor unit and the indoor units without the need for line size changes or traps. I. The outdoor unit shall be capable of operating in heating mode down to -4°F ambient temperatures or cooling mode down to 23°F ambient temperatures, without additional low ambient controls. If an alternate manufacturer is selected, any additional material, cost, and labor to meet low ambient operating condition and performance shall be incurred by the contractor. J. The outdoor unit shall have a high efficiency oil separator plus additional logic controls to ensure adequate oil volume in the compressor is maintained. K. Unit Cabinet: 1. The casing(s) shall be fabricated of galvanized steel, bonderized and finished. Units cabinets shall be able to withstand 960 hours per ASTM B117 criteria for seacoast protected models. L. Fan: 1. Each outdoor unit module shall be furnished with one direct drive, variable speed propeller type fan. The fan shall be factory set for operation under 0 in. WG external static pressure, but capable of normal operation under a maximum of 0.24 in. WG external static pressure via dipswitch. 2. All fan motors shall have inherent protection, have permanently lubricated bearings, and be completely variable speed. 3. All fan motors shall be mounted for quiet operation. 4. All fans shall be provided with a raised guard to prevent contact with moving parts. 5. The outdoor unit shall have vertical discharge airflow. M. Refrigerant: 1. R410A refrigerant shall be required for all systems. 2. Polyolester (POE) oil shall be required. Prior to bidding, manufacturers using alternate oil types shall submit material safety data sheets (MSDS) and comparison of hygroscopic properties for alternate oil with list of local suppliers stocking alternate oil for approval at least two weeks prior to bidding. N. Coil: 1. The outdoor coil shall be of nonferrous construction with lanced or corrugated plate fins on copper tubing. 2. The coil fins shall have a factory applied corrosion resistant finish. Variable Refrigerant Flow HVAC Systems 23 81 29 - 5 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. The coil shall be protected with a factory-installed metal guard consisting of 1/2” welded wire mesh and factory mounting hardware with UV-resistant PVC coating. Meshgard by Hardgard or equal approved by Engineer and VRF manufacturer. 4. Refrigerant flow from the outdoor unit shall be controlled by means of an inverter driven compressor. 5. The outdoor coil shall include 4 circuits with two position valves for each circuit, except for the last stage. O. Compressor: 1. Each outdoor unit module shall be equipped with one inverter driven scroll hermetic compressor. Non inverter-driven compressors, which cause inrush current (demand charges) and require larger wire sizing, shall not be allowed. 2. A crankcase heater(s) shall be factory mounted on the compressor(s). 3. The outdoor unit compressor shall have an inverter to modulate capacity. The capacity shall be completely variable with a turndown of 19%-5% of rated capacity, depending upon unit size. 4. The compressor will be equipped with an internal thermal overload. 5. The compressor shall be mounted to avoid the transmission of vibration. 6. Field-installed oil equalization lines between modules are not allowed. Prior to bidding, manufacturers requiring equalization must submit oil line sizing calculations specific to each system and module placement for this project. P. Controls: 1. The outdoor unit shall have the capability of up to 8 levels of demand control for each refrigerant system. Q. Electrical: 1. The outdoor unit electrical power shall be equal to that shown on the plans. 2. The outdoor unit shall be controlled by integral microprocessors. 3. The control circuit between the indoor units, heat recovery devices, and the outdoor unit shall be 24VDC completed using a 2-conductor, twisted pair shielded cable to provide total integration of the system. Variable Refrigerant Flow HVAC Systems 23 81 29 - 6 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.03 HEAT RECOVERY BOX A. General: 1. Unit will include multiple branches to allow simultaneous heating and cooling by allowing either hot gas refrigerant to flow to indoor unit(s) for heating or subcooled liquid refrigerant to flow to indoor unit(s) for cooling. Refrigerant used for cooling must always be subcooled for optimal indoor unit LEV performance; alternate branch devices with no subcooling risk bubbles in liquid supplied to LEV and are not allowed. These units shall be equipped with a circuit board that interfaces to the manufacturer’s controls system and shall perform all functions necessary for operation. The unit shall have a galvanized steel finish. It shall be completely factory assembled, piped and wired. Each unit shall be run tested at the factory. This unit shall be mounted indoors, with access and service clearance provided for each controller. The sum of connected capacity of all indoor air handlers shall range from 50% to 130% of rated capacity. B. Cabinet: 1. The casing shall be fabricated of galvanized steel. 2. Each cabinet shall house a liquid-gas separator and multiple refrigeration control valves. 3. The unit shall house two tube-in-tube heat exchangers. C. Refrigerant: 1. R410A refrigerant shall be required. D. Refrigerant valves: 1. The unit shall be furnished with multiple branch circuits which can individually accommodate up to 54,000 BTUH and up to three indoor units. Branches may be twinned to allow more than 54,000 BTUH. 2. Each branch shall have multiple two-position valves to control refrigerant flow. 3. Service shut-off valves shall be field-provided/installed for each branch to allow service to any indoor unit without field interruption to overall system operation. 4. Linear electronic expansion valves shall be used to control the variable refrigerant flow. 5. Future Use: a. Each VRF system shall include at least one (1) unused branches or branch devices for future use. Branches shall be fully installed & wired in central location with capped service shutoff valve & service port. E. Integral Drain Pan: 1. An Integral drain pan and drain shall be provided if the heat recovery box produces condensate. F. Electrical: 1. The unit electrical power shall be 208/230 volts, 1 phase, 60 Hertz. 2. The heat recovery box shall be controlled by integral microprocessors. Variable Refrigerant Flow HVAC Systems 23 81 29 - 7 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. The control circuit between the indoor units and outdoor units shall be 24VDC completed using a 2-conductor, twisted pair shielded cable to provide total integration of the system. 2.04 3’ X 3’ 4-WAY CEILING-RECESSED CASSETTE WITH GRILLE A. General: 1. The unit shall recess into the ceiling and come with a ceiling grille. 2. The indoor unit shall be factory assembled, wired and run tested. Contained within the unit shall be all factory wiring, piping, electronic modulating linear expansion device, control circuit board and fan motor. The unit shall have a self-diagnostic function, 3- minute time delay mechanism, an auto restart function, and a test run switch. Indoor unit and refrigerant pipes shall be charged with dehydrated air before shipment from the factory. B. Unit Cabinet: 1. The cabinet shall be space-saving ceiling-recessed cassette. 2. The cabinet panel shall have provisions for a field installed filtered outside air intake. 3. Branch ducting shall be allowed from cabinet. 4. Four-way grille shall be fixed to bottom of cabinet allowing two, three or four-way blow. 5. The grille vane angles shall be individually adjustable from the wired remote controller to customize the airflow pattern for the conditioned space. C. Fan: 1. The indoor fan shall be an assembly with a turbo fan direct driven by a single motor. 2. The indoor fan shall be statically and dynamically balanced to run on a motor with permanently lubricated bearings. 3. The indoor fan shall consist of five (5) speed settings, Low, Mid1, Mid2, High and Auto. 4. The fan shall have a selectable Auto fan setting that will adjust the fan speed based on the difference between controller set-point and space temperature. 5. The indoor unit shall have an adjustable air outlet system offering 4-way airflow, 3-way airflow, or 2-way airflow. 6. The indoor unit shall have switches that can be set to provide optimum airflow based on ceiling height and number of outlets used. 7. The indoor unit vanes shall have 5 fixed positions and a swing feature that shall be capable of automatically swinging the vanes up and down for uniform air distribution. 8. The vanes shall have an Auto-Wave selectable option in the heating mode that shall randomly cycle the vanes up and down to evenly heat the space. 9. Return air shall be filtered by means of a long-life washable filter. Variable Refrigerant Flow HVAC Systems 23 81 29 - 8 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Coil: 1. The indoor coil shall be of nonferrous construction with smooth plate fins on copper tubing. 2. The tubing shall have inner grooves for high efficiency heat exchange. 3. All tube joints shall be brazed with phos-copper or silver alloy. 4. The coils shall be pressure tested at the factory. 5. A condensate pan and drain shall be provided under the coil. 6. The unit shall be provided with an integral condensate lift mechanism that will be able to raise drain water 33 inches above the condensate pan. 7. Both refrigerant lines to the indoor units shall be insulated. E. Electrical: 1. The unit electrical power shall be 208/230 volts, 1-phase, 60 hertz. 2. The system shall be capable of satisfactory operation within voltage limits of 187-228 volts (208V/60Hz) or 207-253 volts (230V/60Hz). F. Controls: 1. This unit shall use controls provided by manufacturer to perform functions necessary to operate the system. 2. Indoor unit shall compensate for the higher temperature sensed by the return air sensor compared to the temperature at level of the occupant when in HEAT mode. Disabling of compensation shall be possible for individual units to accommodate instances when compensation is not required. 3. Control board shall include contacts for control of external heat source. External heat may be energized as second stage with 1.8°F – 9.0°F adjustable deadband from set point. 4. Indoor unit shall include no less than four (4) digital inputs capable of being used for customizable control strategies. 5. Indoor unit shall include no less than three (3) digital outputs capable of being used for customizable control strategies. 2.05 2’ X 2’ 4-WAY CEILING-RECESSED CASSETTE UNIT WITH GRILLE A. General: 1. The unit shall recess into the ceiling and come with a ceiling grille. 2. The indoor unit shall be factory assembled, wired and run tested. Contained within the unit shall be all factory wiring, piping, electronic modulating linear expansion device, control circuit board and fan motor. The unit shall have a self-diagnostic function, 3- minute time delay mechanism, an auto restart function, an emergency operation function and a test run switch. Indoor unit and refrigerant pipes shall be charged with dehydrated air before shipment from the factory. Variable Refrigerant Flow HVAC Systems 23 81 29 - 9 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Unit Cabinet: 1. The cabinet shall be a compact 22-7/16” wide x 22-7/16” deep so it will fit within a standard 24” square suspended ceiling grid. 2. The cabinet panel shall have provisions for a field installed filtered outside air intake. 3. Four-way grille shall be fixed to bottom of cabinet allowing two, three or four-way blow. C. Fan: 1. The indoor fan shall be an assembly with a turbo fan direct driven by a single motor. 2. The indoor fan shall be statically and dynamically balanced to run on a motor with permanently lubricated bearings. 3. The indoor fan shall consist of three (3) speeds, Low, Mid, and High. 4. The indoor unit shall have an adjustable air outlet system offering 4-way airflow, 3-way airflow, or 2-way airflow. 5. The auto air swing vanes shall be capable of automatically swinging up and down for uniform air distribution. D. Filter: 1. Return air shall be filtered by means of a long-life washable filter. E. Coil: 1. The indoor coil shall be of nonferrous construction with smooth plate fins on copper tubing. 2. The tubing shall have inner grooves for high efficiency heat exchange. 3. All tube joints shall be brazed with phos-copper or silver alloy. 4. The coils shall be pressure tested at the factory. 5. A condensate pan and drain shall be provided under the coil. 6. The unit shall be provided with an integral condensate lift mechanism that will be able to raise drain water 19-3/4” inches above the condensate pan. 7. Both refrigerant lines to the indoor units shall be insulated. F. Electrical: 1. The unit electrical power shall be 208/230 volts, 1-phase, 60 hertz. 2. The system shall be capable of satisfactory operation within voltage limits of 187-228 volts (208V/60Hz) or 207-253 volts (230V/60Hz). G. Controls: 1. This unit shall use controls provided by manufacturer to perform functions necessary to operate the system. 2. Indoor unit shall compensate for the higher temperature sensed by the return air sensor compared to the temperature at level of the occupant when in HEAT mode. Disabling of compensation shall be possible for individual units to accommodate instances when compensation is not required. Variable Refrigerant Flow HVAC Systems 23 81 29 - 10 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. Control board shall include contacts for control of external heat source. External heat may be energized as second stage with 1.8°F – 9.0°F adjustable deadband from set point. 4. Indoor unit shall include no less than four (4) digital inputs capable of being used for customizable control strategies. 5. Indoor unit shall include no less than three (3) digital outputs capable of being used for customizable control strategies. 2.06 MEDIUM STATIC DUCTED UNIT A. General: 1. The air handler shall be a ceiling-concealed ducted indoor fan coil design that mounts above the ceiling with a 2-position, field adjustable return and a fixed horizontal discharge supply. 2. The indoor unit shall be factory assembled, wired and run tested. Contained within the unit shall be all factory wiring, piping, electronic modulating linear expansion device, control circuit board and fan motor. The unit shall have a self-diagnostic function, 3- minute time delay mechanism, an auto restart function, and a test run switch. Indoor unit and refrigerant pipes shall be charged with dehydrated air before shipment from the factory. B. Unit Cabinet: 1. The unit shall be, ceiling-concealed, ducted. 2. The cabinet panel shall have provisions for a field installed filtered outside air intake. C. Fan: 1. Models shall feature external static pressure settings from 0.14 to 0.60 in. WG. 2. The indoor unit fan shall be an assembly with one or two Sirocco fan(s) direct driven by a single motor. 3. The indoor fan shall be statically and dynamically balanced and run on a motor with permanently lubricated bearings. 4. The indoor fan shall consist of three (3) speeds, High, Mid, and Low plus the Auto-Fan function 5. The indoor unit shall have a ducted air outlet system and ducted return air system. D. Filter: 1. Return air shall be filtered by means of a standard factory installed return air filter. a. Return filter box (rear or bottom placement) with high-efficiency filter shall be available for all medium static indoor units. E. Coil: 1. The indoor coil shall be of nonferrous construction with smooth plate fins on copper tubing. 2. The tubing shall have inner grooves for high efficiency heat exchange. Variable Refrigerant Flow HVAC Systems 23 81 29 - 11 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. All tube joints shall be brazed with phos-copper or silver alloy. 4. The coils shall be pressure tested at the factory. 5. A condensate pan and drain shall be provided under the coil. 6. Both refrigerant lines to the indoor units shall be insulated. F. Electrical: 1. The unit electrical power shall be 208/230 volts, 1-phase, 60 hertz. 2. The system shall be capable of satisfactory operation within voltage limits of 187-228 volts (208V/60Hz) or 207-253 volts (230V/60Hz). G. Controls: 1. This unit shall use controls provided by manufacturer to perform functions necessary to operate the system. 2. Indoor unit shall compensate for the higher temperature sensed by the return air sensor compared to the temperature at level of the occupant when in HEAT mode. Disabling of compensation shall be possible for individual units to accommodate instances when compensation is not required. 3. Control board shall include contacts for control of external heat source. External heat may be energized as second stage with 1.8°F – 9.0°F adjustable deadband from set point. 4. Indoor unit shall include no less than four (4) digital inputs capable of being used for customizable control strategies. 5. Indoor unit shall include no less than three (3) digital outputs capable of being used for customizable control strategies. 2.07 HIGH STATIC DUCTED UNIT (DOAS) A. General: 1. The air handler shall be a ceiling concealed ducted indoor fan coil that mounts above the ceiling with a fixed rear return and a horizontal discharge supply. 2. The indoor unit shall be factory assembled, wired and run tested. Contained within the unit shall be all factory wiring, piping, electronic modulating linear expansion device, control circuit board and fan motor. The unit shall have a self-diagnostic function, 3- minute time delay mechanism, an auto restart function, and a test run switch. Indoor unit and refrigerant pipes shall be charged with dehydrated air before shipment from the factory. B. Unit Cabinet: 1. The cabinet shall be ceiling-concealed, ducted. 2. The cabinet panel shall have provisions for a field installed filtered outside air intake. C. Fan: 1. The indoor unit fan shall be an assembly with one or two Sirocco fan(s) direct driven by a single motor. Variable Refrigerant Flow HVAC Systems 23 81 29 - 12 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. The indoor fan shall be statically and dynamically balanced to run on a motor with permanently lubricated bearings. 3. The indoor unit shall have a ducted air outlet system and ducted return air system. D. Filter: 1. Return air shall be filtered by a field-supplied filter. a. Rear return filter box with long-life filter shall be available for all high static indoor units. E. Coil: 1. The indoor coil shall be of nonferrous construction with smooth plate fins on copper tubing. 2. The tubing shall have inner grooves for high efficiency heat exchange. 3. All tube joints shall be brazed with phos-copper or silver alloy. 4. The coils shall be pressure tested at the factory. 5. A condensate pan and drain shall be provided under the coil. 6. Both refrigerant lines to the indoor units shall be insulated. F. Electrical: 1. The unit electrical power shall be 208/230 volts, 1-phase, 60 hertz. 2. The system shall be capable of satisfactory operation within voltage limits of 187-228 volts (208V/60Hz) or 207-253 volts (230V/60Hz). G. Controls: 1. This unit shall use controls provided by manufacturer to perform functions necessary to operate the system. 2. Indoor unit shall compensate for the higher temperature sensed by the return air sensor compared to the temperature at level of the occupant when in HEAT mode. Disabling of compensation shall be possible for individual units to accommodate instances when compensation is not required. 3. Control board shall include contacts for control of external heat source. External heat may be energized as second stage with 1.8°F – 9.0°F adjustable deadband from set point. 4. Indoor unit shall include no less than four (4) digital inputs capable of being used for customizable control strategies. 5. Indoor unit shall include no less than three (3) digital outputs capable of being used for customizable control strategies. Variable Refrigerant Flow HVAC Systems 23 81 29 - 13 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.08 CONTROLS A. OVERVIEW 1. General: A. The controls network shall be capable of supporting remote controllers, centralized controllers, an integrated web based interface, graphical user workstation, and system integration to Building Management Systems via BACnet. B. ELECTRICAL CHARACTERISTICS 1. General: a. The controls network shall operate at 30VDC. Controller power and communications shall be via a common non-polar communications bus. 2. Wiring: a. Control wiring shall be installed in a daisy chain configuration from indoor unit to indoor unit, to the heat recovery boxes and on to the outdoor unit. Control wiring to remote controllers shall be run from the indoor unit terminal block to the controller associated with that unit. b. Wiring shall be 2-conductor (16 AWG), twisted, stranded, shielded wire. c. Network wiring shall be CAT-5 with RJ-45 connection. C. CONTROLS NETWORK 1. General: a. The controls network consists of remote controllers, centralized controllers, and/or integrated web based interface communicating over a high-speed communication bus. The controls network shall support operation monitoring, scheduling, occupancy, error email distribution, personal web browsers, tenant billing, online maintenance support, and integration with Building Management Systems (BMS) using either LonWorks® or BACnet® interfaces. Variable Refrigerant Flow HVAC Systems 23 81 29 - 14 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2. Remote Controllers: a. Smart Remote Controller : 1). The smart remote controller shall be capable of controlling up to 16 indoor units (defined as 1 group). The controller shall be approximately 5.5” x 5” in size and white in color with an auto-timeout touch screen LCD display. The controller shall support a selection from multiple languages (English, Spanish or French) for display information. The controller supports temperature display selection of Fahrenheit or Celsius. The controller shall control the following grouped operations: On/Off, Operation Mode (cool, heat, auto, dry, fan and setback), temperature set point, fan speed setting, and airflow direction setting. The Smart remote controller shall support timer settings of on/off/temperature up to 8 times in a day in 5-minute increments. The controller shall support an Auto Off timer. The controller shall be able to limit the set temperature range from the smart remote controller, or via a PC through a licensed central controller. The smart remote controller shall display a four-digit error code in the event of system abnormality or error. 2). The smart remote controller shall only be used in same group with other smart remote controller with a maximum of two smart remote controllers per group. 3). The smart remote controller shall require manual addressing using rotary dial switch to the VRF communication bus. The controller shall connect using two- wire, stranded, non-polar control wire to TB5 connection terminal on the indoor unit. b. Backlit Simple Remote Controller: 1). The backlit simple remote controller shall be capable of controlling up to 16 indoor units (defined as 1 group). The controller shall be compact in size, approximately 3” x 5” and have limited user functionality. The controller supports temperature display selection of Fahrenheit or Celsius. The controller shall allow the user to change on/off, mode (cool, heat, auto, dry, setback and fan), temperature setting, and fan speed setting and airflow direction. The controller shall be able to limit the set temperature range from the backlit simple remote controller. The controller shall be capable of night setback control with upper and lower set temperature settings. The room temperature shall be sensed at either the backlit simple remote controller or the indoor unit dependent on the indoor unit dipswitch setting. The backlit simple remote controller shall display a four-digit error code in the event of system abnormality/error. 2). The backlit simple remote controller shall only be used in same group with wireless remote controllers or with other backlit simple remote controllers, with up to two remote controllers per group. a). The backlit simple remote controller shall require no addressing. The controller shall connect using two-wire, stranded, non-polar control wire to TB15 connection terminal on the indoor unit. The controller shall require cross-over wiring for grouping across indoor units. Variable Refrigerant Flow HVAC Systems 23 81 29 - 15 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3. Input/Output Boards: a. Third-Party HVAC Controller: a). The third-party HVAC controller shall be capable of providing programmable binary and analog inputs and outputs to control general equipment in conjunction with indoor unit functions and states. Input and output states and values shall be monitored through the central controller. The smart remote controller shall be able to adjust temperature and humidity set points for equipment controlled by the third-party HVAC controller. In addition to analog and binary inputs the third-party HVAC controller can monitor equipment states and sensor values. Available inputs include room temperature, room humidity, occupancy, brightness, outdoor temperature, on/off state, mode, ventilation on/off, error status. In addition to programmable analog and binary outputs, the third-party HVAC controller can control indoor unit on/off, mode, temperature set point, fan speed, LOSSNAY on/off and LOSSNAY fan speed. b. Digital Input Digital Output Board: 1). Each DIDO board shall have two digital inputs and two digital outputs for on/off control, monitoring, and scheduling of non-VRF equipment. c. Analog Input (AI) Board: 1). The AI board shall be capable of monitoring temperature or humidity via central controller. 2). Each AI board shall have two analog inputs. Each input shall be capable of receiving a 4/20mA, 0/10 VDC, or 1/5 VDC signal for monitoring temperature or humidity. Notification of user adjustable high and low level alarms shall be capable of being emailed to distribution list or outputted via a digital output. 3). The AI board shall be capable of setting the following parameters on the indoor unit On/Off, Mode, and Set Temperature to predefined settings based on the input value of the temperature or humidity. The AI board shall also be capable of interlocking the On/Off state of a digital output on the input value of the temperature or humidity. 4. Centralized Controller (Web-enabled) : a. VRF Central Controller: 1). The VRF central controller shall be capable of controlling a maximum of 50 indoor units across multiple outdoor units and shall be approximately 7- 1/2”x12” in size. Variable Refrigerant Flow HVAC Systems 23 81 29 - 16 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2). The VRF central controller shall support system configuration, daily/weekly scheduling, monitoring of operation status, night setback settings, free contact interlock configuration and malfunction monitoring. The VRF central controller shall have five basic operation controls which can be applied to an individual indoor unit, a group of indoor units (up to 50 indoor units), or all indoor units (collective batch operation). This basic set of operation controls shall include on/off, operation mode selection (cool, heat, auto, dry, and fan), temperature setting, fan speed setting, and airflow direction setting. Since the VRF central controller provides centralized control it shall be able to enable or disable operation of local remote controllers. 3). In terms of scheduling, the VRF central controller shall allow the user to define both daily and weekly schedules with operations consisting of ON/OFF, mode selection, temperature setting, air flow (vane) direction, fan speed, and permit/prohibit of remote controllers. 4). All VRF central controllers shall be equipped with one RJ-45 Ethernet port to support interconnection with a network PC via a closed/direct Local Area Network (LAN). 5). The VRF central controller shall be capable of performing initial settings via the 9” high-resolution, backlit, color touch panel on the controller or via a PC using the initial setting browser. a). Standard software functions shall be available so that the building manager can securely log into each central controller via the PC’s web browser to support operation monitoring, scheduling, error email, interlocking and online maintenance diagnostics. 5. Building Management Systems (BMS) Interface: a. BACnet® Interface: 1). The interface shall be compliant with BACnet® Protocol (ANSI/ASHRAE 135- 2004) and be Certified by the (BTL) BACnet® Testing Laboratories. The BACnet® interface shall support BACnet Broadcast Management (BBMD). The BACnet® interface shall support a maximum of 50 indoor units. Operation and monitoring points include, but are not limited to, on/off, operation mode, fan speed, prohibit remote controller, filter sign reset, alarm state, error code, and error address. 3.00 EXECUTION 3.01 INSTALLATION A. General: 1. Rig and install in full accordance with manufacturer’s requirements, project drawings, and contract documents. Refer to the manufacturer’s installation manual for full requirements. Variable Refrigerant Flow HVAC Systems 23 81 29 - 17 DTN18104 – Lake Lewisville WTP/RWPS Improvements B. Location: 1. Locate indoor and outdoor units as indicated on drawings. Provide service clearance per manufacturer’s installation manual. Adjust and level outdoor units on support structure. 2. For climates that experience snowfall, mount the outdoor unit a minimum of 12” above the average snowfall line. In climates where this height requirement proves unfeasible, the outdoor units may be installed at the average snowfall line provided regular snow removal in the area surrounding the units keeps the snow line below the bottom of the units. C. Components / Piping: 1. Installing contractor shall provide and install all accessories and piping for a fully operational system. Refer to manufacturer’s installation manual for full instructions. 2. Traps, filter driers, and sight glasses are NOT to be installed on the refrigerant piping or condensate lines. 3. Standard ACR fittings rated for use with R410A are to be used for all connections. 4. Refrigerant pipe for the VRF system shall be made of phosphorus deoxidized copper, and has two types: a. ACR Type-L “Annealed Temper”: Soft copper pipe, can be easily bent with human's hand. b. ACR Type L “Drawn Temper”: Hard copper pipe (Straight pipe), being stronger than Type-O pipe of the same radical thickness. 5. The maximum operation pressure of R410A air conditioner is 4.30 MPa [623psi]. The refrigerant piping should ensure the safety under the maximum operation pressure. Refer to recommend piping specifications in manufacturer’s engineering manual. Pipes of radical thickness 0.7mm or less shall not be used. 6. Contractor shall verify with manufacturer the steps necessary to make certain all sections of the refrigerant piping are open for both pressure testing and vacuuming. 7. Pressure testing refrigerant piping shall follow manufacturer’s instructions and shall be observed by the general contractor and start-up agent. 8. Vacuuming of refrigerant lines shall be performed as instructed by manufacturer. This process shall be observed by the general contractor and accepted by start-up agent. 9. Manufacturer’s equipment selection and piping software shall be updated with actual as-built line lengths. The contractor shall produce a document titled “As-Built VRF Equipment & Piping”. This document shall be submitted to manufacturer’s start-up agent for acceptance and be made a part of the commissioning documentation. Variable Refrigerant Flow HVAC Systems 23 81 29 - 18 DTN18104 – Lake Lewisville WTP/RWPS Improvements D. Insulation: 1. Refrigerant pipes, as well as any valves and accessories, shall be insulated end to end with closed-cell pipe insulation. Insulation shall be sized with inner diameter corresponding to pipe size. Insulation shall, at the minimum, match VRF equipment connections integral insulation; for substituted equipment, confirm pipe temperatures with VRF manufacturer and compare to IECC 2015 Table C403.2.10. Insulation thickness shall, at the minimum, be the following values: a. 2-pipe systems 1). Main High-Pressure Pipe (liquid in cooling, hot gas in heating) – from HRU to BS (190 F) a). Pipe size less than 1.5 inches: 1.5 inches insulation thickness b). Pipe size greater than 1.5 inches: 2 inches insulation thickness 2). Main Low-Pressure Pipe (suction gas) – from BS to HRU (32 F to 55 F) a). Pipe size less than 1 inch: 1/2 inch insulation thickness b). Pipe size greater than 1 inch: 1 inch insulation thickness 3). Branch Liquid Pipe (liquid in cooling, hot gas in heating) – from BS to AHU (90 F to 140 F) a). Pipe size less than 1.5 inches: 1 inch insulation thickness b). Pipe size greater than 1.5 inches: 1.5 inches insulation thickness 4). Branch Suction Pipe (gas in cooling, liquid in heating) – from AHU to BS (32 F to 40 F or 120 F to 150 F) a). Pipe size less than 1.5 inches: 1.5 inches insulation thickness b). Pipe size greater than 1.5 inches: 2 inches insulation thickness b. 3-pipe systems 1). Main High-Pressure Pipe (gas in cooling, hot gas in heating) – from HRU to BS (32 F - 50 F or 115 F to 150 F) a). Pipe size less than 1.5 inches: 1.5 inches insulation thickness b). Pipe size greater than 1.5 inches: 2 inches insulation thickness 2). Main Low-Pressure Pipe (gas) – from HRU to BS (32 F - 50 F) a). Pipe size less than 1 inch: 1/2 inch insulation thickness b). Pipe size greater than 1 inch: 1 inch insulation thickness 3). Main Liquid Pipe (liquid) – from HRU to BS (70 F to 90F) a). Pipe size less than 1.5 inches: 1/2 inch insulation thickness b). Pipe size greater than 1.5 inches: 1 inch insulation thickness Variable Refrigerant Flow HVAC Systems 23 81 29 - 19 DTN18104 – Lake Lewisville WTP/RWPS Improvements 4). Branch Liquid Pipe (liquid) – from BS to AHU (70 F to 90F) a). Pipe size less than 1.5 inches: 1/2 inch insulation thickness b). Pipe size greater than 1.5 inches: 1 inch insulation thickness 5). Branch High/Low-Pressure Pipe (gas in cooling, hot gas in heating) - from AHU to BS (32 F - 50 F or 115 F to 150 F) a). Pipe size less than 1.5 inches: 1.5 inches insulation thickness b). Pipe size greater than 1.5 inches: 2 inches insulation thickness 2. PVC Condensate pipes: 1/2 inch insulation thickness. E. Electrical: 1. Installing contractor shall coordinate electrical requirements and connections for all power feeds with electrical contractor. Refer to Division 26 for additional information. F. Third Party Controls: 1. Installing contractor shall coordinate all BAS/BMS control requirements and connections with controls contractor. 3.02 STARTUP & DEMONSTRATION A. Engage the manufacturer or a factory-authorized service representative to perform startup on the entire VRF system, following the factory extended warranty startup procedure. B. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain the entire VRF system. 1. Train Owner's maintenance personnel on procedures and schedules for starting and stopping, troubleshooting, servicing, and maintaining equipment. a. Training shall be recorded by professional videographer and burned to DVD. Owner shall receive three (3) copies of training DVD upon completion. 2. Review data in maintenance manuals. Refer to Division 01. 3. Schedule training with Owner, through Owners Representative, with at least 7 days' advance notice. END OF SECTION Propeller Unit Heaters 23 82 39.16 - 1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 23 82 39.16 PROPELLER UNIT HEATERS 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes propeller unit heaters. 1.03 SUBMITTALS A. Product Data: Include specialties and accessories for each unit type and configuration. B. Field Test Reports: Written reports of tests specified in Part 3 of this Section. C. Maintenance Data: For propeller unit heaters to include in maintenance manuals specified in Division 01. Include the following: 1. Maintenance schedules and repair parts lists for motors, coils, integral controls, and filters. 1.04 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. 1.05 COORDINATION A. Coordinate layout and installation of propeller unit heaters and suspension system components with other construction that penetrates ceilings or is supported by them, including light fixtures, HVAC equipment, fire-suppression-system components, and partition assemblies. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Chromalox. 2. Carrier Corp. 3. International Environmental Corp. 4. McQuay International. 5. Rosemex Products. 6. Ruffneck Heaters, Starozik Industries Ltd. Propeller Unit Heaters 23 82 39.16 - 2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 7. Trane Company (The); North American Commercial Group. 8. U S A Coil & Air Inc. 2.02 UNIT HEATERS A. Description: An assembly including casing, coil, fan, and motor in horizontal discharge configuration with horizontal, adjustable louvers in blow-through configuration. 2.03 MATERIALS A. Casing: Galvanized steel, with removable panels. B. Cabinet Finish: Bonderize, phosphatize, and flow-coat with baked-on primer and manufacturer's standardpaint applied to factory-assembled and -tested propeller unit heater before shipping. 2.04 ELECTRIC-RESISTANCE HEATING ELEMENTS A. Nickel-chromium heating wire, free from expansion noise and 60-Hz hum, embedded in magnesium-oxide insulating refractory and sealed in high-mass steel or corrosion-resistant metallic sheath with fins no closer than 0.16 inch (4 mm). Element ends shall be enclosed in terminal box. Fin surface temperature shall not exceed 550 F (288 C) at any point during normal operation. 1. Circuit Protection: One-time fuses in terminal box for overcurrent protection and limit controls for overtemperature protection of heaters. 2. Wiring Terminations: Match conductor materials and sizes indicated. 2.05 FAN A. Propeller with aluminum blades directly connected to motor. 2.06 FAN MOTORS A. Motors, 1/2 HP and Smaller: shaded-pole or permanent-split capacitor, multispeed motor with integral thermal-overload protection. B. Motors, 3/4 HP and Larger: Totally enclosed with permanently lubricated ball bearings. 2.07 ACCESSORIES A. Horizontal Configuration: Louver fin diffuser. B. Vertical Configuration: Louver cone diffuser. 2.08 CONTROLS A. Control Devices: Unit-mounted fan-speed switch and thermostat. Propeller Unit Heaters 23 82 39.16 - 3 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.09 SOURCE QUALITY CONTROL A. Test propeller unit heater coils according to ASHRAE 33. 3.00 EXECUTION 3.01 EXAMINATION A. Examine areas to receive propeller unit heaters for compliance with requirements for installation tolerances and other conditions affecting performance. B. Examine roughing-in for piping and electrical connections to verify actual locations before propeller unit heater installation. C. Proceed with installation only after unsatisfactory conditions have been corrected. 3.02 INSTALLATION A. Install propeller unit heaters level and plumb. B. Install propeller unit heaters to comply with NFPA 90A. C. Suspend propeller unit heaters from structure with rubber-in-shear vibration isolators (rubber hangers). D. Install wall-mounting thermostats and switch controls in electrical outlet boxes at heights to match lighting controls. 3.03 CONNECTIONS A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate general arrangement of piping, fittings, and specialties. B. Unless otherwise indicated, install shutoff valve and union or flange on each connection. C. Install piping adjacent to machine to allow service and maintenance. D. Ground equipment. E. Tighten electrical connectors and terminals according to manufacturer's published torque- tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B. 3.04 FIELD QUALITY CONTROL A. Testing: Perform the following field quality-control testing and report results in writing: 1. After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation. 2. Operate electric heating elements through each stage to verify proper operation and electrical connections. 3. Test and adjust controls and safeties. B. Repair or replace malfunctioning units. Retest as specified above after repairs or replacements are made. Propeller Unit Heaters 23 82 39.16 - 4 DTN18104 – Lake Lewisville WTP/RWPS Improvements 3.05 CLEANING A. After installing units, inspect unit cabinet for damage to finish. Remove paint splatters and other spots, dirt, and debris. Repair damaged finish to match original finish. B. After installing units, clean propeller unit heaters internally according to manufacturer's written instructions. C. Install new filters in each propeller unit heater within 2 weeks after Substantial Completion. END OF SECTION Testing of Electrical Systems 26 01 26 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 01 26 TESTING OF ELECTRICAL SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED Furnish labor, material, equipment and incidentals of an independent testing agency. These specifications cover the suggested field tests and inspections that are available to assess the suitability for initial energization and final acceptance of electrical power equipment and systems. The purpose of these specifications is to assure that electrical equipment and systems are operational, are within applicable standards and manufacturer’s tolerances, and are installed in accordance with design specifications. The work specified in these specifications may involve hazardous voltages, materials, operations, and equipment. These specifications do not purport to address all of the safety issues associated with their use. It is the responsibility of the user to review all applicable regulatory limitations prior to the use of these specifications. Testing shall be inclusive of all low voltage equipment including conductors that are provided under this contract. 1.02 QUALITY ASSURANCE A. Testing Organization: 1. The testing organization shall be an independent, third party entity which can function as an unbiased testing authority, professionally independent of the manufacturers, suppliers, and installers of equipment or systems being evaluated. 2. Testing organization shall be regularly engaged in the testing of electrical equipment devices, installations, and systems. 3. The Testing organization shall use technicians who are regularly employed for testing services. 4. An organization having a designation of NETA Accredited Company issued by the InterNational Electrical Testing Association meets the above criteria. 5. Independent testing agency shall follow all tests and recommendations in NETA Acceptance Testing Specification for all equipment provided. 6. Testing Organization performing the work shall submit appropriate documentation to demonstrate that it satisfactorily complies with these requirements. 7. Acceptable Testing Agencies: a. National Field Services b. Real Power Technologies c. Shermco Industries d. Electrical Power Systems Testing of Electrical Systems 26 01 26 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 8. Testing Personnel a. Technicians performing these electrical tests and inspections shall be trained and experienced concerning the apparatus and systems being evaluated. These individuals shall be capable of conducting the tests in a safe manner and with complete knowledge of the hazards involved. They must evaluate the test data and make a judgment on the serviceability of the specific equipment. b. Technicians shall be certified in accordance with ANSI/NETA ETT, Standard for Certification of Electrical Testing Technicians. Each on-site crew leader shall hold a current certification, Level 3 or higher, in electrical testing. 1.03 SUBMITTALS Submittals shall be in accordance with Section 01 30 00, “Submittal Procedures” and shall include: ELECTRICAL QUALIFICATIONS & LIST OF TEST SUBMITTAL 1. 60 days prior to any testing taking place, Contractor shall submit to the Owner/Engineer the name of the testing agency; a list of all tests to be conducted shall also be submitted at this same time. No testing shall take place until this has been submitted and approved by the Engineer. ELECTRICAL TESTING PLAN 1. A minimum of two (2) weeks before testing is to take place, Contractor shall submit a detailed testing plan of the different configurations to be tested for the Owner’s and Engineer’s approval. ELECTRICAL TESTING REPORT 1. A written report shall be submitted by the testing agency performing installation checks, operation and testing of the low voltage equipment. This report shall certify that a. The equipment has been properly installed b. Is in accurate alignment c. Meets the acceptance testing specifications of NETA and the equipment manufacturer. 2. Provide a detailed list of all tests that were performed and the test results as part of the Electrical Testing Report. 3. Electrical Testing Report(s) shall be submitted to Engineer for approval no later than one week after testing has been conducted. 1.04 STANDARDS The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American National Standards Institute (ANSI) 2. Association of Edison Illuminating Companies (AEIC) 3. Electrical Apparatus Service Association (EASA) 4. American Standards for Testing and Materials (ASTM) Testing of Electrical Systems 26 01 26 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 5. Institute of Electrical and Electronic Engineers (IEEE) 6. Insulated Cable Engineers Association (ICEA) 7. National Electrical Manufacturers Association (NEMA) 8. International Electrical Testing Association (NETA) 9. National Fire Protection Association (NFPA) 10. Occupational Safety and Health Administration (OSHA) 11. State and local codes and ordinances 12. Underwriters Laboratories, Inc. (UL) 2.00 EXECUTION 2.01 GENERAL All testing shall be witnessed by the Owner’s Representative. Types of equipment required to be tested by these specifications shall include but not be limited to the following: 1. Low Voltage Cables 2. Switchboards 3. Medium Voltage Cables 4. Medium Voltage Metal-Clad Switchgear 5. Medium Voltage Pad-Mounted Switch 6. Medium Voltage Transformers – Pad Mounted, Liquid-Filled 7. Medium Voltage Motor Control Center 8. Automatic Transfer Switch 9. Transformers – Low Voltage Distribution 10. Grounding At a minimum, unless indicated otherwise, all testing shall be in accordance with the manufacturer’s recommendations for energization and start-up of the equipment. Testing shall include a complete functionality testing of electrical equipment under all the different operating parameters identified by the OWNER and ENGINEER. Electrical testing instrument calibration shall be as indicated in ANSI/NEMA ATS-2017. 2.02 TEST REPORT The test report shall include the following: 1. Summary of the project. 2. Description of equipment tested. 3. Description of tests. 4. Test data. 5. Analysis and recommendations. Testing of Electrical Systems 26 01 26 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements Test data records shall include the following minimum requirements: 1. Identification of the testing organization. 2. Equipment identification. 3. Nameplate data. 4. Humidity, temperature, and other conditions that may affect the results of the tests and/or calibrations. 5. Date of inspections, test, maintenance, and/or calibrations 6. Identification of the testing technician. 7. Identification of inspections, tests, maintenance, and/or calibrations to be permed and recorded. 8. Identification of expected results when calibrations are to be performed. 9. Identification of as-found and as-left results, as applicable. 10. Identification of all test results outside of specified tolerances. 11. Sufficient spaces to allow all results and comments to be indicated. The testing organization shall furnish a copy or copies of the complete test report as specified. 2.03 TEST DECAL The testing organization shall affix a test decal on the exterior of equipment or equipment enclosure of protective devices after performing electrical tests. The test decal shall be color-coded to communicate the condition of maintenance for the protective device. Color scheme for condition of maintenance of overcurrent protective device shall be: 1. White: electrically and mechanically acceptable. 2. Yellow: minor deficiency not affecting fault detection and operation, but minor electrical or mechanical condition exists. 3. Red: deficiency exists affecting performance, not suitable for service. The decal shall include: 1. Testing organization 2. Project identifier 3. Test date 4. Technician identifier 2.04 POWER SYSTEM TESTING CONTRACTOR shall test the operation of the power distribution system, i.e. switchgear, transformers, 480V Switchboard, automatic transfer switch, etc., for the various possible system configurations under load conditions. Testing shall include, but not be limited to the following: 1. Power from Main No.1 Testing of Electrical Systems 26 01 26 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Power from Main No.2 CONTRACTOR shall submit a detailed testing plan of the different configurations to be tested for the Owner’s and Engineer’s approval. END OF SECTION Common Work Results for Electrical 26 05 00 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 00 COMMON WORK RESULTS FOR ELECTRICAL 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary for complete and operational electrical systems, as specified herein. B. This Section, as well as Division 1, concerns all other Sections in Division 26 shall be considered a part of each of those Sections as if written in their entirety. C. Contractor shall be responsible to coordinate labor and materials required to install and test equipment supplied by Aeration Basin blower system identified under this contract. D. Permanent Utilities: 1. Contractor shall be responsible to coordinate power at the site with local utility company. 2. Contractor will be responsible to absorb the cost of providing utility power to the site. E. Temporary utilities: 1. Contractor may need to include generator power for outages, depending on the contractors’ means and methods of connecting to existing power equipment. 2. Contractor shall provide electrical testing and inspection services for temporary connections to existing equipment. 3. Fusing for temporary equipment shall be coordinated with upstream devices to assure the fuses will terminate before interrupting electrical service to plant process equipment. F. Electrical outages must be coordinated with Operations, as well as the Electrical, Instrumentation and Inspections Divisions. 1. Known electrical outages include: a. Rerouting of Utility service feeders into two (2) new Owner provided 2000kVA transformers. 2. Shut down sequencing shall be coordinated by the contractor and if a generator is required to power equipment to maintain service, contractor shall be responsible to provide the generator, fuel, and conductors required to keep the plant operational. 1.02 QUALITY ASSURANCE A. ELECTRICAL CONTRACTORS' QUALIFICATIONS 1. Use adequate numbers of skilled workmen, trained and experienced in their crafts, and who are familiar with the specifications and methods of performing the work in this Division. A licensed Journeyman shall be on site at all times when electrical work is being performed. Electrical work shall be performed under the direct supervision of a Master Electrician who holds a valid license in the State of Texas. The Contractor shall provide a monthly report to the Owner/Engineer for review stating that the Master Common Work Results for Electrical 26 05 00 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements Electrician has been to the job site and thoroughly reviewed the work. The report shall be signed by the Master Electrician and include the data and time the Master Electrician was on site. 2. Contractors company must have 10 years experience with performing electrical work within pump stations and water treatment plants. B. WORKMANSHIP Work shall be performed in accordance with quality, commercial practices. The appearance of finished work shall be of equal importance with its operation. Materials and equipment shall be installed based upon the actual dimensions and conditions at the project site. Locations for materials or equipment requiring an exact fit shall be field measured. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, Submittal Procedures and shall include: 1. Submittals shall be submitted separated by specification section. Combined submittals will not be reviewed. Submittal will be marked not approved, revise and resubmit. 2. Incomplete submittals will not be reviewed and will be marked revise and resubmit. 3. Resubmittals shall be marked with a red strike through for the items removed from the submittal and clouded with the items added to the submittal. Submittals shall be marked to track changes between resubmittals. 4. Component catalog number and manufacturing data sheet, indicating pertinent data and identifying each component by the item number and nomenclature as specified. 5. Component drawings showing dimensions, mounting, and external connection details in AutoCAD format. 6. Operation and maintenance manuals shall contain the shop drawings, submittals, spare part lists, schematics, project specific final wiring diagrams with any changes made during start-up and maintenance procedures. 7. Unless other additional information is required by the detailed equipment specifications, the following information shall be included for motors: a. Motor identification number and nomenclature as specified b. Make and motor type c. Brake horsepower of the motor d. Locked rotor current at full load e. Motor efficiency at full load (3-phase motors only) f. Starting torque g. Method of insulating and impregnating motor coils (3-phase only) h. Speed of the motor at full torque i. Full load current Common Work Results for Electrical 26 05 00 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements j. Service factor k. Motor temperature rise measured by resistance over 40 degrees C ambient B. Delays during submittals due to contractor not following the format mentioned above shall not be the fault of the Owner or Engineer. C. The Contractor shall provide a monthly report to the Owner/Engineer for review stating that the Master Electrician has been to the job site and thoroughly reviewed the work. The report shall be signed by the Master Electrician and include the data and time the Master Electrician was on site. D. The Contractor shall: 1. Prepare, and keep up-to-date, the Record Drawings and detailed construction drawings. 2. Record the exact locations of each of these differences, sizes and details of the Construction Work as executed, with cross-references to and other requirements on the Record Drawings. 3. Keep the Record Drawings on the Work Site; 4. Upon completion of the Work, or at such other time as may be determined by the Engineer, submit the Record Drawings and copies to the Owner’s Representative in accordance with the Owner’s Requirements. 5. Underground Interference drawing showing all underground duct banks, ground rods, ground conductors, pipes, piers, vaults, manholes, pull boxes, etc. that clearly identifies the location and routing of these systems. All interferences shall be brought to the Engineer’s attention. 6. Provide revised drawings in AutoCAD noting any changes made to equipment during start-up. 1.04 STANDARDS A. Electrical work shall be executed in accordance with local, State and national codes, ordinances and regulations which have jurisdiction or authority over the work. If the standards and codes conflict with each other, the most stringent shall apply. The applicable provisions of the following standard shall apply as if written here in their entirety: National Electrical Manufacturer Association (NEMA) American Society for Testing and Materials (ASTM) National Fire Protection Association (NFPA) National Electrical Safety Code (NESC) Institute of Electrical and Electronic Engineers (IEEE) National Electrical Code (NEC) Underwriters Laboratories (UL) American National Standards Institute (ANSI) Uniform Building Code (UBC) Common Work Results for Electrical 26 05 00 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements Occupational Safety and Health Administration (OSHA) Local utility companies Local Electrical Ordinance Rural Electrification Association (REA) Insulated Power Cable Engineers Association (IPCEA) International Electrical Testing Association (NETA) National Electrical Contractors Association (NECA) Association Edison Illuminating Companies (AEIC) Texas Commission on Environmental Quality (TCEQ) Environmental Protection Agency (EPA) International Electrotechnical Commission (IEC) 1.05 DELIVERY AND STORAGE A. Follow the Manufacturer's directions for the delivery, storage and handling of equipment and materials. Tightly cover equipment and materials and protect it from dirt, water, chemical or mechanical injury and theft. Major electrical equipment shall be stored indoors and space heaters energized where applicable. Equipment that will be stored indoors for an extended period of time and that do not have space heaters shall have a 100 watt incandescent light placed in it and energized to eliminate the build-up of condensation in the equipment. Coordinate with equipment manufacturer for storage requirements. Damaged equipment shall not be acceptable. Upon installation, protect the materials until the work is completed and accepted by the Owner. 1.06 JOB CONDITIONS A. Permits, licenses and inspections shall be secured and paid for as required by law for the completion of the work. Certificates of approval shall be secured, paid for, and delivered to the Owner before receiving the final acceptance of the work. B. The location of materials, equipment, devices and appliances indicated are approximate and subject to revisions at the time the work is installed. Final location shall be as proposed by the Contractor and approved by the Engineer. C. Should project conditions require any rearrangement of work, or if equipment or accessories can be installed better than the general arrangement of work on the plans, the Contractor shall prepare and submit plans of the proposed rearrangement for the Engineer's review and approval. D. Motor Horsepower ratings identified are anticipated ratings. If the actual equipment is a different size, the contractor shall provide the appropriate wiring, conduit, over current protection, starters and accessories for a complete and working system at no cost to the owner. E. All enclosures for equipment unless specifically identified otherwise shall be: 1. NEMA 12 for indoor air-conditioned areas. Common Work Results for Electrical 26 05 00 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. NEMA 3R enclosures for indoor ventilated areas. 3. NEMA 4, FRP for rooms housing Chlorine. 4. NEMA 4X, 316 stainless steel for exterior applications and all other locations. F. Contractor is required to abide by the Owners Construction Safety and Health Program where applicable. G. Clearances indicated in the National Electrical Code must be maintained around equipment. H. Enclosures shall be installed such that enclosure doors open toward the individual requiring access. 2.00 PRODUCTS 2.01 MATERIALS A. Supplemental or alternative materials supplied and installed by the contractor shall be approved prior to installation. Materials installed without pre-approval, through the submittals process, shall be removed from the job site and replaced at no additional cost to the owner. No exceptions. B. Discrepancies between the plans and specifications shall be addressed prior to bidding the project, otherwise the most expensive of the two options shall be assumed. 3.00 EXECUTION 3.01 INSTALLATION A. Maintain waterproof integrity of conduit penetrations through enclosures, the roof, exterior walls and floors. B. Install steel reinforced concrete foundations below floor mounted switchboards, panelboards, motor control centers, transformers, and other floor mounted electrical equipment. Concrete foundations shall not be less than 4" high. Neatly chamfer top edges. Concrete foundations shall be 4" wider and 4" longer than the base of the equipment being installed. Concrete shall be in accordance with Division 03, and shall be reinforced with a minimum of 6" x 6" #6 welded wire mesh. C. Route all conduits parallel to building lines, columns, or steel route conduits near to columns and roof beams. 3.02 CUTTING AND PATCHING A. Provide adequate support during cutting operations to prevent any damage to the affected masonry. Where openings are cut through masonry walls, provide lintels or structural supports to protect the remaining masonry. The cutting of structural members shall not be permitted without the specific written approval of the Engineer. 3.03 PAINTING A. Painting shall be in accordance with Division 09. Maintain the original factory finish on material and equipment installed, unless specifically indicated on the plans or specifications. Common Work Results for Electrical 26 05 00 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements If the finish is marred in transit or during installation, re-finish to a neat, workmanlike appearance. Leave equipment and raceway systems clean and free of grease, dirt, rust, and in a suitable condition for painting. 3.04 EXCAVATION, TRENCHING, BACKFILLING AND GRADING A. Prior to any excavation or trenching, notify the Owner’s representative, utility companies and Owner’s facilities department. Allow sufficient time for utilities to be located prior to excavation to avoid disruption of services. Provide a minimum of 72 hours written notice to the Owner prior to trenching or excavation. Do not proceed with trenching or excavation until authorized by the Owner. Utilities or services which are damaged, which are identified prior to excavation or trenching, or where confirmation by utility companies has not been obtained verifying that utilities are marked, shall be repaired to operable condition immediately, at no cost to the Owner. B. Barricade open trenches and excavations for the entire duration of the project. Barricades for excavations shall have warning lights maintained during hours of darkness. Trenches shall be marked with warning tape, or access to trenches shall be prohibited with readily identifiable sawhorses, warning tape or other acceptable means. Barriers shall be illuminated or recognizable during hours of darkness. Barriers and tape shall be properly maintained at all times. C. Protect all adjacent work, structures and properties. Damage to adjacent work, structures or properties shall be repaired, or the cost of repair reimbursed in full. D. All construction areas shall be finally graded as indicated on the contract documents, or to the conditions of the site prior to construction. Grading shall bring the site back to the existing conditions as close as practical. Turfed areas shall be sodded, or hydro-mulched with matching turf. Landscaping shall be replaced with identical shrubbery, ground cover, or plants as existed. Contractor shall be responsible for maintaining water on new turf and landscaping until established. If new turf and landscaping is impractical due to weather conditions, contractor shall provide satisfactory arrangements to have turf and landscaping furnished and installed at the earliest opportunity thereafter. Provide a 90-day warranty on new turf and landscaping. E. Determine if irrigation systems exist prior to trenching and excavation. Obtain record or as- built drawings and locate control wiring and pressure main branches and devices. Determine by actual operation that systems are functional and repair or replace damaged systems to their original condition prior to beginning construction. F. In cases where high voltage ductbanks may exist, Contractor shall employ safe drilling/excavating techniques such as vacuum excavation, etc. 3.05 LOCKING OF ELECTRICAL FACILITIES A. Install locks immediately upon the installation of the electrical facility. Provide padlocks for exterior electrical facilities subject to unauthorized entry. Furnish the Owner with two (2) keys per lock up to a quantity of 10 keys. Furnish locks to match the Owner's locking system. Common Work Results for Electrical 26 05 00 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.06 CLEAN AND ADJUST A. Remove shipping labels, dirt, paint, grease, and stains from equipment. Remove debris as it accumulates. Upon completion of work, clean electrical equipment and the entire electrical installation. END OF SECTION Electrical Demolition 26 05 10 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 10 ELECTRICAL DEMOLITION 1.00 GENERAL 1.01 GENERAL A. The work of this section includes furnishing of all labor, tools, materials, and equipment necessary to complete all the demolition required for the project as specified herein and shown on the drawings. B. Cooperation with the Owner is required, and the work described herein and shown on the drawings shall be coordinated as required to fulfill the intent of the contract. 1.02 INTENT A. It is the intent of this specification and accompanying drawings to describe and indicate the demolition work to be performed. It is not intended that the specifications and drawings describe and indicate every piece of equipment required to be removed for where items are intended to be removed or as required for the satisfactory completion of the project or is considered to be the accepted practice of the trade, they shall be considered to be specified and indicated. B. The contractor shall disconnect and remove all conduit, wire and related electrical items as indicated on the drawings, or as required by the project. This includes all abandoned medium voltage cable, low voltage power, instrumentation, signal and communication cables. C. The contractor shall seal floor, wall and ceiling openings with thermo setting fire resistive compound and non-shrink grout after removal of conduits. 1.03 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. 1.04 SCHEDULES A. Schedule with the Owner/Engineer for required shutdowns to accommodate system demolition and installation of temporary facilities. 1.05 STANDARDS A. Temporary wiring of systems to maintain operation of facilities while undergoing modifications and demolition shall be provided in accordance with: 1. American National Standards Institute / National Fire Protection Association (ANSI/NFPA), No. 70 – National Electrical Code (NEC), Article No. 590 – Temporary Wiring. 1.06 QUALITY ASSURANCE A. Verify field measurements and circuiting arrangements are as shown on the Drawings. Electrical Demolition 26 05 10 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Properly locate and mark all underground cable and conduit both inside and outside the pump station area. C. Verify that abandoned wiring and equipment serve only abandoned facilities. D. 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. E. 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. 2.00 PRODUCTS 2.01 MATERIALS AND EQUIPMENT A. Materials and equipment for patching and extending work: As specified in individual Sections. 2.02 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 and the requirements of the Owner. 3.00 EXECUTION 3.01 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. D. Existing Electrical Service: Maintain at least one service of existing system at all times. Disable system only to make switchovers and connections. Obtain permission from the Owner/Engineer at least two weeks in advance, before partially or completely disabling system. 3.02 DEMOLITION AND EXTENSION OF EXISTING ELECTRICAL WORK A. Prior to start of demolition, check to determine that power, communication services, etc., such as electricity and telephone, have been disconnected at the source of supply. B. Demolition shall be performed in such a manner as to avoid hazards to persons and property. Work shall be performed in strict accordance with all Municipal, State and Federal Rules, Regulations, Codes, and Laws which may govern and apply to this work. C. Remove, relocate and extend existing installations to accommodate new construction. D. Remove abandoned wiring to source of supply. Electrical Demolition 26 05 10 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements E. Remove exposed abandoned conduit, including abandoned conduit above accessible ceiling finishes. Cut conduit flush with walls and floors, patch surfaces and paint to match existing. F. 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. G. Disconnect and remove abandoned panelboards and distribution equipment. H. Disconnect and remove electrical devices and equipment that has been removed. I. Repair adjacent construction and finishes damaged during demolition and extension work. J. Maintain access to existing installations which remain active. Modify installation or provide access to panels as appropriate. K. 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. L. Extend existing installations using materials and methods as specified for new work. M. 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. N. Salvaged Equipment and Materials 1. The contractor shall be responsible for all damage to existing materials not affected by the demolition work. The contractor shall repair or replace damaged material or equipment as directed at no additional cost to the owner. Repairing, patching and painting of areas shall be done by the respective trade involved with the demolition, utilizing workmen skilled in the trade involved with the repair or replacement of the material in question. 2. All equipment, removed during demolition shall remain on the site, unless otherwise noted. The Owner reserves all rights to claiming material removed during demolition. The contractor is responsible to remove from the site all material not claimed by the Owner. In addition, the contractor is responsible to deliver to the Owner's storage facilities, equipment claimed by the Owner. 3. The Owner shall have the right to retain any or all electrical and instrumentation equipment shown or specified to be removed from the site. 4. 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. 5. Equipment and material designated by the Owner, as remaining the property of the Owner, shall be removed from the structure and hauled to a designated location on the site and stored for the Owner’s use. Store on wood runners raised above the surrounding grade and cover with weather resistant covering and tie securely or store inside Owner furnished storage as directed by the Owner/Engineer. Electrical Demolition 26 05 10 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 6. Take necessary precautions in removing Owner designated property to prevent damage during the demolition process. Remove steel structural members by unbolting, cutting welds, or cutting rivet heads and punching shanks through holes. Do not use a cutting torch to separate the Owner’s equipment or material unless approved by the Owner/Engineer. 7. 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. O. 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 and properly disposed of. P. 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. 3.03 CLEANING AND REPAIR A. Clean and repair existing materials and equipment which remain or are to be reused. B. Panelboards: Clean exposed surfaces and check tightness of electrical connections. Replace damaged circuit breakers and provide closure plates for vacant positions. Provide typed circuit directory showing revised circuiting arrangement. END OF SECTION Medium Voltage Cables 26 05 13- 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 13 MEDIUM VOLTAGE CABLES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install medium voltage cables. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.02 QUALITY ASSURANCE A. ACCEPTABLE MANUFACTURERS 1. Okonite 2. General Cable 3. Southwire 4. No equal 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Shop Drawings for: a. Medium Voltage Cables b. Connectors c. Stress Cones d. Load Break Elbows 2. Cable pulling tension calculations and dynamometer readings. Once cable is pulled, CONTRACTOR shall submit to the cable manufacturer the recorded pulling tensions for their approval. A letter from the cable manufacturer stating that the pulling tensions are acceptable shall be formally submitted to the Engineer for approval. 3. Manufacturer’s letter stating terminations are installed correctly. This letter shall be submitted to the ENGINEER for approval prior to the energization of the conductors. 4. Once cable is delivered to the site, Contractor shall provide as a formal submittal documentation/pictures showing when cable the manufactured. Cables shall be manufactured within on e year of installation. 5. Electrical Testing Report shall be submitted to the ENGINEER for approval a maximum of 4 weeks after the test has been performed. The Contactor shall not be allowed to wait for the final test to be performed to submit a single testing report. Individual test reports may be submitted to maintain the maximum of four weeks after test has been performed. Testing report shall include Hi-pot test results, Megger test results, and all testing identified in Section 3.02. Medium Voltage Cables 26 05 13- 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: IEEE 1202 Standard for Flame Test of Cables for use in Cable Tray in Insulated Commercial Occupancies U.L. 1685 Standard for Vertical-Tray Fire Propagation and Smoke- release Test for Electrical & Optical-Fire cables ICEA S-93-639 / NEMA WC74 Standard for Shielded Power Cables Rated 5-46kV for the Distribution of Electrical Energy UL 1072 Standard for Medium-Voltage Power Cables IEEE 48 Standard Test Procedures and Requirements for High- Voltage Alternating Current Cable Terminators AEIC CS8 Specification for Extended Dielectric, Shielded Power Cables Rated 5 through 46kV NEC National Electrical Code 1.05 DELIVERY AND STORAGE A. Deliver cable to the project on original reels with cable ends capped. 2.00 PRODUCTS 2.01 MATERIALS A. SINGLE CONDUCTOR CABLE: 1. Conductor: Annealed uncoated copper compressed stranded. The conductor shall be Class B compressed soft or annealed copper in accordance with ASTM specs B3 and B8 and ICEA Part 2, Section 2.1 and 2.5. Compact stranding not permitted. 2. Strand Screen: Extruded semiconducting EPR strand screen. Strand screen shall meet or exceed electrical and physical requirements of ICEA S-93-639/NEMA WC74 & S-97- 682, AEIC CS8, CSA C68.3 and UL 1072. 3. Insulation: 133% Meets or exceeds electrical and physical requirements of ICEA S-93- 639/NEMA WC74 & S-97-682, AEIC CS8, CSA C68.3 and UL 1072. 4. Insulation Screen: Extruded semiconducting EPR insulation screen. Insulation screen shall meet or exceed electrical and physical requirements of ICEA S-93-639/NEMA WC74 & S-97-682, AEIC CS8, CSA C68.3 and UL 1072. 5. Shield: 5 mil coated copper tape helically applied with 25% nominal overlap unless a concentric neutral conductor is called out. Concentric neutral cable shall be as manufactured by Southwire Primary UP EPR cable. Medium Voltage Cables 26 05 13- 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 6. Jacket: Meets or exceeds electrical and physical requirements of ICEA S-93-639/NEMA WC74 & S-97-682, AEIC CS8, CSA C68.3 and UL 1072. 7. Cable shall be UL Listed as Type MV-105, sunlight resistant and for use in cable tray in accordance with UL 1072 8. Cable shall be rated for 105°C continuous operating temperature, 140°C emergency rating temperature and 250°C short circuit rated temperature. 9. Cable shall pass U.L. and IEEE 383 and 1202 (1/0 AWG and larger) Vertical Flame Test. B. MULTI-CONDUCTOR METAL CLAD CABLE: 1. Conductors: Uncoated copper compact stranded per ASTM B-496. 2. Strand screen: Extruded semiconducting EPR strand screen meeting or exceeding electrical and physical requirements o ICEA S-93-639/NEMA WC74 and UL 1072. 3. Insulation: Meets or exceeds the electrical and physical requirements of ICEA S-93- 639/NEMA WC74 and UL 1072. The insulated conductors shall be tested in accordance with AEIC CS8. 4. Insulation Screen: Comprised of extruded semiconducting EPR insulation screen per ICEA S-93-639/NEMA WC74, AEIC CS8 and UL 1072. 5. Shield: 5 mil uncoated copper tape with 25% nominal overlap. 6. Sheath: Close fitting, impervious, continuous, corrugated aluminum C-L-X per UL 1072, and UL listing E-60545; C-L-X shall be recognized as a grounding conductor by NEC. 7. Jacket: Low temperature, sunlight resistant, yellow PVC jacket in accordance with UL 1072. 8. Ground: Annealed Class B stranding per ASTM B8. 9. Cable shall pass the vertical tray flame test requirements of IEEE 383 and 1202, UL 1072, ICEA T-29-520 (210,000 BTU/hr.). 10. Cable shall be UL Listed as Type MV-105, sunlight resistant and for use in cable tray in accordance with UL 1072 11. Cable shall be rated for 105°C continuous operating temperature, 140°C emergency rating temperature and 250°C short circuit rated temperature. 12. The continuous sheath shall provide grounding safety. C. STRESS CONES: The cable termination must have a voltage class rating that is equal to or greater than the cable being terminated. The rating shall be 5kV, 15kV or 25kV (as indicated) as an IEEE Class I termination for application. Non-skirted for indoor applications and skirted for outdoor applications. The terminations shall be installed with the application of heat. Stress cones shall be Raychem HVT, 3M or DSG Canusa. D. LOAD BREAK ELBOWS: 15kV. Rated for 105°C continuous operating temperature. The Contractor shall furnish 200 Amp load-break elbows (8.3 kV line-to-ground maximum) elbow terminators for each bushing in accordance with ANSI C119.2 and conforming to ANSI/IEEE Std. 386 and ANSI C119.2 with copper current carrying parts. The bushings shall be provided with removable copper studs. Elbows shall be manufactured with copper current carrying Medium Voltage Cables 26 05 13- 4 DTN18104 – Lake Lewisville WTP Phase II Improvements parts and shall be furnished for each bushing. Elbows shall be manufactured by Elastimold, Cooper Power Systems or approved equal. E. Connectors, compression, copper, medium voltage: of the appropriate hole sizes and spacing which are in accordance with NEMA Standards; two (2) holes in the tongue for use on all power conductors. All compression connectors shall be long-barrel type, no exceptions. NEMA 2-hole connectors shall be long barrel type requiring two crimp places 90 degrees apart. 3.00 EXECUTION 3.01 INSTALLATION A. Before any 5kV or 15kV installations are made, the CONTRACTOR shall have Raychem, DSG Canusa or 3M provide installation-training class, on site, to train all personnel in the proper technique of installing stress cones. All personnel involved in the installation of stress cones shall be Raychem, 3M, or DSG Canusa certified. Personnel involved in the installation of stress cones shall have a minimum of five years making 5kV and 15kV installations. A manufacturer’s trained representative shall inspect terminations prior to energization of the conductors. Any terminations deemed to be incorrectly installed shall be replaced at no cost to the OWNER. Provide in writing as a formal submittal a letter from the manufacturer’s trained representative that the terminations are correctly installed. Terminations applied before training is completed shall be removed and replaced at expense of the CONTRACTOR. If termination replacement causes the cable to be too short, then the cable shall be remove and replaced at the expense of the CONTRACTOR. B. The cable shall not be bent to a radius no smaller than the manufacturer cable’s minimum bending radius. Minimum radius shall be twelve (12) times the overall cable outside diameter. Cable bent with a diameter of less than twelve times the overall cable outside diameter shall be remove, discarded, replaced, reinstalled and re-terminated at the Contractor’s expense. Once cable is over bent, it shall not be reused in any manner. C. Pull all conductors into a raceway at the same time using U.L. listed wire pulling lubricant. D. When inserting conductors in raceways, comply with the following: 1. First, install raceways as a complete raceway system without conductors. 2. Do not install pull wires and conductors until the raceway system is in place. 3. Do not use cleaning agents and lubricants which have a deleterious effect on the conductors. 4. Completely and thoroughly swab raceway system before installing conductors. E. Pulling tension calculations are required for all cable pulls that are too long to be done by hand. All cable pulls done with measuring the pulling tension (dynamometer) shall have a resettable maximum tension recorder. Any pulls done without approved calculations or done without a specified pulling tension meter will be rejected. The cables shall be removed, discarded, replaced, reinstalled, and re-terminated at the Contractor’s expense. F. All cable pulls shall be done using cable reels. No cables shall be laid on the ground for installation. Cables laid on the ground will be rejected. The cables shall be removed, discarded, replaced, reinstalled, and re-terminated at the Contractor’s expense. Medium Voltage Cables 26 05 13- 5 DTN18104 – Lake Lewisville WTP Phase II Improvements G. Do not pull cables using Kellum-grip type supports. H. Splicing shall not be permitted. I. Identify each circuit with non-ferrous metal or fiber tags in manholes and junction boxes and at terminations. J. Waste certain footage (3’- 6’) of cable at each end to get a good piece of cable after the pull. Verify with cable manufacturer for exact distance to waste. K. Cable terminations shall have a voltage rating of not less than the phase to phase voltage of the system. L. Remove and replace conductors with insulation showing deterioration within one (1) year after final completion and acceptance of the work and at no cost to the OWNER. M. Megger test conductors to verify circuit N. Cables shall be tested per IEEE Standard 400.2 Very Low Frequency (VLF). Utilize test voltages per IEEE 400.2. Testing of multiple cables together is not acceptable. O. Perform Tan-Delta testing per IEEE400.2. Utilize test voltages per IEEE 400.2. Perform test of each phase conductor of each cable tag identified on the one-line diagram. Perform tan- delta testing shall be performed on each cable tag identified on the one-line diagram. Testing of multiple cables together is not acceptable. P. VLF test cables and document test results for each cable reel delivered to the jobsite upon offloading at the jobsite. Record all readings and submit to the Owner, Engineer and cable manufacture. Test results shall be confirmed by the cable manufacturer prior to installing the cable. Cables not passing test shall be shipped back and replaced at no cost to the OWNER. Q. Once installed, VLF test and Tan-Delta test cables and record all readings and submit to the OWNER. R. VLF Withstanding testing of cables shall be tested in accordance with IEEE 400.2 and testing duration shall be for 60 minutes and be conducted at a frequency of 0.1Hz using a sinusoidal waveform. S. Tan-Delta testing shall be tested in accordance with IEEE 400.2 and tested at a minimum of four test voltages. T. Provide terminal connectors with the hole sizes and spacing in accordance with NEMA standards. Terminal connectors shall be rated for MV-105 cable. Provide terminal connectors with two (2) holes and torque for use on conductor sizes #2 or up to 1000 kcmil size lettering or larger. Conductors shall be torqued down per the manufacturer’s settings and instructions. Mechanical lugs shall not be used. Terminal connectors shall be compression type. U. Soldered connections shall not be allowed. V. Medium voltage cable shall be fireproofed in all manholes and handholes. Fireproofing shall be done with a half-lapped layer of 3M “Scotch 77 Fire and Electric Arc Proofing Tape”, anchored at each end with a double wrap of 3M “Scotch 69 Glass Cloth Electrical Tape”. Entire cable in manholes and handholes shall be wrapped with the 3M Scotch Glass Cloth Electrical Tape per instructions listed above in this paragraph. Medium Voltage Cables 26 05 13- 6 DTN18104 – Lake Lewisville WTP Phase II Improvements W. Provide stress-relief cones at the terminals of shielded cables except where load break/dead break elbows are required. See one-line diagram in electrical plans for cable sizes. X. Cable with a manufacture date of greater than twelve (12) months previous of being installed will not be acceptable. If cable is older than 12 months and is installed then Contractor shall replace and install new cable at no cost the Owner. 3.02 TESTING A. Testing: All testing required shall be per Specification 26 01 26, “Testing of Electrical Systems”. B. Perform tests and inspections and prepare test reports. Test reports shall be submitted as required by Specification Section 26 01 26, “Testing of Electrical Systems”. All test reports shall be submitted in one binder under Specification Section 26 01 26, “Testing of Electrical Systems”. C. OWNER’S INSPECTOR SHALL WITNESS ALL TESTING. CABLES TESTED THAT ARE NOT WITNESSED BY THE OWNER WILL NOT BE ACCEPTED. CONTRACTOR SHALL PROVIDE A MINIMUM OF TWO WEEKS’ NOTICE TO THE OWNER WHEN THE TESTING WILL BE CONDUCTED. D. NO PAYMENT FOR CABLES SHALL BE MADE UNTIL TESTING IS COMPLETED AND ACCEPTED. NO PAYMENT SHALL BE MADE FOR ANY CABLES THAT ARE PULLED IN BY MACHINE FOR WHICH NO PULLING TENSION MEASUREMENTS ARE MADE AND SUBMITTED AS SPECIFIED. E. Tests and Inspections: 1. After installing conductors and cables and before electrical circuitry has been energized, test 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 60 days after Final Acceptance, perform an infrared scan of each cable and conductors No. 3 AWG and larger. Remove box and equipment covers so terminations are accessible to portable scanner. a. Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of each termination 11 months after date of Substantial Completion. b. Instrument: Use an infrared scanning device designed to measure temperature or to detect significant deviations from normal values. Provide calibration record for device. c. 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. 4. Test Reports: Prepare a written report to record the following: a. Test procedures used. b. Test results that comply with requirements. Medium Voltage Cables 26 05 13- 7 DTN18104 – Lake Lewisville WTP Phase II Improvements c. Test results that do not comply with requirements and corrective action taken to achieve compliance with requirements. 5. Remove and replace malfunctioning units and retest as specified above. END OF SECTION Low Voltage Electrical Conductors & Cables 26 05 19-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 19 LOW VOLTAGE ELECTRICAL CONDUCTORS & CABLES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install and test 600 volt wires and cables. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. B. Work shall include building wire, cable, wiring connections and terminations, and modular wiring systems. 1.02 QUALITY ASSURANCE: TESTING A. Megger test circuits for continuity and ground. Verify phasing at connection points. Torque test conductor connections and terminations to the Manufacturer's recommended values. Megger tests shall be performed by a testing company with a minimum of 10 years’ experience. All low voltage cables shall be verified by use of telephone communications. 1.03 SUBMITTAL PROCEDURES A. Submittal Procedures shall be in accordance with Section 01 30 00, “Submittal Procedures” and shall include: 1. Shop Drawings: a. Low voltage wire b. Ground wire c. Shielded cable d. Terminations and Connections 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: ICEA S-19-81/NEMA WC-3 Rubber-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy ICEA S-61-402/NEMA WC-5 Thermoplastic-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy NFPA 70 National Electrical Code ANSI/TIA/EIA 606A Standard for Telecommunications Infrastructure UL 83 Thermoplastic Insulated Wires and Cables UL 1063 Machine Tool Wires and Cables ASTM B3 Soft or Annealed Copper Wires Low Voltage Electrical Conductors & Cables 26 05 19-2 DTN18104 – Lake Lewisville WTP Phase II Improvements ASTM B8 Concentric-Lay-Stranded Copper Conductors, Hard, Medium, Hard, Soft 1.05 DELIVERY AND STORAGE A. Deliver cable and wire to the project site in the original packages. Conductors with damaged insulation or exposed nylon jacketing shall not be permitted. B. Where cut lengths are specified, mark reel footage accordingly. Each reel shall contain one continuous length of cable. C. Check for reels not completely restrained, reels with interlocking flanges or broken flanges, damaged reel covering or any other indication of damage. Provide impact protection by wood lagging or suitable barrier across the traverse of the reel. D. Do not drop reels from any height. E. Unload reels using a sling and spreader bar. Roll reels in the direction of the arrows shown on the reel and on surfaces free of obstructions that could damage the wire and cable. F. Store cable on a solid, well drained location. Cover cable reels with plastic sheeting or tarpaulin. Do not lay reels flat. G. Provide moisture protection by using manufacturer’s standard procedure or heat shrinkable self-healing end caps applied to both ends of cable. Do not remove end caps until cables are ready to be terminated. 2.00 PRODUCTS 2.01 GENERAL A. Wires and cables shall be soft-drawn, annealed copper with a conductivity of not less than that of 98% pure copper, UL83 and UL1063 listed, rated 600 volts and certified for continuous operation at maximum conductor temperature of 90 Celsius in dry locations and in wet locations B. Conductors #8 or larger shall be stranded and conductors #14 shall be stranded. Utilize single conductors. C. Except for control, signal and instrumentation circuits and as specifically indicated on the plans the minimum conductor permitted is #12. 2.02 WIRE MARKING 1. Wire marking shall be in accordance with the National Electrical Code Article 310 and shall be printed on the wire insulation at 2 foot intervals. The printing method used shall be permanent and the color shall sharply contrast with the jacket color. 2. Wire marking shall include the U.L. label and necessary identification, including the Manufacturer, the number of conductors, size, conductor insulation type, sun- resistance, and other pertinent information. Low Voltage Electrical Conductors & Cables 26 05 19-3 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.03 CONDUCTORS AND CABLES A. SINGLE CONDUCTOR CABLES: Conductor with thermoplastic insulation rated at 600 volts and insulated with type XHHW-2 insulation. Wire shall be water tank tested and approved as machine tool wire, in accordance with National Machine Tool Builders Association. Wire in light fixture channels and other special locations shall be as specifically noted for temperature in NEC Article 300. Conductors #8 or larger and conductors #14 shall be stranded. Wire shall be manufactured by Southwire, Okonite, Encore, or General Cable. B. MULTI-CONDUCTOR CABLES: Type TC; multi-conductor cable specifically approved for the installation of cable trays, in accordance with NEC Article 340. Each cable conductor shall be insulated with XHHW-2 type insulation rated at 600 volts. The individual conductors shall be twisted together and jacketed with a PVC outer covering. Cables shall be 600 volts in accordance with NEC-725 and IEEE 383 and shall be suitable for wet location. Cable shall be as manufactured by Southwire, Okonite Okoseal-N, or General Cable. C. GROUND WIRE: Ground wire shall be Class B stranded tin-plated conductor without insulation in all cases where a single ground wire is indicated to be installed in a conduit with no other conductors in the conduit, or where the ground wire is directly buried in earth or concrete. In all other cases, insulate ground wire with green insulator as specified for low voltage wire. D. PAIRED SHIELDED CABLE: Individually and overall shielded 18 gauge, 7/28 stranded, tinned copper conductors with .021" extruded PVC; .004" nylon insulation twisted into pairs, stranded into a core and enclosed by a non-hygroscopic core tape, 100% coverage, helically wound, aluminum foil shield, drain wire, and .050" minimum extruded PVC jacket. Pairs shall be black/red or black/white numbered. Cables shall be 600 volts in accordance with NEC-725 and IEEE 383 and shall be suitable for wet location and cable tray rated. Cables shall be manufactured by Alpha, Okonite, General Cable, Southwire, or Belden E. TRIAD SHIELDED CABLE (RTD CABLE): RTD cable shall have the following characteristics: 1. Eight (8) or as indicated on the plans, with three (3) 18 AWG conductors. 2. Triads shall each have individual shield and overall shield. 3. Each conductor insulated for 600V and entire cable rated for 90 Celsius in dry locations and 75 Celsius in wet locations. a. Primary Insulation: 15 mils nominal; PVC; 4 mils nylon b. Number of Conductors: 3 c. Color Code: Black and white and red d. Group Identification: Each triad numbered e. Pair Shield: 100% coverage; .35 mil aluminum x .5 mil Mylar tape and 20 gauge 7 strand tinned copper drain wire; shield tape to be applied to give a total shield isolation from all other triad shields. f. Cable Shield: 100% coverage; 2.35 mil aluminum Mylar tape shield and an 18 gauge 7 strand tinned copper drain wire. g. Jacket: Black 90 Celsius FR PVC Low Voltage Electrical Conductors & Cables 26 05 19-4 DTN18104 – Lake Lewisville WTP Phase II Improvements 4. RTD cable shall be as manufactured by General Cable, Okonite or Belden. 2.04 WIRE CONNECTIONS AND DEVICES A. CONNECTORS, COMPRESSION, COPPER, 600 VOLT: As manufactured by Burndy, Thomas & Betts, or Ideal Industries; of the appropriate hole sizes and spacing which are in accordance with NEMA standards; two (2) holes in the tongue for use on conductor sizes 250 kcmil or larger; not required for connections to the circuit breakers in the lighting and/or receptacle panels. All compression connectors shall be long-barrel type, no exceptions. B. 600 VOLT PLASTIC TAPE: Minnesota Mining & Manufacturing Company (3M), No. 35. C. WIRENUTS: Silicone-based pre-filled spring wire connecting devices with plastic covering; UL listed for damp and wet locations. Wirenut shall meet requirements of UL 486D for Sealed Wire Connector Systems and shall be manufactured by Ideal Industries, Inc model 63, or as manufactured by ITT or Panduit. Wirenut shall be spring insulated, properly sized and resistant to vibration may be used for No.12 through No.10 solid gauge conductor for lighting and branch circuits only. D. SPLIT BOLTS: Kearney, Burndy, or Ilsco; shall be usable for connecting conductors which are both copper, both aluminum or one copper and one aluminum. Split bolts shall have a spacer between the two conductors, which it connects. E. MECHANICAL SET SCREW CONNECTOR: Blackburn HPS, ADR-ALCUL, GP or GT, Burndy or Ilsco; consisting of an aluminum body which has openings on opposite ends for insertion of the conductors. Conductors inserted into these holes shall each be clamped by two set screws. Connectors shall be suitable for use with copper conductors. F. RUBBER TAPE: Scotch 2210. G. VINYL TAPE: Scotch 88. H. ARC PROOFING TAPE: 3M “Scotch 77 Fire and Electric Arc Proofing Tape”. Fireproofing shall be done with a half-lapped layer of arc proofing tape, anchored at each end with a double wrap of 3M “Scotch 69 Glass Cloth Electrical Tape”. I. INSULATING RESIN: Scotch 3576, 3577, or 3578. J. POWER DISTRIBUTION BLOCKS: Mersen, Ilsco or Allen-Bradley; rated for 600 VAC and termination of copper conductors. Individual poles shall be constructed of tin plated aluminum and mounted on an insulating base. 3.00 EXECUTION 3.01 PREPARATION A. Completely swab raceway system before installing conductors. Do not use cleaning agents and lubricants which have a deleterious effect on the conductors or their insulation. Low Voltage Electrical Conductors & Cables 26 05 19-5 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.02 INSTALLATION A. GENERAL 1. Install raceway first as a complete system without conductors. Do not install pull wires and conductors until the raceway system is in place in accordance with the NEC and these specifications. Exception: Only flexible connections to motors shall be permitted to be installed after the installation of the remainder of the raceway system. The installation of these conductors shall be limited to exposure to damage for a maximum of one (1) week prior to installing flexible connection and making final terminations. Any conductors exposed to damage (i.e. not installed in raceway) longer than one (1) week shall be subject to rejection by the Owner and/or Engineer. If rejected, the cables shall be removed, discarded, replaced, reinstalled and retermination at the Contractor’s expense. 2. Installed unapproved wire shall be removed and replaced at the Contractor’s expense. 3. Grouping conductors together into one conduit shall not be allowed where the plans indicate the conductors to be placed in separate conduits. Each home run shown on the plans shall be in its own conduit. 4. Neatly train wiring inside boxes, equipment and panelboards. Pull conductors into a raceway at the same time and use U.L. listed, wire pulling lubricant for pulling No. 4 AWG and larger wire. 5. Except for hand-pulled conductors into raceways, all wire and cable installation shall be installed with tension-monitoring equipment. Where conductors are found to have been installed without tension-monitoring, the conductors and cables shall be immediately removed from the raceways, permanently identified as rejected material, and removed from the jobsite. New conductors and cables shall be reinstalled, tagged and raceways resealed, all at the Contractor’s expense. 6. Do not exceed cable manufacturer’s recommendations for maximum pulling tensions and minimum bending radii. Where pulling compound is used, use only UL listed compound compatible with the cable outer jacket and with the raceway involved. 7. All wire and cable installed in cable trays shall be UL Listed as Type TC, for cable tray use. 8. Where single conductors and cables in manholes, hand holes, vaults, cable trays, and other indicated locations are not wrapped together by some other means such as arc and fireproofing tapes, bundle throughout their exposed length all conductors entering from each conduit with nylon, self-locking, releasable, cable ties placed at intervals not exceeding 4 inches on center. 9. Properly support cables in accordance with the NEC and manufacturer’s recommendations in all raceways. Provide strain relief as required. 10. Arrange wiring in cabinets and panels neatly cut to proper length, remove surplus wire, and bundle and secure in an acceptable manner. Identify all circuits entering motor control centers or other control cabinets in accordance with the conductor identification system specified herein and in specification Section 26 05 53, “Identification For Electrical Systems.” 11. Cap spare conductors and conductors not terminated, with the UL listed end caps. Low Voltage Electrical Conductors & Cables 26 05 19-6 DTN18104 – Lake Lewisville WTP Phase II Improvements 12. Where conductors pass through holes or over edges in sheet metal, remove all burrs, chamfer all edges, and install bushings and protective strips of insulating material to protect the conductors. 13. For conductors that will be connected by others, provide at least 6 feet spare conductors in free standing panels and at least 2 feet spare in other assemblies. Provide additional spare conductor in any particular assembly where it is obvious that more conductor will be needed to reach the termination point. 14. Each circuit shall include a ground wire. Sharing grounds or neutrals is not allowed. B. SPLICES 1. Power Conductors: Splice in junction boxes or at outlets only for lighting and receptacle branch circuits. Splices for all other circuits shall be disallowed. All splices are subject to the Engineer’s approval. Obtain approval from Engineer before installing any splices. a. For existing installations, splices of 120V circuits shall use twist-on wire nuts. b. For splices of existing 480V circuits, the Contractor shall terminate the existing and new conductors using power distribution blocks mounted in a junction box. 2. Control and Instrumentation Conductors: No splicing of control and instrumentation conductors shall be permitted between terminal points except as specifically indicated on the plans. 3. No splicing of conductors shall be performed in any below ground structure. 4. Condulet type fittings shall not contain splices. Under no condition shall conductors of a different color be spliced together. 5. For No. 10 and smaller, connect conductors with a twist-on spring wirenut. If a splice or tap is below 3' above the final grade, fill the spring connectors with an electrical insulating resin so that the resin encapsulates conductor and spring materials. Conductor splices and taps inside the MCC, VFDs, panels, etc. shall be on the terminal strips or power distribution blocks. 6. For No. 8 and larger, connect conductors with a split bolt type of connector or a mechanical, set screw type connector. Wrap splices and taps with a single half-lapped layer or rubber tape followed by successive layers of vinyl tape until a vinyl tape layer thickness of twice the original conductor insulation thickness is achieved. If splice or tap is below 3' above the finished grade, the tape or splice shall have a final outer coating or insulating resin. C. TERMINATIONS 1. Conductors terminated on a screw termination shall have a crimp on type spade connector applied on the wire end, Panduit PanTerm or approved equal. 2. Furnish and install power distribution blocks as required for tapping conductors at their load connection point with conductors of smaller size. Install power distribution blocks with the number of poles and sizes needed for connecting the phase, neutral, and ground conductors. 3. Tighten all screws and terminal bolts using torque type wrenches and/or drivers to tighten to the inch-pound requirements of the NEC and UL. Low Voltage Electrical Conductors & Cables 26 05 19-7 DTN18104 – Lake Lewisville WTP Phase II Improvements 4. Use crimp connectors on all stranded conductors. 5. Soldered mechanical joints insulated with tape will not be acceptable. 6. SINGLE CONDUCTORS: Sufficient wire shall be left at outlets to make connections to equipment without straining. Light switches and receptacles shall be connected with pig-tails and crimp-on connectors. 7. PAIRED SHIELDED AND TRIAD SHIELDED CABLE: Ground paired shielded and triad shielded cables at the instrument panel or starter end only and insulate from ground elsewhere. The shield shall be continuous for the entire run. The paired shielded and triad shielded cable shall not be laced with or placed in the same conduit with power cables and digital control cables. Each termination of paired shielded or triad shielded cable shall be coated with silicone jelly after termination. The shield of pair shielded cable and triad shielded cable shall only be broken when the conductors are terminated on terminal strips. Each conductor and shield shall be landed on its own terminal. Sharing of shield shall not be allowed. D. GROUNDING 1. Conduits and other raceway shall contain an equipment grounding conductor whether the raceway is metallic or not. Conduits, motors, cabinets, outlets, and other equipment shall be properly grounded in accordance with National Electrical Code requirements. Where ground wire is exposed to mechanical damage, install wire in rigid aluminum conduit. Make connections to equipment with solderless connections. All connections to ground rods shall be of the fused type utilizing an exothermic welding process. 2. Ground metallic material, including but not limited to metallic raceway, metallic boxes and metallic enclosures. Where metallic material is not connected by raceway to a solid ground, connect the metallic material to the largest equipment grounding conductor, which it houses. Clean the metal surface under the grounding lug to bright metal. Grounding connections to motors shall be to the grounding stud, which shall be threaded into the stationary frame; Use Burndy KC Servit, or approved equal. The ground wire shall not be lugged to a mounting bolt. 3. Ground wire shall be uninsulated tin plated copper sized as shown on the plans in all cases where a single ground wire is indicated to be installed in a conduit with no other conductors in the conduit, or where the ground wire is directly buried in earth or concrete. In all other cases, insulate ground wire with green insulation as specified for low voltage wire. Provide and size bonding conductors in accordance with the National Electrical Code. 4. Provide a bare uninsulated ground wire to run the entire length of all cable trays. The contractor shall bond to each section and to every enclosure served by conductors routed through the cable tray system E. TESTING 1. Testing: All testing required shall be per Specification Section 26 01 26, “Testing of Electrical Systems”. Low Voltage Electrical Conductors & Cables 26 05 19-8 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Perform tests and inspections and prepare test reports and submit to the Owner/Engineer prior to final inspection. Test reports shall be submitted as required by Specification Section 26 01 26, “Testing of Electrical Systems”. All test reports shall be submitted in one binder under Specification Section 26 01 26, “Testing of Electrical Systems”. 3. Tests and Inspections: a. After installing conductors and cables and before electrical circuitry has been energized, test for compliance with requirements. b. Perform each visual and mechanical inspection and electrical tests stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. c. Test Reports: Prepare a written report to record the following: 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 Grounding and Bonding for Electrical Systems 26 05 26 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 26 GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install a complete grounding system in strict accordance with Article 250 of the National Electrical Code (NEC) as shown on the drawings or as specified herein. Electrical work shall be in accordance with Section 26 05 00, COMMON WORK RESULTS FOR ELECTRICAL. 1.02 SUMMARY A. Submittal shall be in accordance with Section 01 33 00, SUBMITTAL PROCEDURES and shall include: 1. Product Data: For each type of product indicated. 2. Test wells. 3. Ground rods. 4. Ground Conductors 5. Connectors 6. Grounding arrangements and connections for separately derived systems. 7. Field quality-control reports in accordance with Section 26 01 26 TESTING OF ELECTRICAL SYSTEMS. 1.03 QUALITY ASSURANCE A. Testing Agency Qualifications: An independent agency, with the experience and capability to conduct the testing indicated, that is a member company of the InterNational Electrical Testing Association or is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29 CFR 1910.7, and that is acceptable to authorities having jurisdiction. 1. Testing Agency's Field Supervisor: Person currently certified by the InterNational Electrical Testing Association to supervise on-site testing specified in Part 3. B. 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. C. Comply with UL 467 for grounding and bonding materials and equipment. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Burndy; Part of Hubbell Electrical Systems. 2. ERICO International Corporation. Grounding and Bonding for Electrical Systems 26 05 26 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Harger Lightning & Grounding. 4. ILSCO. 5. O-Z/Gedney; a brand of Emerson Industrial Automation. 6. Thomas & Betts Corporation, A Member of the ABB Group. 2.02 CONDUCTORS A. Insulated Conductors: tinned-copper wire or cable insulated for 600 V unless otherwise required by applicable Code or authorities having jurisdiction. B. Tin-plated Bare Copper Conductors: 1. Solid Conductors: ASTM B 3. 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 inch 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 inch thick. 7. Tinned Bonding Jumper: Tinned-copper tape, braided conductors terminated with copper ferrules; 1-5/8 inches wide and 1/16 inch thick. 2.03 CONNECTORS A. Listed and labeled by a Nationally Recognized Testing Laboratory (NRTL) 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. C. Welded Connectors: Exothermic-welding kits of types recommended by kit manufacturer for materials being joined and installation conditions. D. Bus-Bar Connectors: Mechanical type, cast silicon bronze, solderless compression-type wire terminals, and long-barrel, two-bolt connection to ground bus bar. 2.04 GROUNDING ELECTRODES A. Ground Rods: 316 copper-clad steel; 3/4 inch by 10 feet. B. Chemical-Enhanced Grounding Electrodes: Copper tube, straight or L-shaped, charged with nonhazardous electrolytic chemical salts. 1. Termination: Factory-attached No. 4/0 AWG bare conductor at least 48 inches long. 2. Backfill Material: Electrode manufacturer's recommended material. Grounding and Bonding for Electrical Systems 26 05 26 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements C. Ground Plate Electrodes: 1/4” thick, 2’-0” wide x 2’-0” long serrated copper plate with #4/0 tinned copper conductor terminated ten (10) foot welded pigtail connection, ALT Fabrication Item #3280-40 or equal. 2.05 MISCELLANEOUS A. CONDUIT GROUND FITTINGS: Fittings for bonding ground cable to the conduit shall be FCI Burndy Corp., type NE or Thomas & Betts No. 3951 series. B. GROUND ROD BOXES: Precast Box with cast iron lid. Lid shall read “ground rod”. H-10 rated boxes shall be Brooks Precast Model “3-RT” or approved equal. Ground rod boxes located in driveway areas shall have an AASHO HS-20 rating by ALT Fabrication Item #3114 or approved equal. C. EXOTHERMIC WELDING PROCESS: CADWELD MATERIALS – as manufactured by ERICO products or approved equal. 2.06 PROCESSES A. All grounding system connections to building steel and ground rods shall be exothermically welded including all cable connections, and cable steel terminations. The use of mechanical type connections is not acceptable. B. Any concealed connection (buried, encased in concrete or otherwise sealed) shall be done only with exothermic welds. C. All materials involved must be from the same sources to insure compatibility. Connections made from this process shall meet the requirements of IEEE Standards 80 and 837 and as listed in MIL 419 and other standards, National Electrical Code, etc. 2.07 GROUNDING SYSTEM A. Provide a complete grounding system that includes all connections and the testing of ground rods, ground cables, ground buses, conduits, fittings, anchor supports, thermite process materials and equipment and other materials required for a complete installation. Grounding system shall be installed and sized in accordance with the National Electrical Code. 3.00 EXECUTION 3.01 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 tin-plated copper conductor, No. 4/0 AWG minimum. 1. Bury at least 30 inches below grade. 2. Duct-Bank Grounding Conductor: Place conductor on top of duct bank prior to back filling above duct bank when indicated as part of duct-bank installation. Grounding and Bonding for Electrical Systems 26 05 26 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 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 equipment rooms, in rooms housing service equipment, and elsewhere as indicated. 1. Install bus horizontally, on insulated spacers 2 inches 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, and down; connect to horizontal bus. E. Conductor Terminations and Connections: 1. Pipe and Equipment Grounding Conductor Terminations: Bolted/clamp type connectors. 2. Underground Connections: Exothermically welded connectors. 3. Connections to Ground Rods at Test Wells: Exothermically welded connectors. 4. Connections to Structural Steel: Exothermically welded connectors. 5. Connections to Equipment: NEMA ground pads and insulated jumpers. 6. Connections to Ground Pad: Exothermic. 7. The use of “pig tails” for connections to ground loops or equipment shall not be allowed. 3.02 GROUNDING AT THE SERVICE A. Equipment grounding conductors and grounding electrode conductors shall be connected to the ground bus. Install a main bonding jumper between the neutral and ground buses. 3.03 GROUNDING UNDERGROUND DISTRIBUTION SYSTEM COMPONENTS A. Comply with IEEE C2 and NFPA 70 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. 1/0 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, non-shrink 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 conductor. Train conductors level or plumb around corners and fasten to manhole walls. Connect to cable armor and cable shields according to written instructions 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 Grounding and Bonding for Electrical Systems 26 05 26 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements with substations by connecting them to underground cable and grounding electrodes. Install tinned-copper conductor not less than No. 2 AWG for ground ring and for taps to equipment grounding terminals. Bury ground ring not less than 6 inches from the foundation. 3.04 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. Air-Duct Equipment Circuits: Install insulated equipment grounding conductor to duct- mounted electrical devices operating at 120 V and more, including air cleaners, heaters, dampers, humidifiers, and other duct electrical equipment. Bond conductor to each unit and to air duct and connected metallic piping. D. 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. E. 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. F. 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. G. Signal and Communication Equipment: For telephone, alarm, voice and data, and other communication equipment, provide No. 4 AWG minimum insulated grounding conductor in Grounding and Bonding for Electrical Systems 26 05 26 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements 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 1/4-by-2-by-12-inch grounding bus. H. Terminal Cabinets: Terminate grounding conductor on cabinet grounding terminal. I. 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. J. Metallic Fences: Comply with requirements of IEEE C2. 1. Grounding Conductor: Bare, tin-plated copper, not less than No. 8 AWG. 2. Gates: Shall be bonded to the grounding conductor with a flexible bonding jumper. 3. Barbed Wire: Strands shall be bonded to the grounding conductor. 3.05 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. Ground Bonding Common 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 6 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. 2. For grounding electrode system, install at least three rods spaced at least one-rod length from each other and located at least the same distance from other grounding electrodes, and connect to the service grounding electrode conductor. D. Test Wells: Ground rod driven through bottom of Ground Rod Box. Ground Rod Box 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. Grounding and Bonding for Electrical Systems 26 05 26 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Bonding to Equipment Mounted on Vibration Isolation Hangers and Supports: Install bonding so vibration is not transmitted to rigidly mounted equipment. 3. Use exothermic-welded connectors for outdoor locations; if a disconnect-type connection is required, use a bolted clamp. F. Grounding and Bonding for Piping: 1. Metal Water Service Pipe: Install insulated tin-plated 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; use a bolted clamp connector or bolt a lug-type connector to a pipe flange by 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. Concrete-Encased Grounding Electrode (Ufer Ground): Fabricate according to NFPA 70; using electrically conductive coated steel reinforcing bars or rods, at least 20 feet long. If reinforcing is in multiple pieces, connect together by the usual steel tie wires or exothermic welding to create the required length. 1. Bond grounding conductor to reinforcing steel in at least four locations and to anchor bolts. Extend grounding conductor below grade and connect to building's grounding grid or to grounding electrode external to concrete. J. Ground electrical work in accordance with the National Electrical Code Article 250 and local codes. K. Install ground cables continuously between connections. Splices shall not be permitted, except where indicated on the plans. Where ground cables pass through floor slabs. buildings, etc., and when not in metallic enclosures, provide a sleeve of approved, non- metallic materials. L. Install a green-colored, equipment grounding conductor in raceways. Size conductors in accordance with NEC Article 250. M. Where ground wire is directly buried in earth or concrete, use standard bare-tinned copper cable, in all other cases install a green-colored insulation, equipment grounding conductor in accordance with Section 26 05 19 LOW VOLTAGE ELECTRICAL POWER CONDUCTORS & CABLES. Size conductors in accordance with NEC Article 250. Provide grounding conductors as required per the NEC. Grounding and Bonding for Electrical Systems 26 05 26 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements N. Metal conduits stubbed up into switchgear, motor control center or other electrical equipment shall be terminated with insulated grounding bushings and connected to the equipment ground bus. Size the grounding wire in accordance with applicable sections of the National Electrical Code. O. Provide exothermic weld connection for extension to existing stub-up ground conductors. P. Liquid tight flexible metal conduit in sizes 1-1/2” or larger shall have bonding jumpers. Bonding jumpers shall be external, run in parallel (not spiraled) and fastened with plastic tie wraps. Contractor shall provide bonding jumpers sized in accordance with the National Electrical Code. Q. All equipment enclosures, motor and transformer frames, conduit systems, cable armor, exposed structural steel and all other equipment and materials required by the NEC to be grounded, shall be grounded and bonded in accordance with the NEC. Provide grounding and bonding jumpers as required per the NEC. R. Ground transformer neutrals to the nearest available grounding electrode with a conductor sized in accordance with NEC Article 250. S. Run a grounding cable the full length of each cable tray section and bond to each cable tray section. Provide #4/0 bare tin plated copper in cable tray. T. Where exothermic bonding is used, molds shall be of the appropriate size for the wire and rod used. All bonds shall remain exposed for inspection of the Owner’s Representative. U. At each convenience outlet, install a grounding clip attached to the outlet box and leave a sufficient length of #12 wire with green-colored insulation to connect to the grounding terminal at the receptacle. V. Ground pad shall be installed in concrete foundations or pad for connections to equipment and grounding system. Flat plate all copper alloy Erico CADWELD B164-2Q or equal Ground pad shall be exothermic weld connection for connection to ground cable. 1. Transformer Pads: Provide a ground pad in the concrete pad. Provide a #4/0 bare copper to the grounding system. Provide two hole spade terminals connected to a #4/0 bare copper conductor at each end and connect to the transformer enclosure and to the ground pad. 2. Motor Grounding: Provide a ground pad in the concrete slab. Provide a #4/0 bare copper to the grounding system. Provide two hole spade terminals connected to a #4/0 bare copper conductor at each end and connect to the motor enclosure and to the ground pad and to the pump frame. 3. The use of “pig tails” for connections to ground loops or equipment shall not be allowed. W. Provide a minimum of two ground connections to all medium voltage equipment including switchgear, motor control centers, VFD’s and transformer frames and to all 480V switchboards. 3.06 FIELD QUALITY CONTROL A. Testing Agency: Engage a qualified testing agency to perform tests and inspections. Testing shall be in accordance with Section 26 01 26 TESTING OF ELECTRICAL SYSTEMS. Grounding and Bonding for Electrical Systems 26 05 26 - 9 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Tests and Inspections: 1. After installing grounding system but before permanent electrical circuits have been energized, test for compliance with requirements. 2. Inspect the grounding and bonding system conductors and connections for tightness and proper installation. 3. Inspect physical and mechanical condition. Verify tightness of accessible, bolted, electrical connections with a calibrated torque wrench according to manufacturer's written instructions. 4. Use Biddle Direct Reading Earth Resistance Tester or equivalent to measure resistance to ground of the system. Perform testing in accordance with the test instrument manufacturer’s recommendation using the fall of potential method. 5. All test equipment provided under this section shall be approved by the ENGINEER. 6. Resistance to ground testing shall be performed during dry season. Submit test results in the form of a graph showing the number of points measured (12 minimum) and the numerical resistance to ground. The contractor shall test the grounding system at each ground rod shown on plans. 7. Testing shall be performed before energizing the distribution system. 8. A separate test shall be conducted for each building or system. 9. Notify the ENGINEER immediately if the resistance to ground for any building or system is greater than five ohms. Provide additional ground rods and conductors as required to bring the resistance to five ohms 10. 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 no fewer 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. 11. 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 and 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. C. Grounding system will be considered defective if it does not pass tests and inspections. D. Prepare test and inspection reports. E. Report measured ground resistances that exceed the following values: 1. Power and Lighting Equipment or System with Capacity of 500 kVA and Less: 10 ohms. 2. Power and Lighting Equipment or System with Capacity of 500 to 1000 kVA: 5 ohms. Grounding and Bonding for Electrical Systems 26 05 26 - 10 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Power Distribution Units or Panelboards Serving Electronic Equipment: 3 ohms. 4. Substations and Pad-Mounted Equipment: 5 ohms. 5. Manhole Grounds: 10 ohms. F. Excessive Ground Resistance: If resistance to ground exceeds specified values, notify Architect promptly and include recommendations to reduce ground resistance. END OF SECTION Hangers And Supports For Electrical Systems 26 05 29 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 29 HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED A. Drawings and general provisions of the Contract, including General and Supplementary Con- ditions and Division 01 Specification Sections, apply to this Section. B. This Section includes the following: 1. Hangers and supports for electrical equipment and systems. 2. Construction requirements for concrete bases. 1.02 PERFORMANCE REQUIREMENTS A. Design supports for multiple raceways capable of supporting combined weight of supported systems and its contents. B. Design equipment supports capable of supporting combined operating weight of supported equipment and connected systems and components. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include Record Data. B. Provide calculations for load limits for all trapeze-type supports, support assemblies and field fabricated support systems. 1.04 QUALITY ASSURANCE A. Welding: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel." B. Comply with NFPA 70. 1.05 COORDINATION A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. Con- crete, reinforcement, and formwork requirements are specified in Division 03. 2.00 PRODUCTS 2.01 SUPPORT, ANCHORAGE, AND ATTACHMENT COMPONENTS A. Steel Slotted Support Systems: Comply with MFMA-4, factory-fabricated components for field assembly. 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. Allied Tube & Conduit. b. Cooper B-Line, Inc.; a division of Cooper Industries. Hangers And Supports For Electrical Systems 26 05 29 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements c. ERICO International Corporation. d. GS Metals Corp. e. Thomas & Betts Corporation. f. Unistrut; Tyco International, Ltd. g. Wesanco, Inc. 2. Channel Dimensions: Selected for applicable load criteria. 3. Slotted channel shall be 316 stainless steel. B. Raceway and Cable Supports: As described in NECA 1 and NECA 101. C. Conduit and Cable Support Devices: 316 stainless steel hangers, clamps, straps and associ- ated fittings, designed for types and sizes of raceway or cable to be supported. D. Structural Steel for Fabricated Supports and Restraints: ASTM A 36/A 36M, steel plates, shapes, and bars; 316 stainless steel. E. 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, 316 stainless steel, for use in hard- ened portland cement concrete with tension, shear, and pullout capacities appropriate for supported loads and building materials in which used. a. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1). Cooper B-Line, Inc.; a division of Cooper Industries. 2). Empire Tool and Manufacturing Co., Inc. 3). Hilti Inc. 4). ITW Ramset/Red Head; a division of Illinois Tool Works, Inc. 5). MKT Fastening, LLC. 2. Concrete Inserts: Stainless Steel, slotted support system units similar to MSS Type 18; complying with MFMA-4 or MSS SP-58. 3. Clamps for Attachment to Steel Structural Elements: MSS SP-58, type suitable for at- tached structural element. 4. Through Bolts: 316 Stainless Steel, Structural type, hex head, and high strength. Com- ply with ASTM A 325. 5. Toggle Bolts: 316 Stainless steel springhead type. 6. Hanger Rods: Threaded 316 stainless steel. 7. Washers: 316 Stainless steel. Hangers And Supports For Electrical Systems 26 05 29 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.00 EXECUTION 3.01 APPLICATION A. 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. B. Maximum Support Spacing and Minimum Hanger Rod Size for Raceway: Space supports for RIGID METAL CONDUIT as required by NFPA 70. Minimum rod size shall be 3/8 inch in diam- eter. C. Multiple Raceways or Cables: Install trapeze-type supports fabricated with stainless steel slotted support system, sized so capacity can be increased by at least 25 percent in future without exceeding specified design load limits. 1. Secure raceways and cables to these supports with single-bolt conduit clamps using spring friction action for retention in support channel. 3.02 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, RIGID METAL 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 weight of sup- ported 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 an- chor 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, trans- formers, 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 reinforc- ing bars. Hangers And Supports For Electrical Systems 26 05 29 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.03 CONCRETE BASES A. Construct concrete bases of dimensions indicated but not less than 4 inches larger in both directions than supported unit, and so anchors will be a minimum of 10 bolt diameters from edge of the base. B. Use 3000-psi, 28-day compressive-strength concrete. C. 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 equip- ment. 3. Install anchor bolts according to anchor-bolt manufacturer's written instructions. D. All floor mounted equipment shall have a 4” thick housekeeping pad on top of concrete foundations or floor for interior equipment. END OF SECTION Conduits 26 05 33.01 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 33.01 CONDUITS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install a complete conduit system for each type of electrical system. Electrical work shall be in accordance with Div. 26 ELECTRICAL specifications. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Record Data to include cut sheets of each material to be used on the project. 2. The Electrical Contractor in conjunction with the Contractor shall issue a letter stating that the arrangement of the duct banks to drain is coordinated with the proposed site grading. 1.03 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: ANSI C80.5 Electrical Rigid Aluminum Conduit ANSI/NEMA FB 1 Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit and Cable Assemblies NEMA RN 1 PVC Externally-Coated Galvanized Rigid Steel Conduit and Electrical Metallic Tubing NEMA TC 2 Electrical Plastic Tubing (EPT) and Conduit (EPC-40 and EPC-80) NEMA TC 3 PVC Fittings for Use with Rigid PVC Conduit and Tubing NEMA TC 14 Reinforced Thermosetting Resin Conduit (RTRC) and Fittings 2.00 PRODUCTS 2.01 MANUFACTURED PRODUCTS A. RIGID ALUMINUM CONDUIT: Heavy wall, aluminum alloy 6063, copper free; low temper number, tube, free from defects and manufactured in accordance with ANSI C80.5 standards and U.L. listed. Acceptable manufacturers shall be Indalex, Allied and Wheatland. B. PVC COATED RIGID ALUMINUM: Meeting the requirements of rigid aluminum conduit; 40 mil PVC exterior coating and 2 mil urethane interior coating, U.L. 6A listed. Acceptable Manufacturers shall be Rob Roy Plastibond Red, Ocal and Perma-Cote. Conduits 26 05 33.01 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements C. LIQUID TIGHT FLEXIBLE ALUMINUM CONDUIT: Single strip, helically wound, interlocking, aluminum, in accordance with U.L. 1. Liquid tight conduit shall have an extruded, polyvinyl jacket over the flexible metal. Acceptable product shall be Anaconda Type U.A. D. FITTINGS AND CONDUIT BODIES: 1. RIGID METAL CONDUIT: Threaded type material to match the conduit, in accordance with ANSI/NEMA FB1 and as manufactured by Appleton Form 35, Killark "O" Series, Crouse Hinds, OZ Gedney, or RACO. 2. FLEXIBLE AND LIQUID TIGHT FITTINGS: In accordance with ANSI/NEMA FB1; cadmium- plated, malleable iron body and nut; aluminum ferrule; insulated throat; integrally-cast, external ground lugs, as manufactured by Appleton "ST" series, Hubbel, OZ Gedney Type 4QL, or RACO. E. ELBOW AND BENDS: Conduit systems shall use PVC coated aluminum or as indicated on plans. F. BUSHINGS: High impact, thermosetting, phenolic insulation; 150 degrees C.; as manufactured by Appleton "BBUH", Blackburn, or OZ Gedney type A. G. GROUNDING BUSHINGS: Conduit grounding bushings shall consist of an aluminum, insulated throat conduit bushing with an attached aluminum set screw lug. Grounding bushing shall comply with Fed. Spec. W-F-408b and W-W-C-581d, UL Standards 514B and 467, and shall be Crouse Hinds Lazy Lug or approved equal. H. HUBS: 1. ALUMINUM CONDUIT: Cast aluminum, with broad flat surfaces with gripping teeth on both sides of conduit entry. Hub portion on exterior side of entry shall contain "O" ring for watertight seal of conduit entry. Hubs shall be Meyers Hub, Appleton or Efcor. I. CONDUIT THROUGH-WALL AND FLOOR SEAL: Malleable iron body with oversized sleeves, sealing ring, pressure clamp and rings and sealing grommet; hex head cap screw, as manufactured by OZ Gedney, type FSK. J. END BELLS: Threaded, malleable iron or fiberglass or PVC, as manufactured by OZ Gedney type TNS. Fiberglass or PVC end bells shall be provided in manholes and hand holes. K. EXPANSION FITTINGS: Aluminum with aluminum bonding jumpers. Linear expansion fittings shall be OZ Gedney Zx for rigid, use with aluminum conduit or Appleton "XJ" series. Combination linear and deflection expansion fittings shall be OZ Gedney type AXDX. L. THREADED NIPPLES: As manufactured by Allied or Triangle. Aluminum Conduit nipples shall have two (2) independent sets of threads. Running threads shall not be used. Utilize the conduit union when joining two (2) fixed conduits in a continuous run. M. ACCESSORIES: Reducers, washers, etc., shall be cadmium-plated, malleable iron. N. IDENTIFYING TAPE FOR BURIED CONDUITS: 6" wide, polyethylene with continuous printing along the length of the tape, as manufactured by Brady "Identoline" or Sentry Line "Terra Tape". Use red with black letters for buried electrical power conduits. Use green with black letters for buried electric instrumentation and communication conduits. O. CONDUIT DRAINS: Conduit drains shall be 316 stainless steel as manufactured by Crouse Hinds ECD Universal, or approved equal. Conduits 26 05 33.01 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements P. DUCT BANK SPACERS: Interlocking module spacers as manufactured by Formex, or approved equal. Q. LINK SEAL: Link seal shall be modular, mechanical type, consisting of inter-locking synthetic rubber links shaped to continuously fill the space between the conduit and the wall opening. Link seal shall be suitable for use in a core-drilled and pre-cast wall openings and shall be manufactured by Pipeline Seal & Insulator, Inc or approved equal. R. KELLEM GRIPS: Kellem grips shall be stainless steel, as manufactured by Hubbell or approved equal. 3.00 EXECUTION 3.01 CONDUIT INSTALLATION SCHEDULE A. Conduit types shall be installed in accordance with the following schedule: 1. BURIED OR CONCRETE ENCASED CONDUIT: Schedule 40 PVC unless noted otherwise. Conduit below grade shall not be smaller than 2”. 2. ABOVE GRADE CONDUIT: Rigid Aluminum unless noted otherwise. 3. PVC COATED RIGID ALUMINUM CONDUIT: Shall be used for conduit stub-ups through concrete and concrete wall penetrations and for elbows and bands in concrete encased duct banks as required by specification. 4. RIGID ALUMINUM CONDUIT: May be used in all locations. PVC coated rigid aluminum conduit shall be used in corrosive environments or where in contact with concrete. 5. LIQUID TIGHT FLEXIBLE METALLIC CONDUIT: Shall only be used to equipment in non- hazardous locations not subject to physical damage or excessive temperatures, requiring vibration isolation unless otherwise indicated, 18” maximum length for conduits less than 2”, a maximum of a 4’-0” for conduits larger than 2”. The bending radius shall be in accordance with Chapter 9, Table 2 of the NEC and shall not deform or alter the flex jacket. 3.02 INSTALLATION A. GENERAL 1. Size conduits as required by the National Electrical Code for the number and sizes of wires to be drawn into the conduit. Conduit less than ¾” shall not be used unless specified otherwise. No conduit less than 2” shall be allowed to be installed in ductbanks even if exposed section of raceway is a smaller trade size. 2. The following are specific to the Raw Water Pump Station site: a. Conduit routed in the server room at the Administration Building shall not penetrate the ceiling and shall be run exposed within the room (below the drop ceiling), with the exception of conduits for light fixtures within the room. Conduits 26 05 33.01 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements b. Conductors in vertical conductor runs shall include supports in accordance with the NEC article 300 if the vertical rise exceeds: 1). 30 feet for cables #1 AWG and larger, or 2). 50 feet for cables that are below #1 AWG. 3. Conduit stubbed-up under free standing enclosures located indoors/outdoors in an electrical room, etc., such as a motor control center, shall be PVC and have a PVC end bell terminator that is solvent welded onto each conduit end. End bell shall be installed flush with the finished floor. No PVC shall be exposed to daylight or be installed such that any portion is out of concrete housekeeping pad or duct bank. 4. Underground conduit shall be steel reinforced concrete encased. Conduit which is below the finished grade shall be PVC schedule 40, except where indicated on the plans or noted otherwise. Unless otherwise indicated, all other conduit shall be rigid aluminum. 5. Conduits terminating inside an air-conditioned space from outside shall be sealed to prevent moisture/condensation from entering the enclosure. 6. Conduit penetrations thru drop ceiling in the Server room shall not be allowed. All conduits installed in the Server room shall be exposed conduits. 7. Duct banks routed below building slabs or any equipment pad shall be steel reinforced concrete encased. 8. At the transition from underground and or from concrete, protect conduit from mechanical damage by extending PVC coated rigid aluminum conduit a maximum of 12" and a minimum of 4" into the earth or concrete at the transition. 9. Aluminum conduit, straps, and struts shall not be in direct contact with concrete. Provide a neoprene washer between the two materials. 10. Aluminum conduit which penetrates into concrete shall be factory-coated with 0.40" of polyvinylchloride, per Spec. MIL-P-15147. 11. Conduit extending into concrete shall not be closer than 3" from adjacent conduit and shall not be closer than 1" from any reinforcement bars. 12. PVC conduit shall not be installed above grade level, above concrete slab level, or for any exposed installations unless specified. All transitions from concealed to exposed shall be made with PVC coated aluminum. Conduit shall not be placed horizontally in a concrete floor slab or a beam without the ENGINEER's written approval. 13. Flexible metal conduit (sealtight) used for connecting light fixtures, i.e., fixture whips, shall be 1/2" as a minimum. Fixture whips shall contain only three conductors: one hot, one neutral, and one equipment grounding conductor. Other conduit types shall be 3/4" as a minimum. The inside surface of the conduit shall be reamed smooth after it has been cut. 14. Provide conduit sizes as shown on the plans. Where hash marks are used to indicate the number of conductors in a conduit without indicating the conduit size, provide a 3/4" conduit for up to nine #12 conductors, and a 1" conduit for ten to 20 #12 conductors. Conduits 26 05 33.01 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements 15. Where conduits stub up through a floor slab from below finished floor level for multi- level structures, install a threaded fitting with PVC plug so that the top of the fitting is flush with the concrete or finished floor surface. 16. Conduit system shall be swabbed clean prior to installation of conductors. 17. Ground conduits in accordance with the National Electrical Code and Specification 26 05 26, “Grounding & Bonding for Electrical Systems”. 18. Contractor shall properly tape PVC coated aluminum conduit where it transitions to PVC conduit in underground concrete encased duct banks so that no aluminum conduit is in contact with concrete encasement. Tape shall be manufactured by Scotch or approved equal. Coordinate with tape manufacturer for type of tape to use for the installation. B. UNDERGROUND 1. Underground conduit shall be steel reinforced concrete encased. Where underground conduits are routed under a concrete slab on grade and brought up under slab the duct bank reinforcing steel shall be tied into the slab. 2. Bury underground conduit a minimum of 24" deep to the top of the concrete encasement for 600V duct banks and 36” for medium voltage duct banks, and as shown on the plans, whichever is greater. Backfill buried conduit banks with material which is free from large rock, paving material, or large angular substance. Install underground conduit with the conduit duct bank dimensions shown on the plans. Adhere to conduit spacing by using spacers at intervals to ensure that proper spacings are maintained. The concrete shall be red in color. Apply dye in concrete truck, sprinkling dye on top of the duct bank after concrete placement is prohibited. PAYMENT WILL NOT BE MADE FOR CONCRETE POURED WITHOUT APPLYING THE RED DYE IN TRUCK AS SPECIFIED. Place 3” CMU blocks under rebar cage to suspend rebar off of the bottom of the trench so that it does not contact the soil and is completely encased in the concrete envelope when concrete is placed. 3. Where underground conduits terminate in a vault or underground structure, dowell duct bank rebar into any below grade structure-wall, vault, manhole, etc. Where duct bank goes below slab-on grade, rebar shall follow raceway under slab and turn up with raceway and be concrete encased and tied into slab rebar. 4. Grade underground and outdoor conduits to drain free of condensation and moisture. Provide for automatic draining at low points. Install horizontal runs of conduit to provide a natural drain for condensation without pockets or traps where moisture may collect. 5. Underground conduits shall drain to an underground structure with a floor drain, such as a manhole. 6. Install conduit drain assemblies in outside or underground conduits to provide for draining. 7. Underground conduit bends shall have a long sweep bend radius. 8. Minimum size for underground conduits is 2”. 9. Contractor shall install duct bank spacers a minimum of every 5 feet. Conduits 26 05 33.01 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements 10. Conduit shall slope uniformly at not less than 4” per 100’, or more than 60” per 100’ unless indicated otherwise on the plans or approved by the Engineer. Arrange duct banks to drain into manholes with no low pockets in the duct runs. The electrical contractor shall coordinate with the Contractor and the plans on the proposed grades for the site. C. ROUTING AND SUPPORT 1. Use the conduit route where shown on the plans. Route conduits that do not have a specified route in the most direct path between the two points, i.e. home runs shown with an arrow symbol. Route conduits parallel to building lines. Concealed conduits on the plans shall be below grade, within walls, or above ceilings. 2. Route conduit through roof openings for piping and ductwork where possible. Otherwise, route conduit through the roof with pitch pocket. Conduit shall not penetrate ductwork. Exposed conduit shall not be installed on the roof without the ENGINEER's prior approval. 3. Install conduit at elevations which maintain headroom, and at locations which avoid interference with other work requiring grading of pipe, the structure, finished walls, etc. Avoid crossing other work. Conduits shall not be placed in close proximity to equipment, systems, and service lines. Maintain a minimum of 3" separation, except in crossing which shall be a minimum of 1". Conduits shall not be installed/concealed in water bearing walls. 4. Conduits in buildings shall be exposed on unfinished ceilings and basements, as shown on the plans. Rigidly support conduits to the building structures using hardware bolted or screwed to the structure. The mounting hardware shall not mount the conduit directly on concrete walls and ceilings, but shall space the conduit away from the surfaces using mineralac-type hardware, strut channel clamps, or one hole straps with clamp backs. 5. Provide expansion fittings at expansion, construction and seismic joints. Provide combination expansion/deflection fittings where conduits are concealed at these joints. 6. Group conduit in parallel runs where practical. Use a conduit rack constructed of channels with conduit straps or clamps. Provide space for an additional 25% conduit. 7. Parallel runs of conduit shall have bends and offsets made at the same point such that the angle of bend is the same in each conduit and the conduits remain parallel throughout the run. Conduits not installed in this manner shall be removed and reinstalled at the Contractor’s expense. Conductors that are installed shall be removed and replaced at the Contractor’s expense. 8. Conduits installed in parallel shall be arranged such that crossings are eliminated. 9. Rigid aluminum conduit systems shall utilize aluminum straps, clamps and strut channel. Coated rigid steel or aluminum conduit shall utilize PVC factory coated or fiberglass straps, clamps and thread rods, etc. as manufactured by Robroy. 10. Nuts, bolts, concrete anchor bolts and other metallic fasteners shall be 316 stainless steel. Conduits 26 05 33.01 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements 11. Install conduit other than fiberglass with threaded couplings and other threaded fittings. Threadless, or clamp type fittings shall not be used on metallic conduit. Rigid aluminum conduit shall have each set of threads coated with an oxidation inhibitor, Ilsco, De-Ox, ITT Noalox, Blackburn Contax or approved equal. 12. Use PVC coated aluminum elbows for bends in PVC conduit. 13. Use suitable conduit caps to protect installed conduit against entry of dirt and moisture. The use of duct tape or any other tape shall be prohibited. 14. Use watertight hubs to fasten conduit to metal boxes, etc. in wet or damp locations per the National Electrical Code. 15. Install a pulling string in empty (spare) conduit, except sleeves and nipples, and leave for future pulling as applicable. 16. Expansion/deflection fittings made of neoprene in outdoor applications shall have aluminum lagging over the neoprene held in place with stainless steel tie-wraps. D. TERMINATIONS 1. Use threaded hubs for termination of conduits. Locknut termination of conduits shall not be used on this project. 2. Conduit terminations shall not penetrate the top of NEMA 4X and NEMA 3R enclosures. Enclosures with top penetrations shall be removed and replaced with conduits re- routed for side or bottom penetration at Contractor’s expense. If conductors have been installed and are too short to accommodate the re-routed conduit, then they shall be removed and replaced at the Contractor’s expense. END OF SECTION Conduits 26 05 33.01 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements THIS PAGE INTENTIONALLY LEFT BLANK Wireways 26 05 33.02 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 33.02 WIREWAYS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install a complete wireway system. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. Contractor shall size wireways in accordance with the National Electrical Code. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include Record Data for: 1. Wireways 2.00 PRODUCT 2.01 MATERIALS A. WIREWAY: Provide as manufactured by Hoffman or equal. B. WIREWAY ENCLOSURES, SUPPORTS AND ASSOCIATED FITTINGS: NEMA 1 (metallic) for Air Conditioned spaces and NEMA 4X, 316 stainless steel for all other locations, lay-in wireway, quick release cover stainless steel latches, continuously welded seams, oil resistant gasket. Hoffman Lay-In-Type NEMA 1 or NEMA 4X wireway or equal. Factory ANSI 61 gray finish for NEMA 1. NEMA 1 for Air Conditioned spaces and NEMA 4X, 316 stainless steel for all other locations. C. Wireways shall have integral lugs. NEMA 4X wireways shall have quick release luggage type stainless steel latches. 2.02 FABRICATIONS A. WIREWAYS: Complete wireway system with enclosures, supports, and associated fittings, having the form and dimension suited to the application, and as manufactured by Hoffman or approved equal. 3.00 EXECUTION 3.01 INSTALLATION A. Provide systems of wireways of sufficient size where indicated. B. Size wireway cross-sectional area and length based upon conductor fill and equipment served as required by NEC and local codes. C. Install types based on environmental conditions to which exposed. Wireways 26 05 33.02 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements D. Mount wireways only with lugs. Space 1/4” off of wall. Drilling of NEMA 4X wireways is prohibited. NEMA 4X wireways drilled will be removed and replaced at contractor’s expense. END OF SECTION Outlet Boxes 26 05 33.03 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 33.03 OUTLET BOXES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install outlet boxes. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.02 QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS A. Cooper Crouse-Hinds; Div. of Cooper Industries, Inc. B. EGS/Appleton Electric. C. Erickson Electrical Equipment Company. D. Hoffman. E. Hubbell Incorporated; Killark Electric Manufacturing Co. Division. F. O-Z/Gedney; a unit of General Signal. 1.03 SUBMITTALS A. No submittals required for Section 26 05 33.03, “Outlet Boxes”. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: ANSI/NEMA OS 1 Sheet steel outlet boxes, device boxes, covers and box supports. ANSI/NEMA OS 2 Non-metallic outlet boxes, device boxes, covers and box supports. 2.00 PRODUCTS 2.01 MATERIALS A. GENERAL: Furnish boxes with proper covers and device plates B. CAST BOXES: Cast aluminum metal, deep type, gasketed cover, threaded hubs and integral mounting lugs. Use cast boxes for all installation. Boxes shall be manufactured by Crouse- Hinds, Appleton or approved equal. Provide integral mounting lugs and provide integral conduit hubs on all boxes. Outlet Boxes 26 05 33.03 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.00 EXECUTION 3.01 PREPARATION; COORDINATION OF BOX LOCATIONS A. Provide electrical boxes in the locations shown on the Plans, and as required for splices, taps, wire pulling, equipment connections, and code compliance. B. Electrical box locations shown on Contract Drawings are approximate unless dimensioned. Verify locations of boxes and outlets prior to rough-in. Outlet locations may be modified to accommodate changes in door swings, space changes or to clear other interferences that arise or from job modifications. Make such modifications at no cost to the OWNER as a matter of job coordination. Coordinate job conditions and notify the ENGINEER of discrepancies before proceeding with the installation of the work. Set wall boxes in advance of wall construction blocked in place, and secured. Install extension sleeves as required to extend boxes to finished surfaces. C. Provide 1/4” spacer behind all boxes. D. Never drill through the back of boxes for mounting. Drilled boxes will be rejected and shall be replaced at the Contractor’s expense. E. Unless otherwise noted, location of outlet boxes shall be as follows: Equipment or Outlets Elevation *(A.F.F.) Toggle switches 4'0" Receptacles 2’-0” in the Lower Bois d’Arc Creek Reservoir Raw Water Pump Room and everywhere else mount at 1'6" Equipment or Outlets Elevation *(A.F.F.) Flow/Level Transmitters 5'5" Circular Chart Recorder 5'5" Motor starters 5'0" Control stations 4'0" Manual starters 5'0" Thermostats in office areas 4'0" Telephone outlets 1'6" Circuit protective devices 6'6" to top of enclosure * Above Finished Floor. F. Locate and install boxes to allow access. Where installation is inaccessible, coordinate locations and sizes of required access doors in accordance with other sections of the specifications. 3.02 INSTALLATION A. Locate boxes in masonry walls to require cutting of masonry unit corner only. Coordinate masonry cutting to achieve neat openings for boxes. B. Provide plugs for unused openings. C. Use multiple-gang boxes where more than one (1) device is installed together; do not use sectional boxes. Provide barriers to separate wiring of different voltage systems. Outlet Boxes 26 05 33.03 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements D. Install boxes in walls without damaging wall insulation. E. Align wall-mounted outlet boxes for switches, thermostats and similar devices. F. Mount all boxes using only the integral lugs. Drilling through the box to mount is prohibited. Any box mounted by drilling through the box will be rejected and shall be replaced at the Contractor’s expense. G. All boxes shall be installed with spacers so that at least 1/4” air space is maintained between the back of the box and the wall. END OF SECTION Outlet Boxes 26 05 33.03 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements THIS PAGE INTENTIONALLY LEFT BLANK Pull and Junction Boxes for Electrical Systems 26 05 33.04-1 DTN18104 – Lake Lewisville WTP/RWPS Improvements 26 05 33.04 PULL AND JUNCTION BOXES FOR ELECTRICAL SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install pull and junction boxes. The CONTRACTOR shall be responsible for sizing all pull boxes and junction boxes per the National Electrical Code (NEC) Article 314 and all other relevant sections of the NEC. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.02 QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS A. Appleton B. Bryant C. Crouse Hinds D. Hoffman E. Hubbell F. O Z Gedney G. Raco 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include the following shop drawings: 1. Pull and Junction Boxes 2. Pull and Junction Boxes Sizing Calculations: Detailed calculations shall be submitted to the ENGINEER with the pull and junction boxes’ initial submittal. Submittals submitted without sizing calculations shall not be accepted. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: NEMA 250 Enclosure for Electrical Equipment (1000 volts maximum) ANSI/NEMA OS 1 Sheet steel Outlet Boxes, Device Boxes, Covers and Box Supports NEC National Electrical Code Pull and Junction Boxes for Electrical Systems 26 05 33.04-2 DTN18104 – Lake Lewisville WTP/RWPS Improvements 2.00 PRODUCTS 2.01 MATERIALS A. GENERAL: Exposed wall pull and junction boxes shall be 316 stainless steel or aluminum. Exposed pull boxes or junction boxes installed outdoors, per NEMA 250 shall be weatherproof and shall be provided mounting lugs with watertight gasketed covers fastened with stainless steel screws and be 316 stainless steel. All hardware shall be 316 stainless steel. Boxes shall be provided with integral mounting lugs. B. NEMA 1 for Air Conditioned spaces and NEMA 4X, 316 stainless steel for all other locations unless otherwise noted. C. PULL AND JUNCTION BOXES: Metal construction conforming to National Electrical Code and ANSI/NEMA OS 1 with a hinged cover and quick release stainless steel luggage type clasp, 1/4 turn screw with handles or 3-point handle operated latch system. Latching systems requiring tools are not permitted. Provide hinge type for boxes of 12" or larger in any dimension. Boxes shall be provided with integral mounting lugs. Hinge, hasp and all hardware shall be 316 stainless steel. Back panel shall be aluminum. 3.00 EXECUTION 3.01 INSTALLATION A. Use separate pull boxes and junction boxes for electric power, control and communication systems. B. Install pull boxes and junction boxes where required by the National Electrical Code and wherever required to overcome mechanical difficulties. C. Install pull boxes in interior conduit at not more than 100' apart when conduit runs are not broken by junction or outlet boxes. D. Pull and junction boxes shall be accessible and not buried. E. Do not install boxes back to back in walls and provide a minimum of 6" separation, except in acoustic-rated walls, provide 24" separation. F. Support boxes independently of conduit except for cast boxes that is connected to two rigid metal conduits, both supported within 12" of box. G. Junction boxes shall have terminal strips/distribution blocks for splicing conductors where approved by the ENGINEER or as shown/specified on the plans. Terminal strips shall be manufactured by Allen-Bradley, Phoenix Contact or approved equal. Distribution blocks shall be per Section 26 05 19, “Low Voltage Electrical Conductors & Cables”. No top entry in junction boxes with a terminal strip. H. Box shall be mounted using mounting lugs. Drilling through the box to mount is prohibited. Any box drilled to mount will be rejected and shall be removed and replaced at the Contractor’s expense. I. Provide at least 1/4 inch air space between the back of the box and the wall. Pull and Junction Boxes for Electrical Systems 26 05 33.04-3 DTN18104 – Lake Lewisville WTP/RWPS Improvements J. Conduit penetrations in the top of any enclosure or junction box is strictly prohibited in all areas except dry NEMA 1 areas. Any enclosure top penetrated will be rejected and shall be removed and replaced at the Contractor’s expense. END OF SECTION Pull and Junction Boxes for Electrical Systems 26 05 33.04-4 DTN18104 – Lake Lewisville WTP/RWPS Improvements THIS PAGE INTENTIONALLY LEFT BLANK Cable Trays for Electrical Systems 26 05 36-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 36 CABLE TRAYS FOR ELECTRICAL SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install a complete cable tray. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. B. The CONTRACTOR shall provide splice plates as required to join the existing cable tray to the new cable tray. Field verify existing conditions and take field measurements as required. 1.02 QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS A. Products shall comply with the specifications and the following Manufacturers will be acceptable: 1. MP Husky 2. B-Line 3. Cope 4. PW 5. No Equal 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Cable tray, fittings, hangers, covers, steel barriers and fire stop pillows. 1.04 STANDARDS NEMA VE1 Metal Cable Tray Systems NEMA VE2 Cable Tray Installation Guidelines 2.00 PRODUCTS 2.01 MATERIALS A. CABLE TRAY: aluminum, conforming to the requirements of NEMA VE 1, Class 16C. Support spacing for cable tray shall be per NEMA and the manufacturer’s requirements to maintain specified NEMA class designation. The cable tray shall comply to the following: 1. Inside Depth: 5” Loading depth, Outside 6”. 2. Inside Width: as indicated. 3. Straight Section Rung Spacing: 9". Cable Trays for Electrical Systems 26 05 36-2 DTN18104 – Lake Lewisville WTP Phase II Improvements 4. Inside Radius of Fittings: a. 12” radius for cable trays 18” wide and smaller. b. 24” radius for cable trays 24” wide and larger. 3.00 EXECUTION 3.01 INSTALLATION A. Install the cable tray according to the Manufacturer's printed instructions. Support the cable tray on trapeze type hangers, 1-5/8" x 1-5/8" channel or 1/2" diameter, threaded, rod hangers. All supporting devices shall be 316 stainless steel including nuts and washers. Maximum spacing shall be 10’-0”. Coordinate with structural reinforcement. B. Connect sections of the cable tray together with edges free from burrs and sharp projections. Use expansion connectors where indicated by NEMA VE1. C. Provide bonding continuity between cable tray sections and fittings according to the Manufacturer's instructions. D. Install a bare ground conductor routed along the outside of the tray rails the full length of all cable tray runs and bond each tray section, bond to all drop conduits and to the ground of every enclosure fed by the tray system. E. Provide a grounding jumper between each cable tray section and ground cable tray per the National Electrical Code. F. Provide aluminum ladder drop-out at end of tray runs to prevent damage to cable insulation. G. Cable tray shall be anchored to prevent both horizontal and vertical movement. H. Provide #4/0 bare cooper ground conductor the full length of the cable tray, bonded to each section and to all enclosures in accordance with the National Electrical Code and Section 26 05 26, “Grounding & Bonding for Electrical Systems”. I. For cable tray penetrations provide fire barrier self-locking pillows manufactured by 3M, Nelson or approved equal. J. Do not support conduit drops from the cable tray. Provide separate conduit supports from the ceiling or wall or trapeze supports which support the tray. END OF SECTION Manholes and Concrete Pull Boxes for Electrical Systems 26 05 43.01-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 43.01 MANHOLES AND CONCRETE PULL BOXES FOR ELECTRICAL SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install concrete electrical manholes and pull boxes, as specified and indicated on the plans. Manhole sizes, if shown on the plans, are the minimum size allowed. CONTRACTOR shall be responsible for sizing all manholes and pull boxes in accordance with the National Electrical Code, Article 370 and relevant sections of the NEC. CONTRACTOR shall be responsible for setting elevations at manhole and cable entry locations to meet the intent of the specifications and plans. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.02 QUALITY ASSURANCE A. ACCEPTABLE MANUFACTURERS; PRECAST: Precast concrete products shall comply with the specifications and shall be produced by the following Manufacturers: 1. Brooks Products 2. American Industrial Precast Products 3. Dalworth Quickset Co. 4. Old Castle 5. No Equal B. ACCEPTABLE MANUFACTURERS; CASTINGS: Metal castings shall comply with the specifications and shall be produced by the following Manufacturers: 1. McKinley Iron Works, Fort Worth, TX 2. Neenah Foundry, Neenah, WI C. DESIGN CRITERIA: Concrete for precast concrete shall obtain a compressive strength of 4000 psi minimum at 28 days, and shall be an air-entrained mix of the Manufacturer's standard mix design. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures”, and shall include: 1. Manholes and pull boxes 2. CONTRACTOR shall provide detailed conduit layout showing number, size, and location of conduits entering the manholes. Cables routed in conduits shall be clearly identified using project specific cable numbers. Details shall also show elevation of conduits entering manholes. Manhole details shall be submitted to the ENGINEER for approval prior to the duct bank/manhole system being installed. Manholes and Concrete Pull Boxes for Electrical Systems 26 05 43.01-2 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Manhole and Concrete Pull Box Sizing Calculations: Detailed calculations shall be submitted to the ENGINEER with the Manhole and Pull Box initial submittal. Submittals submitted without sizing calculations shall not be accepted. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: AASHO H-20 "Standard Specifications for Highway Bridges" ANSI/ASTM A-15 "Zinc Coating (Hot Dipped) on Iron and Steel Hardware" ANSI/ASTM A-569 "Steel, Sheet and Strip, Carbon (0.15% Maximum), Hot Rolled, Commercial Quality. ASTM A-48 "Gray Iron Castings" ASTM A-123 "Zinc (Hot Galvanized) Coatings on Products fabricated from Rolled, Pressed, and Forged Steel Shapes, Plates, Bars, and Strips." ANSI C-2 "National Electrical Safety Code" 2.00 PRODUCTS 2.01 MATERIALS A. MANHOLE FRAMES AND COVERS: Class 30B gray cast iron conforming to ASTM A-48; machine finished with flat bearing surfaces. B. SUMP COVERS: Class 30B gray cast iron conforming to ASTM A-48. C. PULLING IRONS: 316 Stainless Steel bar with 7/8" diameter forming a triangle of 9" per side when set; galvanized according to ANSI/ASTM A-153 for irregularly shaped articles. D. CABLE RACK INSERTS: 316 Stainless Steel channel inserts with a minimum load rating of 800 pounds; length to match cable rack channel. E. CABLE RACK CHANNEL: 4" x 1-1/2" x 3/16" 316 stainless steel channel wall bracket, 48" long, with cable rack arm mounting slots on 8" centers. F. CABLE RACKS: 2-1/2" x 14" 316 stainless steel channel with high glazed, wet-process porcelain insulators conforming to ANSI/ASTM A-569. G. GROUND ROD: 3/4" x 10’ copper clad steel, installed in the floor of the manhole, and all metallic cable racks, irons, etc. grounded (to the ground rod). Ground rod may be field installed, but floor penetration shall be sealed against the entrance of water under positive head. H. JOINT SEALANT: Flexible plastic gasket of flexible butyl resin sealant. I. DAMPPROOFING: Sonneborn, Div. of ChemRex, Inc. or approved equal. Manholes and Concrete Pull Boxes for Electrical Systems 26 05 43.01-3 DTN18104 – Lake Lewisville WTP Phase II Improvements 1. BITUMINOUS DAMPPROOFING a. Cold-Applied, Emulsified-Asphalt Dampproofing: 1). Brush and Spray Coats: ASTM D 1227, Type III, Class 1. b. MISCELLANEOUS MATERIALS 1). Emulsified-Asphalt Primer: ASTM D 1227, Type III, Class 1, except diluted with water as recommended by manufacturer. 2.02 MIXES A. Concrete and reinforcing shall be in accordance with Section 03 30 00, “Cast-In-Place Concrete”. 2.03 FABRICATIONS A. PRECAST CONCRETE 1. Precast concrete shall be a factory controlled product, reinforced in accordance with AASHTO HS-20 bridge loading requirements. Units shall be precast in modular sections with tongue and groove joints. Manholes shall have the following characteristics: a. Shape: Square 2. Provide a 42" diameter, grooved opening in top section. Neck and shaft diameter shall be 36" clear dimension. Provide a 12" drain opening and two (2) 1" ground rod openings in the base section. 3. Provide conduit openings on each wall for conduits as required. Openings for conduits shall be large enough to permit conduit penetrations. Coordinate with Contractor for the outside diameter of the type of conduit being installed. Openings shall be at elevations required to permit drainage and all other specification and plan requirements. Provide cable pulling irons opposite each set of conduit openings along wall. 4. Conduit openings shall be centered for straight through pulls and off to the outside of center for 90 degree or angled pulls. Coordinate conduit openings with the duct bank routing shown on the site plan. 5. Include inserts for cable racks at 6” on center. Include precast manhole steps at 16" centers. 3.00 EXECUTION 3.01 PREPARATION A. Excavate hole for a suitably sized manhole which permits installation and inspection. Base material and backfill shall be in accordance with the Manufacturer's printed instructions and the provisions of Section 31 05 13, “Soils for Earthwork”, of these specifications. Manholes and Concrete Pull Boxes for Electrical Systems 26 05 43.01-4 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.02 INSTALLATION A. PRECAST CONCRETE MANHOLES: Install manholes in accordance with the Manufacturer's printed instructions. Manholes shall be plumb and level. Use precast neck and shaft sections to bring manhole entrance to finished grade 6” above finished grade. B. At the intersection of electrical duct banks and manholes, both existing and new, Contractor shall install (4) #4x3’-0” dowels into the electrical manhole with Hilti RE 500 adhesive and 2/3 wall thickness embedment. Do not damage manhole wall reinforcement. Do not core drill the holes. Provide a 2’-0” lap splice with continuous duct bank reinforcement. C. MANHOLE ACCESSORIES 1. Install a ground rod in each of two (2) base section openings with the top of the rod protruding 4" above the manhole floor. 2. Attach cable racks to inserts after manhole installation is complete. 3. Dampproof exterior surfaces of manholes, including joints and interruptions after concrete has cured for a minimum of 28 days. Dampproofing shall be cold-applied, emulsified-asphalt dampproofing, Apply two brush or spray coats of Dampproofing at not less than 1.5 gal./100 sq. ft. (0.6 L/sq. m) for first coat and 1 gal./100 sq. ft. (0.4 L/sq. m) for second coat 4. Waterproof exterior surfaces of manholes, including joints and interruptions after concrete has cured for a minimum of 28 days. 5. Manhole frames, pulling irons and cable rack channels shall be grounded to the ground rods. All metal shall be bonded to grounding system. Grounding shall meet the requirements of Section 26 05 26, “Grounding & Bonding for Electrical Systems”, and Articles 250 and 450 of the National Electrical Code. D. SUPPORTING CABLES ON WALLS 1. Support cables by cable racks. Provide quantity of racks by the number of conductors routed through manholes. Provide minimum of two cable hooks per rack. 2. Install a minimum of two racks on each wall in each manhole. 3. Cable racks shall be provided for installation of future conductors. 4. Instrumentation cables, power cables, and control cables shall be kept separately when routed along racks through manholes. E. GROUNDING 1. 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. Manholes and Concrete Pull Boxes for Electrical Systems 26 05 43.01-5 DTN18104 – Lake Lewisville WTP Phase II Improvements F. 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 conductor. Train conductors level or plumb around corners and fasten to manhole walls. Ground all metallic cable racks, supports, and ladders by #4/0 bare copper ground loop exposed on the inside walls of the manhole. Connect the copper loop to the grounding cable that is run above the duct bank and through the manhole. END OF SECTION Manholes and Concrete Pull Boxes for Electrical Systems 26 05 43.01-6 DTN18104 – Lake Lewisville WTP Phase II Improvements THIS PAGE INTENTIONALLY LEFT BLANK Identification For Electrical Systems 26 05 53 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 05 53 IDENTIFICATION FOR ELECTRICAL SYSTEMS 1.00 GENERAL 1.01 WORK INCLUDED A. Drawings and general provisions of the Contract, including General and Supplementary Con- ditions and Division 01 Specification Sections, apply to this Section. B. Section Includes: 1. Identification for raceways. 2. Identification of power and control cables. 3. Identification for conductors. 4. Underground-line warning tape. 5. Warning labels and signs. 6. Instruction signs. 7. Equipment identification labels. 8. Miscellaneous identification products. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Record Data: a. Product Data to include cut sheets for each electrical identification product to be used on the project. Provide example of labeling for Owner/Engineer approval prior to beginning any work. 1.03 QUALITY ASSURANCE A. Comply with ANSI A13.1. B. Comply with NFPA 70. C. Comply with 29 CFR 1910.144 and 29 CFR 1910.145. D. Comply with ANSI Z535.4 for safety signs and labels. E. Adhesive-attached labeling materials, including label stocks, laminating adhesives, and inks used by label printers, are not acceptable. 2.00 PRODUCTS 2.01 POWER AND CONTROL CABLE IDENTIFICATION MATERIALS A. All markings to labels, schedules, tags or nameplates shall be machine printed only. Hand printing is prohibited. Circuits shall be tagged at terminations (both ends), in pull boxes, cab- inets, and enclosures as follows: Identification For Electrical Systems 26 05 53 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1. Tags relying on adhesives or tapes-on markers are not acceptable, unless noted other- wise. 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 perma- nent nylon marker plates with legible designations hot stamped on the plate. Attach these marker plates to conductors and cables 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. Switchlegs shall have the designation described above on their tags, plus an “S” suffix. Travelers shall have the designation described above on their tags, plus a “T” suffix. 7. Where more than one neutral is present with a group of conductors, a tag shall be ap- plied to each neutral indicating which phase conductors are served by each neutral (e.g. HA-2, 4, 6). 2.02 CONDUCTOR IDENTIFICATION MATERIALS A. Color-Coding Conductor Tape: Colored, self-adhesive vinyl tape not less than 3 mils thick by 1 to 2 inches wide. 2.03 UNDERGROUND-LINE WARNING TAPE A. Tape: 1. Recommended by manufacturer for the method of installation and suitable to identify and locate underground electrical and communications lines. 2. Printing on tape shall be permanent and shall not be damaged by burial operations. 3. Tape material and ink shall be chemically inert, and not subject to degrading when ex- posed to acids, alkalis, and other destructive substances commonly found in soils. B. Color and Printing: 1. Comply with ANSI Z535.1 through ANSI Z535.5. 2. Inscriptions for Red-Colored Tapes: ELECTRIC LINE 2.04 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 la- bels, configured for display on front cover, door, or other access to equipment unless other- wise indicated. C. Baked-Enamel Warning Signs: Identification For Electrical Systems 26 05 53 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 1. Preprinted aluminum signs, punched or drilled for fasteners, with colors, legend, and size required for application. 2. 1/4-inch grommets in corners for mounting. 3. Nominal size, 7 by 10 inches. D. 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." 2.05 EQUIPMENT IDENTIFICATION LABELS A. Engraved, Laminated Acrylic or Melamine Label: Punched or drilled for screw mounting. Attach plates to equipment with stainless steel screws. Provide an O-ring for screws on NEMA 4X enclosures, O-rings shall maintain the integrity and NEMA 4X rating for enclosures. B. NAMEPLATES: 1. For indoor applications with Air Conditioning: Plastic, white 1" letters on black back- ground, on the front of each door on the switchgear; identifying the compartment con- tents for each compartment. 2. All other applications: Plastic, white 1" letters on black background, on the front of each door on the switchgear; identifying the compartment contents for each compartment. 3. Attach nameplates with a stainless steel screw and nut at each end of the nameplate. Adhesive backed nameplates shall not be installed. 4. Label that includes tag designation shown on Drawings for the transformer, switchgear, panelboards or other electrical equipment. 2.06 CONDUIT IDENTIFICATION PLATE A. A conduit identification plate shall be installed on all power, control, instrumentation and communications conduits at the end of each run and at the conduit ends inside intermedi- ate junction and pull boxes, manholes, handholes, etc. Conduit plates shall be installed be- fore conductors are pulled into the conduits. Exact identification plate location shall be co- ordinated with the Owner/Engineer at the time on installation. The conduit identification tags shall identify the cable numbers as shown on the FNI plans and the “to” and “from” in- formation. Coordinate with Owner for exact requirements for plate material and type. Pro- vide an example to Owner/Engineer as a formal submittal for approval prior to the installa- tion. Attach conduit identification plate with stainless steel tie wraps or stainless steel wire. 3.00 EXECUTION 3.01 INSTALLATION A. Verify identity of each item before installing identification products. Identification For Electrical Systems 26 05 53 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Location: Install identification materials and devices at locations for most convenient view- ing 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 signs and plastic labels that are not self-adhesive type with stainless steel mechanical fasteners appropriate to the location and substrate. F. Underground-Line Warning Tape: During backfilling of trenches install continuous under- ground-line warning tape directly above line at 6 to 8 inches below finished grade. Use mul- tiple tapes where width of multiple lines installed in a common trench or concrete envelope exceeds 16 inches overall. G. Painted Identification: Comply with requirements in Division 09 painting Sections for sur- face preparation and paint application. 3.02 IDENTIFICATION SCHEDULE A. Power-Circuit Conductor Identification, 600 V or Less: For conductors in vaults, pull and junction boxes, manholes, and handholes, use color-coding conductor tape to identify the phase. 1. Color-Coding for Phase Identification. Use colors listed below for ungrounded service, feeder, and branch-circuit conductors. a. Color shall be field applied for sizes larger than No. 8 AWG b. Colors for 120/240V Circuits: 1). Phase A: Black 2). Phase B: Red 3). Neutral: White 4). Equipment Grounding Conductor: Green c. Colors for 208/120-V or 240V/120V, 3-phase Circuits: 1). Phase A: Black. 2). Phase B: Red. 3). Phase C: Blue. 4). Neutral: White 5). Equipment Grounding Conductor: Green d. Colors for 480/277-V Circuits: 1). Phase A: Brown. 2). Phase B: Orange. 3). Phase C: Yellow. 4). Equipment Grounding Conductor: Green Identification For Electrical Systems 26 05 53 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements e. Colors for 2,400-V Circuits: 1). Phase A: Brown with a purple stripe. 2). Phase B: Orange with a purple stripe. 3). Phase C: Yellow with a purple stripe. 4). Equipment Grounding Conductor: Green f. Colors for 13,200-V Circuits: Colors shall be coordinated with the Owner 1). Phase A: Red. 2). Phase B: White. 3). Phase C: Blue. 4). Equipment Grounding Conductor: Green g. Field-Applied, Color-Coding Conductor Tape: Apply in half-lapped turns for a mini- mum distance of 6 inches from terminal points and in boxes where splices or taps are made. Apply last two turns of tape with no tension to prevent possible unwind- ing. Locate bands to avoid obscuring factory cable markings. B. Locations of Underground Lines: Identify with underground-line warning tape for power, lighting, communication, and control wiring and optical fiber cable. 1. Limit use of underground-line warning tape to direct-buried cables. 2. Install underground-line warning tape for both direct-buried cables and cables in race- way. 3. Identifying line shall be continuous along the entire underground route. C. Warning Labels for Indoor Cabinets, Boxes, and Enclosures for Power and Lighting: Self-ad- hesive warning labels 1. Comply with 29 CFR 1910.145. 2. Identify system voltage with black letters on an orange background. 3. Apply to exterior of door, cover, or other access. 4. For equipment with multiple power or control sources, apply to door or cover of equip- ment including, but not limited to, the following: a. Power transfer switches. b. Controls with external control power connections. D. Operating Instruction Signs: Install instruction signs to facilitate proper operation and maintenance of electrical systems and items to which they connect. Install instruction signs with approved legend where instructions are needed for system or equipment operation. E. Equipment Identification Labels: On each unit of equipment, install unique designation label that is consistent with wiring diagrams, schedules, and the 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 Identification For Electrical Systems 26 05 53 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements include power, lighting, control, communication, signal, monitoring, and alarm systems un- less equipment is provided with its own identification. 1. Labeling Instructions: a. Indoor Equipment: stainless steel screws and nuts, engraved and laminated name- plates. Unless otherwise indicated, provide a single line of text with 1/2-inch high letters on 1-1/2-inch high label; where two lines of text are required, use labels 2 inches high. b. Outdoor Equipment: Engraved, laminated acrylic or melamine label c. Elevated Components: Increase sizes of labels and letters to those appropriate for viewing from the floor. d. Fasten labels with appropriate mechanical fasteners and gaskets that do not change the NEMA or NRTL rating of the enclosure and void the U.L. listing of the enclosure. 2. Equipment to Be Labeled: a. Panelboards: Typewritten directory of circuits in the location provided by panel- board manufacturer. Panelboard identification shall be laminated acrylic or mela- mine label and placed in a clear plastic sleeve. b. Enclosures and electrical cabinets. c. Starters. d. Switchgear. e. Switchboards. f. Transformers: Label that includes tag designation shown on Drawings for the trans- former, feeder, and panelboards or equipment supplied by the secondary. g. Motor-control centers. h. Enclosed switches. i. Enclosed circuit breakers. j. Enclosed controllers. k. Push-button stations. l. Contactors. m. Monitoring and control equipment. n. UPS equipment. o. Conduits p. Power Factor Correction Capacitors q. Adjustable Frequency Drives r. Pull boxes, junction boxes, concrete pull boxes, manholes and hand holes. END OF SECTION Identification For Electrical Systems 26 05 53 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements Identification For Electrical Systems 26 05 53 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements THIS PAGE INTENTIONALLY LEFT BLANK Medium Voltage Pad-Mounted Switch 26 12 01 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 12 01 MEDIUM VOLTAGE PAD-MOUNTED SWITCH 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install pad mount medium voltage switchgear. Electrical work shall be in accordance with Divisions 26. 1.02 QUALITY ASSURANCE A. ACCEPTABLE MANUFACTURERS B. 15KV Pad-Mounted Switch 1. S&C Electric Company 2. No approved equal 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Product data and shop drawings for pad-mounted switch including dimensions, weights, etc. 2. Three-line diagram. 1.04 STANDARDS A. The applicable provisions of the following codes and standards shall apply as if written here in their entirety: 1. ANSI C57.12.28 2. ANSI C37.71 3. ANSI C37.73 B. Institute of Electrical and Electronic Engineers (IEEE) C. National Electrical Code (NEC) D. National Electrical Manufacturers Association (NEMA) 2.00 PRODUCTS 2.01 MEDIUM VOLTAGE SWITCHES A. Pad-mounted switches shall be Vista type by S&C Electric Company. B. The pad-mounted switches shall be in accordance with the one-line diagram and shall conform to the following specification. Medium Voltage Pad-Mounted Switch 26 12 01 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements C. The pad-mounted switches shall consist of a stainless steel gas-tight tank containing SF6 gas load interrupter switches and resettable vacuum fault interrupters with visible open gaps and integral visible grounds, and a microprocessor-based overcurrent control. Load- interrupter switch terminals shall be equipped with bushings rated 600 amperes continuous, and fault-interrupter terminals shall be equipped with bushing wells rated 600 amperes continuous to provide for elbow connection. Manual operating mechanisms and viewing windows shall be located on the opposite side of the tank from the bushing and bushing wells so that operating personnel shall not be required to perform any routine operations in close proximity to high voltage elbows and cables. D. Ratings 1. The ratings for the integrated pad-mounted gear shall be as designed below: KV, Nominal 13.2 KV, Maximum 15.5 KV, BIL 95 Main Bus Continuous, Amperes 600 Three-Pole Load Interrupter Switches Continuous, Amperes 600 Load Dropping Amperes 600 Ten-Time Duty-Cycle Fault-Closing Amperes. RMS Symmetrical 25,000 Fault Interrupters Continuous Amperes 600 Load Dropping Amperes 600 Ten-Time Duty-Cycle Fault Interrupting Amperes RMS Symmetrical 25,000 Ten-Time Duty-Cycle Fault Closing Amperes, RMS Symmetrical 25,000 Short-Circuit Ratings Amperes, RMS Symmetrical 25,000 Medium Voltage Pad-Mounted Switch 26 12 01 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements E. Certification of Ratings 1. The manufacturer of the switchgear shall be completely and solely responsible for the performance of the load interrupter switch and fault interrupters as well as the complete integrated assembly as rated. 2. The manufacturer shall furnish, upon request, certification of ratings of the load interrupter switch, fault interrupter, and the integrated switchgear assembly consisting of switches and fault interrupters in combination with the sealed tank. F. Compliance with Standards and Codes 1. The switchgear shall conform to or exceed the applicable requirements of the following standards and codes: a. Applicable portions of ANSI C57.12.28, covering enclosure integrity for pad- mounted equipment b. Applicable portions of ANSI C37.71, ANSI C37.72 and ANI C37.73, which specify test procedures for load-interrupter switches, fault interrupters, and the complete switchgear assembly. G. Viewing Windows 1. Each load-interrupter switch shall be provided with a large viewing window at least 6 inches by 12 inches to allow visual verification of the switch-blade position (open, closed and grounded) while shining a flashlight on the blades. 2. Each fault interrupter shall be provided with a large viewing window at least 6" x 12" to allow visual verification of the disconnect-blade position (open, closed, and grounded) while shining a flashlight on the blades. 3. Viewing windows shall be located on the opposite side of the gear from the bushings and bushings wells so that operating personnel shall not be required to perform any routine operations in close proximity to high-voltage elbows and cables. 4. A cover shall be provided for each viewing window to prevent operating personnel from viewing the flash which may occur during switching operations. H. High-Voltage Bus 1. Bus and interconnections shall withstand the stresses associated with short-circuit currents up through the maximum rating of the switchgear. 2. Before installation of copper bus, all electrical contact surfaces shall first be prepared by machine abrading to remove any oxide film. Immediately after this operation, the electrical contact surfaces shall be coating with a uniform coating of an oxide inhibitor and sealant. 3. Bus shall be of copper construction. I. Provisions for Grounding 1. One ground-connection pad shall be provided on the gas/liquid-tight tank of the switchgear. 2. The ground-connection pad shall be constructed of stainless steel and welded to the gas-tight tank, and shall have a short-circuit rating equal to that of the switchgear. Medium Voltage Pad-Mounted Switch 26 12 01 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Bus shall be of copper construction J. Load-Interrupter Switches 1. The three-phase, gang-operated load-interrupter switches shall have a ten-time duty- cycle, fault-closing rating equal to or exceeding the short-circuit rating of the switchgear. This rating defines the ability to close the switch ten times against a three-phase fault with asymmetrical (peak) current in at least one phase equal to the rated value, with the switch remaining operable and able to carry and interrupt rated current. Certified test abstracts establishing such ratings shall be furnished upon request. 2. The switch shall be provided with an integral ground position that is readily visible through the viewing window to eliminate the need for cable handling and exposure to high voltage to ground the equipment. 3. The ground position shall have a ten-time duty-cycle fault-closing rating. 4. The switch shall be provided with an open position that is readily visible through the viewing window to eliminate the need for cable handling and exposure to high voltage to establish a visible gap. 5. The open gaps of the switch shall be sized to allow cable testing through a feedthru bushing of the back of the elbow. K. Fault Interrupters 1. Fault interrupters shall have a ten-time duty-cycle fault-closing and fault interrupting rating equal to or exceeding the short-circuit rating of the switchgear. This rating defines the fault interrupter's ability to close ten times against a three-phase fault with asymmetrical (peak) current in at least one phase equal to the rated value and clear the resulting fault current, with the interrupter remaining operable and able to carry and interrupt rated current. Certified test abstracts establishing such ratings shall be furnished upon request. 2. The fault interrupter shall be provided with a disconnect with an integral ground position that is readily visible through the viewing window to eliminate the need for cable handling and exposure to high voltage to ground the equipment. 3. The ground position shall have a ten-time duty-cycle fault-closing rating. 4. The disconnect shall be provided with an open position that is readily visible through the viewing window to eliminate the need for cable handling and exposure to high voltage to establish a visible gap. 5. The open gaps of the disconnect shall be sized to allow cable testing through a feedthru bushing or the back of the elbow. 6. An internal indicator shall be provided for each fault interrupter to show when it is in the tripped condition. The indicator shall be clearly visible through the viewing window. L. Operating Mechanisms 1. Load-interrupter switches and fault interrupters shall be operated by means of a quick- make, quick-break mechanism. 2. The manual handle shall charge the operating mechanism for opening, closing and grounding of the switches and fault interrupters. Medium Voltage Pad-Mounted Switch 26 12 01 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Operating mechanisms shall be equipped with an operation selector to prevent inadvertent operation from the closed position directly to the grounded position, or from the grounded position directly to the closed position. The operation selector shall require physical movement to the proper position to permit the next operation. 4. Operating shafts shall be padlockable in any position to prevent operation. 5. The operation selector shall be padlockable to prevent operation to the grounded position. 6. The operating mechanism shall indicate switch position which shall be clearly visible from the normal operating position. M. Overcurrent Control 1. A microprocessor-based overcurrent control shall be provided to initiate fault interruption. 2. The control shall be capable of three-pole tripping of each fault interrupter. 3. The control shall be mounted in a watertight enclosure and shall be removable in the field without taking the gear out of service. 4. Control settings shall be field programmable using a personal computer connected via a data port to the control. The data port shall be accessible from the exterior of the enclosure. 5. Power and sensing for the control shall be supplies by integral current transformers. 6. The minimum total clearing time (from initiation of the fault to total clearing) for fault interruption shall be 40 milliseconds (2.4 cycles) at 60 hertz. 7. The control shall feature time-current characteristic (TCC) curves, including standard E- speed, coordinating-speed tap, and coordinating-speed main curves. Coordinating speed tap curves shall optimize the coordination with load-size week-link/backup current-limiting fuse combinations, and coordinating-speed main curves shall optimize coordination with tap interrupter curves. 8. The standard E-speed curve shall have phase overcurrent settings ranging from 25E through 200E. The coordinating-speed tap curve shall have phase-overcurrent and independent ground-overcurrent settings ranging from 50 amperes through 400 amperes. The coordinating-speed main curve shall have phase-overcurrent and independent ground-overcurrent settings ranging from 100 amperes through 800 amperes. 9. The control shall have instantaneous-trip (1 kA through 8 kA) and definite-time delay (32 ms through 96 ms) settings to allow tailoring of the coordinating-speed tap and coordinating-speed main curves to the application. 2.02 PAD MOUNTED SWITCH A. Construction 1. SF6 Gas Insulation a. The SF6 gas shall conform to ASTM D2472. Medium Voltage Pad-Mounted Switch 26 12 01 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements b. The switch shall be filled with SF6 gas to a pressure of 7 psig at 68 deg F. c. The gas-tight tank shall be evacuated prior to filling with SF6 gas to minimize moisture in the tank. d. The switch shall withstand system voltage at a gas pressure of 0 psig at 68 deg F. e. A gas-fill valve shall be provided. f. A temperature compensated pressure gauge shall be provided that is color coded to show the operating range. The gauge shall be mounted inside the gas-tight tank (visible through a large viewing window) to provide consistent pressure readings regardless of the altitude at the installation site. 2. Gas-Tight Tank a. The tank shall be submersible and able to withstand up to 10 ft. of water over the base. b. The tank shall be of welded construction and shall be made of Type 304L stainless steel. c. A means of lifting the tank shall be provided. 3. Gas-Tight Tank Finish a. To remove oils and dirt, to form a chemically and anodically neutral conversion coating to improve the finish-to-metal bond, and to retard underfilm propagation of corrosion, mild-steel surfaces shall undergo a thorough pretreatment process comprised of a fully automated system of cleaning, rinsing, phosphatizing, sealing, drying and cooling before any protective coatings are applied. By utilizing an automated pretreatment process, the mild-steel surfaces of the gas-tight tank shall receive a highly consistent thorough treatment, eliminating fluctuations in reaction time, reaction temperature and chemical concentrations. b. After pretreatment, protective coatings shall be applied that shall help resist corrosion and protect the mild-steel surfaces of the gas-tight tank. To establish the capability to resist corrosion and protect the mild steel, representative test specimens coated by the manufacturer's finishing system shall satisfactorily pass the following tests: 1). 1500 hours of exposure to salt-spray testing per ASTM B117 with: a). Underfilm corrosion not to extend more than 1/32" from scribe as evaluated per ASTM D 1645, Procedure A, Method 2 (scraping); and b). Loss of adhesion from bare metal not to extend more than 1/8" from the scribe. 2). 1000 hours of humidity testing per ASTM D 4585 using the Cleveland Condensation Type Humidity Cabinet with no blistering as evaluated per ASTM D714. 3). Crosshatch adhesion testing per ASTM D3359 Method B with no loss of finish. c. The finish shall be inspected for scuffs and scratches. Blemishes shall be touched up by hand to restore the protective integrity of the finish. Medium Voltage Pad-Mounted Switch 26 12 01 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements d. The finish shall be indoor light gray, satisfying the requirements of ANSI Standard Z55.1 for No. 61. 4. The gas-tight tank shall be made of 7-gauge mild-steel. 5. Enclosure a. The switch shall be provided with a pad-mounted enclosure suitable for installation of the switch on a concrete pad. b. The pad-mounted enclosure shall be separable from the switch to allow clear access to the bushings and bushing wells for cable termination. c. The basic material shall be 14-gauge hot-rolled, pickled, and oiled steel sheet. d. The enclosure shall be provided with removable front and back panels, and hinged lift-up roof sections for access to the operating and termination compartments. Each roof section shall have a retainer to hold it in the open position. Lift-up roof sections shall overlap the panels and shall have provisions for pad-locking that incorporate a means to protect the padlock shackle from tampering. e. The base shall consist of continuous 90-degree flanges, turned inward and welded at the corners, for bolting to the concrete pad. f. Panel openings shall have 90-degree flanges, facing outward, that shall provide strength and rigidity as well as deep overlapping between panels and panel openings to guard against water entry. g. For bushings rated 600 amperes continuous, the termination compartment shall be of an adequate depth to accommodate encapsulated surge arresters mounted in 600-ampere elbows having 200-ampere interfaces. h. For bushing wells rated 200 amperes continuous, the termination compartment shall be of an adequate depth to accommodate 200-ampere elbows mounted on feedthru inserts. i. An instruction manual holder shall be provided. 6. Enclosure Finish a. All exterior welded seams shall be filled and sanded smooth for neat appearance. b. To remove oils and dirt, to form a chemically and anodically neutral conversion coating to improve the finish-to-metal bond, and to retard underfilm propagation of corrosion, all surfaces shall undergo a thorough pretreatment process comprised of a fully automated system of cleaning, rinsing, phosphatizing, sealing, drying, and cooling, before any protective coatings are applied. By utilizing an automated pretreatment process, the enclosure shall receive a highly consistent thoroughly treatment, eliminating fluctuations, in reaction time, reaction temperature, and chemical concentrations. c. After pretreatment, protective coatings shall be applied that shall help resist corrosion and protect the steel enclosure. To establish the capability to resist corrosion and protect the enclosure, representative test specimens coated by the manufacturer's finishing system shall satisfactorily pass the following tests: 1). 4000 hours of exposure to salt-spray testing per ASTM B117 with: Medium Voltage Pad-Mounted Switch 26 12 01 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements a). Underfilm corrosion not to extend more than 1/32" from the scribe as evaluated per ASTM D1645, Procedure A, Method 2 (scraping); and b). Loss of adhesion from bare metal not to extend more than 1/8' from the scribe. 2). 1000 hours of humidity testing per ASTM D 4585 using the Cleveland Condensing Type Humidity Cabinet with no blistering as evaluated per ASTM D714. 3). 500 hours of accelerated weathering testing per ASTM G 53 using lamp UVB-313 with no chalking as evaluated per ASTM D659, and no more than 10% reduction of glass as evaluated per ASTM D523. 4). Crosshatch adhesion testing per ASTM D3359 Method B with no loss of finish. 5). 160-inch-pound impact adhesion testing per ASTM D 2794 with no chipping or cracking. 6). Oil resistance testing consisting of a 72-hour immersion bath in mineral oil with no shift in color, no streaking, no blistering, and no loss of hardness. 7). 3000 cycles of abrasion testing per ASTM 4060 with no penetration to the substrate. a). Certified test abstracts substantiating the above capabilities shall be furnished upon request. d. The finish shall be inspected for scuffs and scratches. Blemishes shall be touched up by hand to restore the protective integrity of the finish. e. The finish shall be outdoor light gray, satisfying the requirements of ANSI Standard Z55.1 for No.70. 2.03 LABELING A. Hazard-Altering Signs 1. The exterior of the pad-mounted enclosure (if furnished) shall be provided with "Warning-Keep Out-Hazardous Voltage Inside Can Shock, Burn, or Cause Death" signs. 2. Each unit of switch shall be provided with "Danger-Hazardous Voltage-Failure to Follow These Instructions Will Likely Cause Shock, Burns, or Death" sign. The text shall further indicate that operating personnel must know and obey the employers's work files, know the hazards involved, and use proper protective equipment and tools to work on this equipment. 3. Each unit of switch shall be provided with a "Danger-Keep Away-Hazardous Voltage-Will Shock, Burn, or Cause Death" sign. B. Nameplates, Ratings Labels, and Connection Diagrams 1. Each unit of switchgear shall be provided with a nameplate indicating the manufacturer's name, catalog number, model number, date of manufacture, and serial number. Medium Voltage Pad-Mounted Switch 26 12 01 - 9 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Each unit of switch shall be provided with a ratings label indicating the following voltage rating: main bus continuous rating; short-circuit rating, fault interrupter ratings including interrupting and duty-cycle fault-closing; and load-interrupter-switch ratings including duty-cycle-fault-closing and short-time. 3. The pad-mounted enclosure (if furnished) shall be provided with a connection diagram showing load-interrupter switches, fault interrupters and integral disconnects, and bus along with the manufacturer's model number. 2.04 ACCESSORIES A. A shotgun clamp stick (6'-5-1/2”, 8'-5-1/2") in length shall be provided complete with a canvas storage bag. B. An adapter cable for connecting an overcurrent control to a user-furnished personal computer (having a 25-pin or 9-pin serial communication port) in the field shall be provided. 2.05 TERMINATIONS A. The pad-mounted switch manufacturer shall provide terminals for load-interrupter switches which shall have 600-ampere bushings, the manufacturer shall also supply the 600-ampere dead break elbows on the source side. All conductive material within the elbow and bushing shall be copper, aluminum shall not be allowed. Terminals for load-interrupter switches shall have 600-ampere bushings, and terminals for fault interrupters shall have 200-ampere bushing wells to permit connection of elbows. Bushings and bushing wells shall be located on one side of the gear to reduce the required operating clearance. B. Lightning Arresters: Primary overvoltage protection shall be provided by externally mounted Heavy-Duty distribution M.O.V.E. deadfront primary elbow arresters for each phase rated at 15 KV or as required per operating voltage. C. Primary Bushings and Bushing Wells 1. Bushings shall be deadfront type for use with separable connectors conforming to ANSI/IEEE Standard 386 and ANSI Standard C119.2 2. Bushings and bushing wells shall include a semi-conductive coating. 3. The bushings shall have a continuous current rating of 600-amps 4. Bushings and bushing wells shall be mounted in such a way that the semi-conductive coating is solidly grounded to the enclosure. 5. 600-amp bushings shall be RTE insulated deadbreak type conforming to ANSI/IEEE Std. 386 and ANSI C119.2 with copper current carrying parts. The bushings shall be provided with removable copper studs. A 600-amp deadbreak elbow with copper current carrying parts shall be furnished for each bushing. The 600-amp deadbreak elbow shall be equipped with a 200-amp loadbreak reducing plug that shall be used to connect the lightning arresters to the 600-amp deadbreak elbow. 6. Bushings must be horizontally mounted at least 24 inches above the pad and accept molded, separable deadfront connectors. D. Secondary Bushings and Bushing Wells Medium Voltage Pad-Mounted Switch 26 12 01 - 10 DTN18104 – Lake Lewisville WTP Phase II Improvements 1. Bushings shall be deadfront type for use with separable connectors conforming to ANSI/IEEE Standard 386 and ANSI Standard C119.2. The bushings shall have a continuous current rating of 600-amps 2. Bushings and bushing wells shall include a semi-conductive coating. 3. Bushings and bushing wells shall be mounted in such a way that the semi-conductive coating is solidly grounded to the enclosure. 4. Bushings must be horizontally mounted at least 24 inches above the pad and accept molded, separable deadfront connectors. 3.00 EXECUTION 3.01 INSTALLATION A. Assemble and install the equipment in accordance with instructions and directions furnished by the Manufacturer, and as detailed on the Plans. If neither are available, install the equipment using the best recognized practices of the electrical industry and trade. Manufacturer's representative shall be available to advise the Contractor in this work. Make all electrical connections to all equipment specified. B. Furnish the services of an experienced installation field service Engineer who shall be experienced in the assembly and wiring of the switch units of similar size and character. He shall direct the installation of the equipment and shall assist and advise with the electricians or other workmen who are performing the actual work of installing the switch. He also shall assist in the adjustment and testing of the equipment. C. Program the settings of the fault interrupters per the requirements of the Power System Studies. D. Adjust the calibration of protective relays according to the schedule and test the settings. Prepare a card index for the relays, the settings, the test results and marked thereon, and submit to the Owner. E. Instruct the operating and maintenance personnel in principle of operation of all major devices and the care and maintenance of components included in the switchgear. F. Time spent on the job by the Erection Engineer shall be adequate for performing the above functions but shall in no case be less than that tabulated below: 1. Trips to the project, days: 1 - (8-hour days which does not include travel time) 2. Supervision & work, days: 2 - (8-hour days which does not include travel time) 3. Training, days: 1 - (8-hour day which does not include travel time) G. All costs (travel expenses, testing equipment, etc.) required for testing and start-up shall be the responsibility of the pad-mounted switch manufacturer/contractor. 3.02 FIELD QUALITY CONTROL A. Upon completion of the installation, perform continuity tests and functional checkout to assure the proper operation of all equipment. The manufacturer's representative shall be available to assist the Contractor in checking the operation of the Pad-Mounted Switchgear. Medium Voltage Pad-Mounted Switch 26 12 01 - 11 DTN18104 – Lake Lewisville WTP Phase II Improvements Tests shall be conducted to assure proper operation of all circuits. The manufacturer's representative shall assist in correcting any deficiencies at no expense to the Owner. 3.03 CLEAN AND ADJUST A. The manufacturer shall furnish sufficient touch-up paint of the same type and color used at the factory to repair damages incurred in installation. Perform touch up painting to achieve the original paint thickness, quality and appearance. END OF SECTION Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 12 19 PAD-MOUNTED LIQUID FILLED, MEDIUM VOLTAGE TRANSFORMERS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install pad mount transformers and provide a complete and operational system. Electrical work shall be in accordance with Section 26 05 00, Common Work Results For Electrical. Location Equipment Name Lake Lewisville Water Treatment Plant “TX-1” Lake Lewisville Water Treatment Plant “TX-2” Lake Lewisville Water Treatment Plant “TX-3” 1.02 QUALITY ASSURANCE A. ACCEPTABLE MANUFACTURERS 1. ABB 2. General Electric (G.E.) 3. Eaton/Cutter-Hammer 4. All others shall submit qualifications to the Owner and the Engineer for review and approval prior to bid submittal no later than one week after bid advertisement date. Any submittals after this time period shall not be evaluated. Qualifications shall include equipment manufacturer who have had at least 10 years of successful experience in providing equipment for similar projects with a generator and pump station configurations. Qualifications shall include a list of similar projects within the last 5 years with the name of the project and contact information of the Owner. B. Transformers shall conform to 2010 standard efficiency levels for liquid immersed distribution transformers, as specified in Table I.1 of the Department of Energy ruling, "10 CFR Part 431 Energy Conservation Program for Commercial Equipment: Distribution Transformers Energy Conservation Standards; Final Rule; October 12, 2007." Manufacturer shall comply with the intent of all regulations set forth in noted ruling. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, Submittal Procedures and shall include: 1. SHOP DRAWINGS a. Product Data: Include rated nameplate data, capacities, materials, weights, dimensions, minimum clearances, installed devices and features, location of each field connection, fuse time current curves, and performance for each type and size of transformer indicated Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements b. Transformer magnetizing current magnitude and duration. c. Load and no load losses. d. Itemized bill of materials. 2. Qualification Data: For testing agency. 3. Source quality-control test reports. 4. Factory Test Data: a. No load losses, load losses, efficiency, impedance, X/R, etc. B. FIELD TEST DATA: 1. No load losses, load losses, etc. 2. Field quality-control test reports. 3. NETA Acceptance Testing Specification (ATS) field tests and inspections tests report. C. OPERATION AND MAINTENANCE DATA 1. Operation and maintenance manuals shall contain the final approved shop drawings, submittals, spare parts lists, schematics, final wiring diagrams, and maintenance procedures. Include procedures for sampling and maintaining fluid, cleaning unit, and replacing components. Include procedures for emergency, operation, and maintenance for transformers and accessories. D. FOLLOW-UP SERVICE REPORTS. 1.04 STANDARDS A. The applicable provisions of the latest edition of following standards shall apply as if written here in their entirety: IEEE C57.12.00 IEEE General Requirements for Liquid-Immersed Distribution, Power, and Regulating Transformers IEEE C57.12.22 Pad-Mounted, Compartmental-Type, Self-Cooled Three Phase Distribution Transformers with High-Voltage Bushings, 2500 kVA and Smaller; High Voltage, 34,500 GRD Y/19,920 Volts and Below; Low Voltage, 480 Volts and Below IEEE C57.12.26 Pad-Mounted, Compartmental-Type, Self-Cooled, Three-Phase Distribution Transformers for Use with Separable Insulated High- Voltage Connectors, (34,500 GRD Y/19,920 Volts and Below; 2500 kVA and Smaller) IEEE C57.12.34 Requirements for Pad-Mounted, Compartmental-Type, Self-Cooled, Three-Phase Distribution Transformers (2500 kVA and Smaller) - High Voltage: 34,500 GRD Y/19,920 Volts and Below; Low-Voltage: 480 Volt 2500 kVA and Smaller IEEE C57.12.28 IEEE Standard for Pad-Mounted Equipment - Enclosure Integrity IEEE C57.12.70 Terminal Markings and Connections for Distribution and Power Transformers Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements IEEE C57.12.80 Terminology for Power and Distribution Transformers IEEE C57.12.90 Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers IEEE 386 Separable Insulated Connector Systems for Power Distribution Systems Above 600V IEEE C57.91 Guide for Loading Mineral-Oil Immersed Transformers IEEE C57.92 Guide for Loading Oil-Immersed Power Transformers NEMA TR-1 Transformers, Regulators and Reactors NFPA 70 National Electrical Code NEMA 260-1996 (2004) Safety Labels for Pad-Mounted Switchgear and Transformers Sited in Public Areas 10 CFR Part 431 Department of Energy – Energy Conservation Program for Commercial Equipment: Distribution Transformers Energy Conservation Standards; Final Rule 1.05 DELIVERY, STORAGE AND HANDLING A. The manufacturer shall be responsible for delivery of the equipment, and accessories, f.o.b. to the job site or to such storage site as may be designated by the Owner or Construction Contractor, in good condition and undamaged. B. Unloading and storage of the equipment shall be the responsibility of the Construction Contractor who shall inspect the equipment for apparent damage. Equipment which is found to be damaged will not be accepted until properly repaired or replaced by the Vendor. C. Handling and shipment of the equipment shall be in such a manner to prevent internal component damage, breakage, and denting and scoring of the enclosure finish. D. Equipment must be delivered and stored in accordance with the manufacturer’s recommendation at all times. Equipment shall be stored indoors in a clean, dry, climate controlled heated and air-conditioned environment that is free from dust, No Exceptions. Store equipment indoors in a dry space with uniform temperature to prevent condensation. Protect equipment from exposure to dirt, fumes, water, corrosive substances and physical damage. 1.06 COORDINATION A. Construction Contractor shall coordinate installation of transformer with other construction that penetrates walls or is supported by them, including electrical and other types of equipment, raceways, piping, encumbrances to workspace clearance requirements, and Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels. B. Construction Contractor shall coordinate sizes and locations of concrete bases with actual equipment provided. Cast anchor-bolt inserts into bases. 1.07 WARRANTY A. Equipment Manufacturer shall warrant the equipment furnished under this Specification for a period of two (2) years against defects in materials and workmanship, equipment design, and operational failure. B. In the event of failure in material, workmanship, or equipment design of any part or parts of the equipment during the warranty period, and provided that the equipment has been operated and maintained in accordance with good practice, the Equipment Manufacturer shall furnish, deliver, and install the defective part or parts at Equipment Manufacturer’s own expense. During the warranty period, the Owner will remove and load the Goods on a vehicle provided by the Equipment Manufacturer if it is necessary to return the Goods to the Equipment Manufacturer for correction of defects during the Warranty Period. Owner will reinstall the Goods when they are returned to the Site after defects have been corrected. The Equipment Manufacturer is to provide all parts, labor and incidental cost for making repairs, shipping the Goods to the Site and providing startup services in accordance with specifications. C. The warranty period shall be interpreted as the twenty-four (24) month period following the installation, adjusting and acceptance testing, and the start of actual operation of the equipment or thirty (30) months after complete delivery, whichever occurs first. 2.00 PRODUCTS 2.01 RATINGS A. Transformer shall be self-cooled. For Transformer rated below 2000kVA: Winding temperature rise shall not exceed 55°C above a 30° average ambient with a maximum ambient not to exceed 40°C, operating at full rated load. The insulation system shall allow an additional 12% kVA output at 65°C average winding temperature rise by resistance, on a continuous basis, without a decrease in normal transformer life. Primary windings and Secondary windings shall have the following ratings: Transformer Schedule Identification KVA Rating Primary Voltage Primary BIL Secondary Voltage Secondary BIL Maximum Impedance Connection (Pri./Sec.) Overcurrent Protection TX-1 750 2,400V, 3- phase 60 kV 480Y/277V, 3 Phase 30 kV 5.75 Delta-Wye Grounded CLF with Bay-O-Net Fuses TX-2 750 2.400V, 3- phase 60 kV 480Y/277V, 3 Phase 30 kV 5.75 Delta-Wye Grounding CLF with Bay-O-Net Fuses Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements TX-3 112.5 13,200V, 3-phase 95 kV 208Y/120V, 3 Phase 30 kV 5.57 Delta-Wye Grounding CLF with Bay-O-Net Fuses 2.02 CONSTRUCTION A. Transformer(s) shall be compartmental-type enclosed, self-cooled, liquid filled tamper resistant, weatherproof and suitable for mounting on a concrete pad. Transformer shall be cooled by natural convection. B. Transformer tank(s) shall utilize welded steel construction, sealed to withstand an internal pressure of up to 7 psi without distortion and top oil temperatures ranging from 50°C to 105°C. Tank cover shall be designed to permit access to internal components for inspection or repair. Heavy duty, non-removable lifting lugs and jacking pads shall be provided. When required, welded cooling panels or radiators shall be provided on the back and sides of the tank. C. The high and low voltage compartments shall be located side-by-side separated by a steel barrier. When facing the transformer, the low voltage compartment shall be on the right. Terminal compartments shall be full height with individual doors. The high voltage door fastenings shall not be accessible until the low voltage door has been opened. The low voltage door shall have a 3-point latching mechanism with vault type handle having previsions for a single padlock. The doors shall be equipped with lift-off type stainless steel hinges and door stops to hold the doors open when working in the compartments. The front sill of the compartment shall be removable to allow the transformer to be rolled or skidded into position over conduit stubs. ANSI tank grounding provisions shall be furnished in each compartment. D. Windings and internal leads shall be copper, insulated and braced to prevent phase flashover during fault conditions. Transformers with wye connected primary and secondary windings shall have the neutral insulated from the secondary neutral and brought out into the primary compartment through separate bushing. Both neutral bushings shall be externally connected to the tank with removable copper straps. E. Transformer coils shall be of the continuous wound construction with terminations brazed or welded and shall be impregnated with non-hygroscopic, thermosetting varnish. F. The core of the transformer shall be visibly grounded to the enclosure by means of a flexible grounding conductor sized in accordance with applicable NEMA, IEEE, and ANSI standards. G. Transformer insulating fluid shall be FR3 Less flammable, edible-seed-oil based, and UL listed as complying with NFPA 70 requirements for fire point of not less than 300 deg C when tested according to ASTM D 92. Liquid shall be biodegradable and nontoxic. Insulating oil shall be free of P.C.B. contamination or any E.P.A. listed toxic chemical. H. All transformer shall be Factory Mutual listed and have the FM label. I. Furnish a no load, externally operated, lockable, five position primary winding tap changer located in the secondary terminal compartment. Tap settings must be clearly visible with the compartment door in the open position. Provide transformers rated greater than 30 kVA with two (2) 2-1/2% full capacity taps below and two (2) 2-1/2% above rated voltage in Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements primary. Tap changing shall be via an externally operated manual tap changer for operation when transformer is de-energized. J. The average audible sound level shall not exceed 63 DB for transformers rated above 75 kVA, when measured in accordance with NEMA Standard TR1. K. Terminations: 1. Medium Voltage primary terminations shall be arranged for dead front radial feed and conforms to ANSI C57.12.26 requirements. Provide one piece integrated bushings for use with elbow terminators and parking stands for disengaged elbows. Bushings or wells shall be externally clamped to allow external replacement. a. 5kV 1). The Contractor shall furnish 200 Amp load-break elbows (8.3 kV line-to-ground maximum) elbow terminators for each bushing in accordance with ANSI C119.2 and conforming to ANSI/IEEE Std. 386 and ANSI C119.2 with copper current carrying parts. The bushings shall be provided with removable copper studs. Elbows shall be manufactured with copper current carrying parts and shall be furnished for each bushing. The Contractor shall furnish 200 Amp load-break elbows (8.3 kV line-to-ground maximum) elbow terminators for each bushing in accordance with ANSI C119.2 and conforming to ANSI/IEEE Std. 386 and ANSI C119.2 with copper current carrying parts. The bushings shall be provided with removable copper studs. Elbows shall be manufactured with copper current carrying parts and shall be furnished for each bushing. 2. For bushings rated 600 amperes continuous, the termination compartment shall be of an adequate depth to accommodate encapsulated surge arresters mounted in 600- ampere elbows having 200-ampere interfaces to accommodate Lightning Arresters. 3. For bushing wells rated 200 amperes continuous, the termination compartment shall be of an adequate depth to accommodate 200-ampere elbows mounted on feed thru inserts. L. Low Voltage Bushings and Terminals 1. Bushing Style a. Voltages less than 700 Volts: The transformer shall be provided with tin-plated spade-type bushings for vertical takeoff. The spacing of the connection holes shall be 1.75” on center, per ANSI C57.12.34 figure 13a. The quantity of connection holes shall be a minimum 4 holes. b. Transformers 300 kVA and below, and 500 kVA with 480Y/277 secondary will have two piece low voltage bushings with studs and screw on spades. Transformers 500 kVA with 208Y/120 secondary and all transformers above 500 kVA will have one- piece bushings. c. Bushing supports shall be provided for transformers requiring 10 or more connection holes. Bushing supports shall be affixed to the cabinet sidewalls; tank- mounted supports mountings are not acceptable. 2. Bushing Configuration Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements a. The transformer shall be provided with bushings in a staggered arrangement in accordance with Figure 11a dimensions of ANSI C57.12.34. 2.03 HIGH VOLTAGE PRIMARY SWITCHING AND PROTECTIVE EQUIPMENT A. Primary Fuse Arrangement: 1. Provide oil immersed partial range current limiting fuses (CLF) in series with externally removable Bay-O-Net type expulsion fuses. Fuse mounts shall be dead front, externally removable, hook stick operated, load-break, individual fused disconnect devices, located in the high voltage compartment above the primary bushings to permit fuse replacement without opening the tank. Current limiting fuses shall be accessible through a handhole in the tank cover. 2. The CLF and expulsion fuses shall be properly coordinated such that the CLF protects for fault values above the expulsion fuse interrupting rating, the expulsion fuse protects the CLF for current values below the CLF interrupting capability and the CLF will not operate for low side faults beyond secondary terminals. 3. An interlock shall be required between the load-break switch scheme specified and the bayonet fuses, such that the fuses may not be removed unless the transformer has been de-energized via the load-break switch scheme. B. Lightning Arresters 1. Furnish three arresters for radial-feed 12kV distribution class lightning arresters complying with IEEE C62.11 mounted in the high voltage primary compartment for surge protection. 2. Primary overvoltage protection shall be provided by externally mounted Heavy-Duty distribution M.O.V.E. deadfront primary elbow arresters for each phase rated at 12kV. Arresters shall be suitable for operation on a 13.2kV system that is solidly grounded. C. Primary and secondary conductors are as shown on the plans. 2.04 ACCESSORIES A. Each transformer shall be furnished with the following accessories: 1. Nameplate in the low voltage compartment. 2. 1-in. drain plug with sampling device. 3. 1-in. upper filter press and filling plug. 4. Dial type thermometer with maximum temperature indicator, mounted in a sealed drywell in the low voltage compartment. 5. Auxiliary, sealed, dry contact in thermometer for remote indication of high temperature alarm. 6. Pressure-vacuum gauge mounted in the low voltage compartment. 7. Automatic Pressure relief valve. Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements 8. Magnetic liquid level gauge located in the low voltage compartment at the 25° C level mark. 9. Auxiliary, sealed, dry contact in the level gauge for remote indication of low oil level alarm. 10. Ground provisions per C57.12.34 section 9.11. 11. Meet NEMA TR-1 sound levels. 12. Ground connectors. 13. Touch-up paint. 14. Long barrel NEMA 2-hole lugs for each phase and ground conductor. 2.05 SURFACE PREPARATION AND SHOP COATINGS A. All welds shall be ground smooth and all metal surfaces cleaned of oil, grease and weld splatter using hot phosphate chemical treatment. A zinc-rich, heat cured epoxy primer shall be applied to inhibit rust. B. The entire transformer enclosure shall be degreased, cleaned, phosphatized, primed, and baked enamel finish with 3 mils minimum. Transformers shall be painted per ANSI C57.12.28. 2.06 SHOP TESTING A. Perform manufacturers standard production testing and inspection in accordance with ANSI and/or NEMA standards. Testing shall include the following as a minimum: 1. Resistance measurements of all windings on the rated voltage connection of each unit. 2. Ratio tests on the rated voltage connection and on all tap connections. 3. Polarity and phase-relation tests on the voltage connections. 4. No-load loss at rated voltage on the rated voltage connections. 5. Exciting current at rated voltage on the rated voltage connection. 6. Impedance and load loss at rated current on the rated voltage connection of each unit. 7. Applied potential test. B. Results of the above tests including no load loss data shall be submitted with final drawings in the form of certified test reports. C. For each transformer size provided under this contract, provide as a minimum a copy of the following manufacturer’s standard factory test reports: 1. Short Circuit capability of each kVA size transformer. 3.00 EXECUTION 3.01 FIELD QUALITY CONTROL Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 9 DTN18104 – Lake Lewisville WTP Phase II Improvements A. Testing: All testing required shall be per Specification 16020 ELECTRICAL TESTING and shall include the following: 1. Perform each electrical test and visual and mechanical inspection in NETA Acceptance Testing Specification (ATS). Certify compliance with test parameters 2. After installing transformers but before primary is energized, verify that grounding system at substation is tested at specified value or less. 3. After installing transformers and after electrical circuitry has been energized, test for compliance with requirements. 4. Perform visual and mechanical inspection and electrical test stated in NETA ATS. Certify compliance with test parameters. 5. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. 6. Thermographic Survey in accordance with NETA Acceptance Testing Specification. B. Remove and replace malfunctioning units and retest as specified above. C. Test Reports: Prepare written reports to record the following: 1. Test procedures used. 2. Test results that comply with requirements. 3. Test results that do not comply with requirements and corrective actions taken to achieve compliance with requirements. All corrective actions taken shall be at no additional cost to the Owner. 4. Test reports shall be submitted as required by Specification Section 26 01 26 TESTING OF ELECTRICAL SYSTEMS. All test reports shall be submitted in one binder under Specification Section 26 01 26 TESTING OF ELECTRICAL SYSTEMS. 3.02 PRODUCTION TESTING A. All units shall be tested for the following: 1. No-Load (85°C or 20°C) losses at rated current 2. Total (85°C) losses at rated current 3. Percent Impedance (85°C) at rated current 4. Excitation current (100% voltage) test 5. Winding resistance measurement tests 6. Ratio tests using all tap settings 7. Polarity and phase relation tests 8. Induced potential tests 9. Full wave and reduced wave impulse test B. Minimally, transformers shall conform to efficiency levels for liquid immersed distribution transformers, as specified in Table I.1 of the Department of Energy ruling. “10 CFR Part 431 Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 10 DTN18104 – Lake Lewisville WTP Phase II Improvements Energy Conservation Program for Commercial Equipment: Distribution Transformers Energy Conservation Standards; Final Rule.” Manufacturer shall comply with the intent of all regulations set forth in noted ruling. This efficiency standard does not apply to step-up transformers. C. In addition, the manufacturer shall provide certification for all design and other tests listed in C57.12.00, including verification that the design has passed short circuit criteria per ANSI C57.12.00 and C57.12.90. 3.03 FINISH PERFORMANCE REQUIREMENTS A. The tank coating shall meet all requirements in ANSI C57.12.28 including: 1. Salt Spray 2. Crosshatch adhesion 3. Humidity 4. Impact 5. Oil resistance 6. Ultraviolet accelerated weathering 7. Abrasion resistance – taber abraser B. The enclosure integrity of the tank and cabinet shall meet the requirements for tamper resistance set forth in ANSI C57.12.28 including but not limited to the pry test, pull test, and wire probe test. 3.04 INSTALLATION A. Install transformers on concrete bases. 1. Anchor transformers to concrete bases according to manufacturer's written instructions. 2. Construct concrete bases as shown on plans. 3. Concrete shall be in accordance with Division 03. 4. Install epoxy-coated anchor bolts, for supported equipment, that extend through concrete base and anchor into structural concrete floor. 5. Place and secure anchorage devices. Use supported equipment manufacturer's setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded. 6. The equipment shall be leveled and anchored directly to a concrete equipment pad. Provide hardware and stainless steel shims for installation as required. B. CONNECTIONS - Provide solderless lug bonding connection on the inside of the primary compartment in accordance with NEC. C. Install the equipment in accordance with the manufacturer’s recommendations. D. Maintain minimum clearances and workspace at equipment according to manufacturer's written instructions and NFPA 70. Pad Mounted, Liquid Filled, Medium Voltage Transformers 26 12 19 - 11 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.05 CLEAN AND ADJUST; VOLTAGE ADJUSTMENT A. When final connections have been made, check secondary voltage at transformers and make tap adjustments required to obtain correct voltage. B. The manufacturer shall furnish sufficient touch-up paint of the same type and color used at the factory to repair damages incurred during installation. Perform touch-up painting to achieve the original paint thickness, quality, and appearance. 3.06 FOLLOW-UP SERVICE A. Voltage Monitoring and Adjusting: If requested by Owner, perform the following voltage monitoring after Substantial Completion but not more than six months after Final Acceptance: 1. During a period of normal load cycles as evaluated by Owner, perform seven days of three-phase voltage recording at secondary terminals of each transformer. Use voltmeters with calibration traceable to National Institute of Science and Technology standards and with a chart speed of not less than 1 inch per hour. Voltage unbalance greater than 1 percent between phases, or deviation of any phase voltage from nominal value by more than plus or minus 5 percent during test period, is unacceptable. 2. Corrective Actions: If test results are unacceptable, perform the following corrective actions, as appropriate: a. Adjust transformer taps. b. Prepare written request for voltage adjustment by electric utility. 3. Retests: After corrective actions have been performed, repeat monitoring until satisfactory results are obtained. 4. Report: Prepare written report covering monitoring and corrective actions performed. B. Thermographic Survey in accordance with NETA Acceptance Testing Specification. 3.07 SPARE PARTS A. The following spare parts shall be provided: 1. Three (3) replacement power fuses or refills. 2. One (1) 5 gallon drum of insulating fluid. END OF SECTION Medium Voltage Metal Clad Switchgear 26 13 00 -1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 13 00 MEDIUM VOLTAGE METAL CLAD SWITCHGEAR 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to manufacture, fabricate, assemble, test, and deliver complete NEMA 1 Medium Voltage Metal Clad Switchgear line- up to be installed at the following location: Location Equipment Name Lake Lewisville Water Treatment Plant High Service Electrical Building 2.4kV Switchgear “SWGR-1” 1.02 QUALITY ASSURANCE A. IEC or dual IEC/NEMA equipment shall not be acceptable. 1. ACCEPTABLE MANUFACTURERS a. METAL CLAD SWITCHGEAR TYPE 2.4 kV 1). Eaton 2). Square D 3). General Electric 4). Siemens 5). All others shall submit qualifications to the Owner and the Engineer for review and approval prior to bid submittal no later than one week after bid advertisement date. Any submittals after this time period shall not be evaluated. Qualifications shall include equipment manufacturer who has had at least 10 years of successful experience in providing equipment for similar projects with a generator and pump station configurations. Qualifications shall include a list of similar projects within the last 5 years with the name of the project and contact information of the Owner. 2. DESIGN CRITERIA a. Metal clad switchgear shall be per the one line diagrams, breaker control schematic, and equipment elevations. Metal clad switchgear units shall all come from the same manufacturer. It shall be the responsibility of the switchgear manufacturer to assure that the busses and equipment, line up correctly with the 2400V motor control center (MCC). Switchgear manufacturer shall provide transition section as required to connect to MCC. Refer to plans for more information. The Medium Voltage Metal Clad Switchgear shall be the same manufacturer as the Medium Voltage MCC. NO EXCEPTIONS. b. See one-line diagram in plans for more information. All Units shall be top entry bottom entry/exit. Medium Voltage Metal Clad Switchgear 26 13 00 -2 DTN18104 – Lake Lewisville WTP Phase II Improvements c. The ratings for each of the metal clad switchgear line-ups shall be: 1). Nominal rms voltage class: 2.4 kV 2). Maximum design voltage: 4.76 kV 3). Basic impulse level: 60 kV 4). Power frequency withstand: 19 kV 5). Rms sym. interruption capability: 50,000 A 6). Closing and latching capability rms sym: 130kA Peak 7). Rated interrupting time: 5 cycles 3. The equipment shall be designed for the protection and control of power circuits on a 2.4kV, 3 phase, 3 wire, 60 Hertz low resistance grounded wye system. Main bus shall be tin plated copper rated for 1200A continuous duty. 4. Control power shall be 120 VAC from a control power transformer ahead of the main circuit breakers. All units shall be 120 volts solenoid rectifier close and stored energy trip by an auto-charged capacitor device. Each unit shall contain a DC energy storage device capable of tripping the breaker not less than two times through a period of 70 hours of power failure. B. FACTORY TESTS 1. GENERAL a. Switchgear sections shall be completely assembled, wired, adjusted, and tested at the factory. After complete assembly with breaker vacuum circuit interrupter in position, each unit shall be tested for operating sequence to assure accuracy of wiring, correctness of control scheme and functioning of the equipment. b. Factory tests shall include electrical tests as described by American National Standards Institute Standard C 37.20. c. The switchgear shall be assembled and shipped in sections of the largest size practicable to be unloaded and handled at the job. Breakers shall be shipped separate from switchgear units. d. The manufacturer shall perform all tests required by the applicable standards and shall be responsible for testing all control and relaying circuits within the switchgear to ensure proper function performance and operable condition. e. The switchgear shall be tested and certified in accordance with the applicable requirements of ANSI/IEEE C37.20.2 and ANSI C37.55. The switchgear unit shall be tested with the breakers included. “Test” breakers will not be acceptable. f. All AC high-voltage circuit breakers shall be tested and certified in compliance with the applicable requirements of ANSI/IEEE C37.09 and ANSI C37.54. g. All instrument transformers furnished for metering and relaying service shall be tested and certified in accordance with the applicable requirements of ANSI/IEEE C57.13. Medium Voltage Metal Clad Switchgear 26 13 00 -3 DTN18104 – Lake Lewisville WTP Phase II Improvements h. All busses and power circuit breakers shall undergo a one-minute, 60 Hz dielectric withstand test. All control circuits shall undergo a one-minute insulation resistance test. i. Proper wiring of protective relays shall be checked by injecting secondary current into the associated current transformer circuits and verifying that the relays respond properly. j. Components manufactured in different factories shall be shipped to the main switchgear assembly point for testing at the manufacturer’s expense. Additional testing of components is limited to those tests associated with test of completed equipment. k. Each unit shall be tested for operating sequence to assure accuracy of wiring, correctness of control scheme and functioning of the equipment. l. Factory tests for medium voltage metal enclosed switchgear shall include electrical tests as described by NEMA ICS 1-109 and ANSI C19.3. m. A statement of calibration shall be provided to cover all meters and relays. n. Provide copy of the certified test report to Engineer for approval prior to the switchgear being shipped to the jobsite. o. Detailed functional testing of switchgear main, tie and main breaker controls for all possible operating scenarios. C. FACTORY INSPECTION AND TESTS 1. GENERAL a. Equipment furnished under these specifications shall be subject to inspection during manufacturing by representatives of the Owner who shall be afforded proper facilities for determining compliance with the specifications. b. Switchgear manufacturer shall provide to the Engineer a complete list of all tests to be performed on the switchgear as a formal submittal to the Engineer prior to the switchgear being tested. 2. The switchgear manufacturer shall provide the actual test data, observations and certification that the tests have been completed prior to shipment to the Engineer for approval. 1.03 SUBMITTALS A. Submittals shall be in accordance with this section, the General Requirements, Section 01 33 00 “Submittal Procedures” and shall include the following minimum information: 1. Bid Submittal: In order to evaluate the bids, submit the following information. a. Data Sheet: Submit information requested on the Data Sheet included with the Bid Proposal forms. The Data Sheet is included at the end of the specification. 2. Pre-and Post-Submittal Meeting a. Supplier shall include in his bid the cost of attending a one-day pre-submittal meeting and a one-day post-submittal meeting at the offices of Freese and Nichols Medium Voltage Metal Clad Switchgear 26 13 00 -4 DTN18104 – Lake Lewisville WTP Phase II Improvements in Fort Worth, Texas or at the Lake Lewisville Water Treatment Plant in Denton, Texas – exact location to be determined at a later date. A pre-submittal meeting shall be held before any shop drawings are submitted. A post-submittal meeting shall be held after the Engineer’s shop drawing review comments have been submitted. Vendor shall determine the exact number of people attending the meeting per the specification requirements and cover each person’s cost. b. Any shop drawings submitted before the pre-submittal meeting will be rejected and sent back Not Approved, Revise and Re-submit. The Switchgear Supplier shall bring with them a detailed list of the items their submittal will include for review by the Engineer or a bootleg copy of the actual submittal. c. As a minimum the following shall attend the meeting: 1) General Contractor, 2) Electrical Contractor, 3) Switchgear Supplier and Engineer. Representatives from the Switchgear Supplier shall include: a). The Project Manager who will be responsible for putting together the submittal and who will be responsible for the project at the factory, no exceptions. b). The Project Engineer at the factory who has technical knowledge of the equipment, no exceptions. c). A sales person may attend, but not as a substitute for the Project Manager and/or Project Engineer. B. Shop Drawings shall include: 1. Complete description of all equipment, including catalogs, cuts and pertinent engineering data. Clearly identify on cut sheets the model number of the equipment being provided. Complete Bill of Material identifying make and model number of all major components. 2. Manufacturer of equipment 3. Manufacturer's type 4. Outline dimensions of line-up. 5. Provide overall outline drawing showing Metal-Clad Switchgear. 6. One and three line diagrams. 7. Front and rear elevation drawings clearly showing layout of all devices and mounting heights. 8. Clearly show dimensions from the top and bottom of the switchgear enclosure to the 2.4kV bus for terminating 5kV field cables. 9. Project specific wiring diagrams / interconnection diagrams / terminal strip layout showing customer connections. Terminal strip layout shall be provided as part of initial submittal. Medium Voltage Metal Clad Switchgear 26 13 00 -5 DTN18104 – Lake Lewisville WTP Phase II Improvements 10. Key interlock scheme drawing and detailed written sequence of operations for each set of kirk-key interlocks. Provide a description for kirk-key interlock operation. 11. Project specific control schematics. 12. Mimic bus layout. 13. Nameplate schedule. 14. Electrical interlock scheme with detailed written sequence of operations for main, and tie breakers. 15. Detailed information on remote racking device. 16. Weight of line-up 17. BIL test data on previously tested equipment of the same design 18. Spare parts list 19. Equipment Installation Report C. Where the Supplier's product differs from the specified requirements and/or catalog description, each point of difference shall be clearly stated. This requirement is set forth to facilitate the review of submittals and not to be construed by the Supplier as waiving any of the requirements of the specifications. Setting and foundation plans and dimension sheets for the equipment offered shall be submitted with each submittal. D. Prior to Shipment: The manufacturer shall provide detailed addresses (memory map) for the software I/O points that are communicated over Ethernet, RS485, etc. that are applicable to this project – this would include but not be limited to the data highways associated with the motor protection relay and AFD. Coordinate with OWNER/ENGINEER for the list of I/O that will be transmitted over the data highways, the manufacturer shall verify with NTMWD if any changes have been made to the lists prior to submitting the memory map. E. FACTORY TEST DATA 1. Submit factory test reports as a formal submittal to the Engineer for approval prior to shipping the equipment. F. FIELD TEST REPORTS 1. Submit Equipment Installation Report certifying the equipment is properly installed, is in accurate alignment, is free from undue stress from connecting appurtenances, that it has been operated under full load conditions, and that it is operating satisfactorily. G. OPERATION AND MAINTENANCE MANUALS 1. Submit Manuals with instructions for installation, adjustment, lubrication, operation and maintenance of the equipment in accordance with the specific conditions. 2. List all factory setting relay and provide relay-setting and calibration instructions, including software, where applicable. O&M manuals shall include a hard copy of the power meter settings. Medium Voltage Metal Clad Switchgear 26 13 00 -6 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Operation and maintenance manuals shall be prepared by the equipment manufacturer and shall contain the final certified approved shop drawings, submittals, list of manufacturer’s recommended spare parts, schematics, and maintenance procedures, and field test data. O&M manuals shall include all field changes made during startup and testing. 4. Manuals may be manufacturer's standard instructions, but shall be supplemented as necessary to cover any special feature not included in standard material. 5. Manuals shall be prepared by the Equipment Manufacturer and shall also incorporate appropriate final certified shop drawings and test data. Manuals may be manufacturer's standard instructions, but shall be supplemented as necessary to cover any special feature not included in standard material. 6. O&M manuals shall include a single document that clearly summarizes and states when the routine maintenance per the manufacturer’s recommendations is to be performed on the switchgear. 7. Submit preliminary manuals for review prior to start-up of equipment. 8. O&M Manuals shall be submitted in both hard copy and electronic format. Electronic format shall be fully indexed. 9. O&M Manuals shall be provided in accordance with Section 01 78 23, “Operation and Maintenance Data”. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: ANSI American National Standards Institute C37.010 Application Guide for AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis C37.100 Definitions for Power Switchgear C37.04 Rating Structure for AC High-Voltage Circuit Breakers C37.06 Preferred Ratings for AC High-Voltage Circuit Breakers Rated on a Symmetrical Current Basis C37.07 Factors for Reclosing Service C37.09 Test Procedure for AC High Voltage Circuit Breakers C37.11 Power Circuit Breaker Control C37.20.2 Metal-Clad and Station-Cubicle Switchgear C37.20.3 Standard for Metal-Enclosed Interrupter Switchgear C37.20.4 Standard for Indoor AC Medium - Voltage Switches used in Metal- Enclosed Switchgear C37.21 Application Guide for Metal-Enclosed Power Switchgear C37.54 Conformance Testing of Indoor AC High-Voltage Circuit Breakers Applied as Removable Elements in Metal-Enclosed Switchgear Assemblies Medium Voltage Metal Clad Switchgear 26 13 00 -7 DTN18104 – Lake Lewisville WTP Phase II Improvements C37.13 Standard Requirements for Instrument Transformers C37.55 Conformance Testing of Metal-Clad Switchgear C37.24 Guide for Evaluating the Effect of Solar Radiation NEMA National Electrical Manufacturers Association ICS 1 Industrial Control and Systems - General Requirements ICS 3 Industrial Control and Systems - Factory-Built Assemblies SG-4 Power Circuit Breakers SG-5 Power Switchgear Assemblies 1.05 DELIVERY, STORAGE AND HANDLING A. Follow the Manufacturer's directions for the delivery, storage and handling of equipment and materials. Tightly cover equipment and materials and protect it from dirt, water, chemical or mechanical injury and theft. Switchgear shall be stored indoors in a climate controlled (heated and air conditioned) building. Damaged equipment shall not be accepted. Upon installation, protect the materials until the work is completed and accepted by the OWNER. Manufacturer shall be responsible for delivering the equipment to the jobsite. B. The metal-clad 2.4kV switchgear shall be designed to be off-lifted with a four point hookup and a single point lift. The switchgear size may require more hookup points and a two point lift. Spreader bar, slings, and shackles required to off-load the switchgear. Should transportation require shipping splits, each open area of the switchgear shall be sealed with temporary two (2) inch thick wooden framing and a plywood cover for protection during transportation and storage at the job site. Seams in the temporary cover shall be sufficiently caulked on the exterior. C. The switchgear shall come in shipping splits to fit through the electrical building double doors. Exact shipping splits will be determined during shop drawing review phase. Shop drawings shall reflect the shipping splits. 1.06 WARRANTY A. Equipment Manufacturer shall warrant the equipment furnished under this Specification for a period of two (2) years against defects in materials and workmanship, equipment design, and operational failure. Medium Voltage Metal Clad Switchgear 26 13 00 -8 DTN18104 – Lake Lewisville WTP Phase II Improvements B. In the event of failure in material, workmanship, or equipment design of any part or parts of the equipment during the warranty period, and provided that the equipment has been operated and maintained in accordance with good practice, the Equipment Manufacturer shall furnish, deliver, and install the defective part or parts at Equipment Manufacturer’s own expense. During the warranty period, the Owner will remove and load the Goods on a vehicle provided by the Equipment Manufacturer if it is necessary to return the Goods to the Equipment Manufacturer for correction of defects during the Warranty Period. Owner will reinstall the Goods when they are returned to the Site after defects have been corrected. The Equipment Manufacturer is to provide all parts, labor and incidental cost for making repairs, shipping the Goods to the Site and providing startup services in accordance with specifications. C. The warranty period shall be interpreted as the twenty-four (24) month period following the installation, adjusting and acceptance testing, and the start of actual operation of the equipment or thirty-six (36) months after complete delivery, whichever occurs first. 2.00 PRODUCTS 2.01 METAL-CLAD 2.4KV SWITCHGEAR A. GENERAL 1. The switchgear shall be fabricated of sheet steel and completely enclosed. 2. IEC or dual IEC/NEMA equipment shall not be acceptable. 3. Equipment, including instrument transformers, instruments, switches, controls, etc., shall be furnished for each unit. Instruments, switches, etc., as required shall be mounted on the front face of the switchgear and arranged in an approved, logical and symmetrical manner. 4. Each metal-clad switchgear unit shall consist of a stationary element and a removable element. Stationary element shall include insulated copper busses, insulated copper connections, instrument transformers, primary disconnecting devices, automatic shutters, steel barriers between compartments, a manually or electrically operated mechanism for moving the circuit breaker to and from the connected position, mechanical interlocks, ground bus, terminal blocks and wiring for control and secondary connections, control fuses, and provision for connecting cables. The stationary units shall be constructed of welded structural shaped steel members together with formed sections of smooth panel sheet steel approximately 1/8" thick. Each unit shall be completely enclosed by a hinged panel door and removable plates permitting access to all compartments. The structures shall be rigid and self-supporting and so designed that units can readily be added in the future. The equipment shall be arranged so that all components, except potential or control transformers, may be removed from the front. Hinged-back access doors shall be provided. 5. The removable element shall consist of the circuit breaker, primary disconnecting devices, mechanical interlocks, secondary disconnecting devices, and control wiring. A circuit breaker of the size specified shall be furnished with each unit as shown on the drawings. Medium Voltage Metal Clad Switchgear 26 13 00 -9 DTN18104 – Lake Lewisville WTP Phase II Improvements 6. The circuit breaker shall be isolated from all other primary equipment and arranged so that it may be completely disconnected from the line and bus for test and inspection. All removable elements of like rating and having similar features shall be interchangeable. 7. Each circuit breaker manufacturer shall provide a remote racking device that is connected externally to the switchgear breaker compartment. Remote racking devices shall be provided with sufficient cable to stand twenty-five feet away and still remotely rack in/out the circuit breaker. a. If circuit breaker manufacturer does not offer remote racking device that is internally built into the breaker compartment, then as a minimum circuit breaker manufacturer shall provide a remote racking device that is connected externally to the switchgear breaker compartment. Remote racking devices shall be provided with sufficient cable to stand twenty-five feet away and still remotely rack in/out the circuit breaker. 8. The busses, circuit breaker and instrument transformers shall be mounted in separate grounded metal compartments. Control equipment shall be effectively isolated from the primary device. The busses shall be rigidly supported by insulating material of high mechanical and di-electric strength. Contact surfaces of bolted joints shall be silver plated. Primary circuits and joints shall be insulated. Material shall be included for insulating the bus and connection joints between adjacent metal-clad units separated for shipment. 9. A tin-plated copper ground bus shall extend through the stationary structure. It shall have a momentary rating at least equal to the highest momentary rating of any circuit breaker in the structure assembly. Each stationary unit shall be grounded directly to the ground bus. 10. The units shall be wired at the factory. Secondary and control connections shall be made with #14 gauge SIS wire. Wires shall be tagged (or shall terminate at marked terminals) with the designation given on the wiring diagrams. 11. A control power bus shall run the length of the metal-clad switchgear. Control power shall be derived from a control power transformer located in each main breaker section and generator breaker section. The source of control power shall be switched via an automatic transfer switch and run to a 120/240V power panel with a main circuit breaker located in the 2.4kV switchgear. Circuits out of the power panel shall feed switchgear devices. 12. Terminal blocks shall be supplied for secondary and control connections leaving the metal-clad structure. A fused disconnect switch, complete with fuses, shall be provided for each unit. The main breaker and generator breaker compartment shall contain a fused disconnect switch complete with fuses for the control bus. 13. Switchgear enclosures shall be large enough to accommodate stress cones for incoming conductors without exceeding minimum cable bending radius requirements per the NEC or the cable manufacturer, whichever is more stringent. Medium Voltage Metal Clad Switchgear 26 13 00 -10 DTN18104 – Lake Lewisville WTP Phase II Improvements B. CIRCUIT BREAKERS 1. The circuit breakers shall be of the vacuum interrupting type complete with solenoid operation mechanism, auxiliary switches, and interlocks mounted on a mobile frame. The frame shall be fabricated from formed steel plates electrically welded to form a rugged support for the equipment. A steel barrier shall separate the high-voltage parts of the circuit breaker from the operating mechanism and control devices. The frame shall have four wheels with bearings and a flange construction which shall engage with the rail as the unit is rolled into the housing. Each circuit breaker shall have the capability to be remotely operated (open/close) via the closing of a remote set of dry contacts. 2. The breaker unit shall move between the "test" position and "operating" position by means of a worm gear levering device operated by a removable hand crank. The device shall be mechanically interlocked with the breaker closing mechanism so that a closed breaker cannot be removed from the "operating" position or inserted from the "test" position. C. EQUIPMENT 1. Pump Station 2.4kV switchgear “SWGR;1”. a. Main & Tie Breaker Units: Each main breaker unit shall contain the following: 1 - Metal-clad stationary unit 1 - Time-delay Switch, circuit breaker control with lamps (SC-52) 1 - Solid state protective relay – Multilin 850 Feeder Protection Relay 1 – Power Quality Meter – Multilin PQM II Meter 1 - Power circuit breaker, electrically operated, 1200 ampere, removable element (52) 3 - Current transformers, 800:5 – standard accuracy for 850 Feeder Protection Relay 3 - Current transformers, 800:5 – metering accuracy for PQM II Meter 1 - Ground fault current transformer 50:5 1 – 86 Lockout Relay 1 - Standby power trip unit 1 - Three phase insulated busses, 1200 A., with necessary supports 1 - Control Power Transformer 1 - Control Power Bus, 120 Volts AC 1 - Ground bus 1 - Three phase station - type lightning arrester. 1 - Three phase surge capacitor 2 -Drawout type potential transformers with fuse mountings and one set of current limiting fuses. 1 -Drawout type control power transformers with fuse mountings and one set of current limiting fuses connected to a low voltage automatic transfer switch and main circuit breaker panelboard. 2. Bus Potential Transformers: 2 -Drawout type potential transformers with fuse mountings and one set of current limiting fuses installed on the main 2.4kV bus. See one-line diagram for more information. Medium Voltage Metal Clad Switchgear 26 13 00 -11 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Controls, indicating lights, selector switches, test switch, and protective relays shall be located on the door. In addition to the required indicating lights and selector switches associated with switchgear, the following door-mounted control switches and indicating lights shall be supplied and mounted on the door for each breaker: a. Breaker control switch with indicating lights 1). Red - Closed 2). Green - Open b. White indicating light (breaker spring charging motor charged). 4. Kirk-Key Interlocks: a. The kirk-key interlocks on the Main-Tie -Main shall be installed per the following: Main breakers shall be interlocked such that the tie breakers cannot be closed if one of the mains is closed. It shall not be possible to close both mains with the tie breaker closed. The kirk-key interlocks shall be provided. Provide detailed kirk key interlock sequence of operations on the plans. D. INSTRUMENT CURRENT TRANSFORMERS: Substantial and well built. Insulation shall meet the requirements of the IEEE standards. At normal rated amperes, under usual service conditions, no part of the transformer shall exceed the heating limits specified in the IEEE standards. Each current transformer shall be capable of carrying continuously, its rated primary amperes, under conditions of accidental open secondary circuit, without damage to the primary insulation. Accuracy shall meet or exceed requirements of ANSI C37.20.2, Table 5. Current Transformers shall be metering accuracy rated gong to power meter. Accuracy shall be 0.2% ANSI Accuracy Class with a B0.1 Meter Burden. Current transformers connected to the power meter shall be ANSI metering accuracy class current transformers (C400). All other current transformers shall have an ANSI accuracy classification of C200. E. INSTRUMENT POTENTIAL TRANSFORMERS: Substantial and well built. Insulation shall meet the requirements of the IEEE standards. At normal ratings under usual service conditions no part of the transformer shall exceed the heating limits specified in the IEEE Standards. Number of potential transformers shown on the plans is the minimum required; Coordinate with relay manufacturer for number of potential transformers required. F. BREAKER CONTROL SWITCH: Switch shall be a time-delay Electroswitch, model TD-CSR. Provide control description for the control device on the front of each section of the Metal Clad enclosure that details the operation of the time-delay switch located near each time- delay switch. G. METERING DEVICE: 1. Metering device on main incoming breaker section shall be Multilin PQM II Power Quality Meter. Meter shall have capability to communicate using Ethernet. Provide all hardware and software as required for Ethernet communications. 2. The metering device shall incorporate the following functions and features: a. Metering Functions with accuracy of 0.05 percent for A & V and 0.04 percent for power parameters. Meter shall comply with ANSI C12.20.5 class for revenue meters. 1). A, V, VA, W, var, KWH, KVARH, PF, Hz Medium Voltage Metal Clad Switchgear 26 13 00 -12 DTN18104 – Lake Lewisville WTP Phase II Improvements 2). W, var, A VA Demand 3). A, V, Unbalance 4). Total Harmonic Distortion (THD) of each current and voltage 5). Waveform Capture 6). Data Logging 7). Communications - Ethernet b. User Interface 1). The digital meter shall have the following user interfaces: a). Integrated keypad to access actual values and setpoints. 2). Relay output shall be through alarm, auxiliary and pulse output functions. 3). The meter shall provide a user configurable pulse output base on KWH, KVARH, or KVAH. 4). The meter shall provide a pulse input for demand synchronization. 5). The meter shall include a simulation mode capability for testing the functionality and meter response to programmed conditions without the need for external inputs. 3. Provide GE 515 Blocking and Test Module or approved equal (both current and voltage inputs) for testing of PQM II Power Meters. H. FEEDER PROTECTIVE RELAYS (FPR) 1. Furnish and install where shown on the plans a feeder management and protective relay. 2. Protective functions shall include: Phase overload standard curves (51), overload by custom programmable curve (51), short circuit (50), overcurrent (50), Directional Power (32), ground fault (50g/50n/51g/51n), under voltage (27) and over voltage (59). 3. Management functions shall include Statistical Data, Pre-trip Data, ability to learn, display and integrate critical parameter to maximize feeder protection and communication with external devices. 4. The relay shall be installed in a drawout case with wiring terminated at the rear of the fixed case. Shorting contacts shall be provided for the CT inputs and output relay contacts to allow for removal of the relay for bench testing without feeder shutdown. A test plug shall be provided for testing while in the case. 5. The feeder protective relays shall be Multilin 850 Feeder Protection Relay. See one-line diagram for more information. 6. Provide GE 515 Blocking and Test Module or approved equal (both current and voltage inputs) for testing of 850 Relays. 7. Communications protocol shall be Ethernet. Manufacturer shall provide all hardware, firmware and software to permit communications using Ethernet. Medium Voltage Metal Clad Switchgear 26 13 00 -13 DTN18104 – Lake Lewisville WTP Phase II Improvements a. 8. 86 Lockout Relay, shall be manufactured by Electroswitch, no approved equal. A minimum of four normally open and two normally closed (reset) isolated lockout relay contacts shall be provided for OWNER’s use and wired to terminal blocks. I. CONTROL RELAYS: Industrial type; contacts rated for 10 amps at 600 VAC; Allen-Bradley Bulletin 700 Type PK, Square D Class 8501 Type X, or approved equal. Relays shall have the capability of having contact decks added in the field. Contacts shall be field convertible to normally open or normally closed. Coils and contacts shall each be replaceable without replacing any other part of the relay. J. INDICATING LIGHTS, SELECTOR SWITCHES, PUSHBUTTONS: Heavy duty and oil tight; Square D Class 9001 (30.5mm) or approved equal. Pilot lights shall be push to test (LED type) and shall be Square D SK or approved equal. K. INFRARED INSPECTION WINDOWS: The rear of each breaker section shall be provided with an infrared inspection window. The window shall be permanently fitted into the indicated electrical equipment to give permanent access for infrared inspections. Window material must be transparent to visual, infrared and ultra violet energy (corona) bands. Window shall be manufactured by IRISS and shall be Platinum Series CAP-CT-12 model. Provide number of windows as required to view all three phase busses. L. Mimic Bus 1. Provide an approved mimic bus on front of each switchgear assembly. Color shall be black for the Normal Power system and red for the Essential Electrical System, 1/8" x 1/2" (color selected by purchaser) acrylic mimic bus. Plastic tape shall not be used. Use symbols similar to one line diagram shown on drawings. Plastic or metal strips shall be mounted with plated screws. Mimic bus shall be on each compartment applied to the front of the switchgear shall functionally represent the one-line diagram power circuits including CPT’s, PT’s, etc. M. EQUIPMENT ACCESSORIES: Furnish the following with the switchgear accessories and testing equipment: 1 -Test jumper set (Electrical Control Panel to operate circuit breaker which has been racked out of the Switchgear. 2 - Closing levers for maintenance closing of circuit breakers in the test position. 2 - Removable hand cranks for operation of the levering-in device. 2 - Sets of special wrenches for the primary disconnecting devices. 2 - Sets of test plugs for meters and relays. 6 - Spare fuses of each type and size for Switchgear. 1 - Breaker lifting device for removing circuit breakers. 1 - Remote breaker racking device with 25’ cable Medium Voltage Metal Clad Switchgear 26 13 00 -14 DTN18104 – Lake Lewisville WTP Phase II Improvements N. FINISH: After fabrication, metal structures shall be thoroughly cleaned, bonderized as a unit and then given a primary coat, a coat of rust preventative and a finishing coat of quick- drying lacquer. Unless otherwise specified, the color of the panels and the exteriors of structures shall be gray ANSI-61. Instruments, relays, and meters shall have dull black standard finish. O. CONTROL WIRING: Necessary small wiring, potential busses, fuses, and terminal blocks within each unit shall be furnished installed. Provisions shall be made for Owner's control conduit to the units. Secondary and control wiring within the high voltage compartment shall be completely shielded in a protective metal covering. P. NAMEPLATES: 1. Plastic, white .33" letters on black background, on the front of each door on the switchgear; identifying the compartment contents for each compartment. 2. Attach nameplates with a stainless steel screw and nut at each end of the nameplate. Adhesive backed nameplates shall not be installed. 3. Provide white letters on black background on the rear compartment of each switchgear door section stating what it is associated with. 3.00 EXECUTION 3.01 INSTALLATION A. The manufacturer's representative has responsibilities to direct the installation and field testing of the equipment as described in this section. Installation of the equipment to be performed by the Construction Contractor who shall be required to assemble the equipment and install it in accordance with manufacturer’s recommendations. Installation, Operation and Maintenance instructions which shall be furnished by the vendor or manufacturer and the installation drawings for this project. Manufacturer’s representative in conjunction with the Construction Contractor shall submit a written plan of action for the installation of the switchgear. Plan of action shall be submitted for approval by the Owner. B. Furnish the services of an experienced service person who shall be experienced in the assembly and wiring of the metal clad switchgear units of similar size and character. He also shall assist in the adjustment and testing of the equipment during the testing, checkout and start-up. C. Adjust the calibration of protective relays according to the schedule and test the settings. Prepare a card index for the relays, the settings, the test results and marked thereon, and submit to the Owner. D. Instruct the operating and maintenance personnel in principle of operation of all major devices and the care and maintenance of components included in the switchgear. E. Time spent on the job by the service person shall be adequate for performing the above functions but shall in no case be less than that tabulated below: Field start-up/testing, days: 8 - (8-hour days which does not include travel time) Training days: 2 - (8-hour days which does not include travel time) Medium Voltage Metal Clad Switchgear 26 13 00 -15 DTN18104 – Lake Lewisville WTP Phase II Improvements F. Field start-up/testing shall include programming of the protective relay settings based on short circuit and relay coordination study provided by others. G. In addition, a Relay Specialist shall be provided from the Relay Manufacturer for a 1-day training class. Training shall be one 8-hour day (excluding travel time). Training sessions for switchgear and relays shall follow the method below: H. Training shall include theory of operation, application and troubleshooting. A training outline and manual of training course material shall be provided to the Owner two weeks in advance of the course. Training shall be for four members of the Owner's staff. Eight-hour training sessions shall be broken into two segments each of 4-hours with a 15 minute break every two hours. Lunch break shall be one hour. Training session shall be coordinated and scheduled with Owner. I. Training shall not take place until equipment is online and fully operational. J. When requested within the equipment warranty period, provide an additional training session from that indicated above for the Owner’s Representative at the jobsite or other office location chosen by the Owner. Each eight hour training session shall be broken up into two segments each of 4-hours with a 15 minute break every two hours. Lunch break will be one hour. Training sessions shall be scheduled and coordinated with the Owner. J. All costs (travel expenses, testing equipment, etc.) required for the start-up, testing and training shall be the responsibility of the equipment manufacturer. 3.02 FIELD QUALITY CONTROL A. Upon completion of the installation, perform continuity tests and functional checkout to assure the proper operation of all equipment. The manufacturer's representative shall be available to assist the Contractor in checking the operation of the metal clad switchgear. B. Functional checkout shall include all possible operating scenarios of the main breaker, tie breaker and generator breaker combinations and automatic throw over schemes. C. Start-up procedures, testing and troubleshooting of the metal clad switchgear shall be performed under the supervision of the manufacturer's representative. Energization of the metal clad switchgear shall not be permitted without the manufacturer's representative's permission. D. No equipment is to be energized until the power system studies have been performed by the installation Contractor, the protective relays and breakers have been set per the short circuit and relay coordination study and the arc flash labels have been installed on the equipment. No exceptions. E. The manufacturer's representative shall submit an equipment installation report certifying the equipment if properly installed, has been tested and operated under all conditions which may be encountered during operation and is operating satisfactorily. F. Tests shall be conducted to assure proper operation of all circuits. The manufacturer's representative shall assist in correcting any deficiencies at no expense to the Owner. Medium Voltage Metal Clad Switchgear 26 13 00 -16 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.03 CLEAN AND ADJUST A. The manufacturer shall furnish sufficient touch-up paint of the same type and color used at the factory to repair damages incurred in installation. Perform touch up painting to achieve the original paint thickness, quality and appearance. 3.04 FIELD TESTING A. General Field Testing Requirements: 1. Comply with the provisions of NFPA 70B, "Testing and Test Methods." 2. After installing switchgear and after electrical circuitry has been energized, test for compliance with requirements. 3. Perform each visual and mechanical inspection and electrical test. Certify compliance with test parameters. B. Medium-Voltage Switchgear Assembly Field Tests: 1. Visual and Mechanical Inspection: a. Verify that fuse and circuit breaker sizes and types correspond to Drawings and coordination study. b. Verify that current and voltage transformer ratios correspond to Drawings. c. Inspect bolted electrical connections for high resistance using one of the following two methods: 1). Use a low-resistance ohmmeter to compare bolted connection resistance values to values of similar connections. Investigate values that deviate from those of similar bolted connections by more than 50 percent of the lowest value. 2). Verify tightness of accessible bolted electrical connections by calibrated torque- wrench method according to manufacturer's published data or NETA ATS, Table 100.12. Bolt-torque levels shall be according to manufacturer's published data. In the absence of manufacturer's published data, use NETA ATS, Table 100.12. d. Confirm correct operation and sequencing of electrical and mechanical interlock systems. 1). Attempt closure on locked-open devices. Attempt to open locked-closed devices. e. Verify appropriate lubrication on moving current-carrying parts and on moving and sliding surfaces. f. Inspect insulators for evidence of physical damage or contaminated surfaces. g. Verify correct barrier and shutter installation and operation. h. Exercise active components. i. Inspect mechanical indicating devices for correct operation. j. Verify that filters are in place and vents are clear. Medium Voltage Metal Clad Switchgear 26 13 00 -17 DTN18104 – Lake Lewisville WTP Phase II Improvements k. Perform visual and mechanical inspection of instrument transformers according to according to Article "Instrument Transformer Field Tests." l. Inspect control power transformers 1). Inspect for physical damage, cracked insulation, broken leads, tightness of connections, defective wiring, and overall general condition. 2). Verify that primary and secondary fuse or circuit breaker ratings match drawings. 3). Verify correct functioning of drawout disconnecting and grounding contacts and interlocks. 3.05 SYSTEM FUNCTION TESTS A. System function tests shall prove the correct interaction of sensing, processing, and action devices. Perform system function tests after field quality control tests have been completed and all components have passed specified tests. 1. Develop test parameters and perform tests for the purpose of evaluating performance of integral components and their functioning as a complete unit within design requirements and manufacturer's published data. 2. Verify the correct operation of interlock safety devices for fail-safe functions in addition to design function. 3. Verify the correct operation of sensing devices, alarms, and indicating devices. Medium Voltage Metal Clad Switchgear 26 13 00 -18 DTN18104 – Lake Lewisville WTP Phase II Improvements SUBMITTAL DATA SHEET FOR 26 13 00, MEDIUM VOLTAGE METAL-CLAD SWITCHGEAR Submit the following data with Bid Proposal and with Shop Drawing: Item No. Description 2.4kV Metal-Clad Switchgear “SWG-1” 1 Manufacturer: 2 Total Equipment Dimensions for Switchgear Line-up (inches): Length x Width x Height 3 Total Weight for Switchgear Line-up (lbs.): END OF SECTION Medium Voltage Motor Control Center 26 13 23 -1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 13 23 MEDIUM VOLTAGE MOTOR CONTROL CENTER 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to manufacture, fabricate, test, and deliver a complete Medium Voltage Motor Control Center (MCC) to be used in the Owner’s High Service Electrical Building as shown in the schedule below. Dimensions of line up shall not exceed those shown in the plans-no exceptions. Location Equipment Name Lake Lewisville Water Treatment Plant High Service Electrical Building 2400V MCC “MVMCC-1” & “MVMCC-2” B. The manufacturer shall provide the services of factory field engineers for startup, field tests, troubleshooting, Owner training and the supervision of storage and installation. The minimum time required for the manufacturer field services to be on-site shall include a minimum of the following. These times do not include travel time and include a minimum of 8 hours working per day. Field Tests/ Start-up 10 days (4 trips minimum) Troubleshooting 4 days (2 trips minimum) Owner Training 1 day (1 trip minimum) 1.02 QUALITY ASSURANCE A. IEC or dual IEC/NEMA equipment shall not be acceptable. B. Products shall comply with the specifications and shall be by the following Manufacturers: 1. Eaton 2. General Electric 3. Square D 4. Siemens 5. No other manufacturers will be accepted C. DESIGN CRITERIA 1. The metal enclosed switchgear/motor control center shall be per the 2400V one-line diagram in the Contract Documents. See the 2400V one-line diagram in the Contract Documents for more information. 2400V MCC line-up shall consist of the following: “MVMCC-1” Starter Pump No.1 Across-the-line starter (Bottom Exit) Starter Pump No.2 Across-the-line starter (Bottom Exit) Medium Voltage Motor Control Center 26 13 23 -2 DTN18104 – Lake Lewisville WTP Phase II Improvements Starter Pump No.3 Across-the-line starter (Bottom Exit) Starter Pump No.4 Across-the-line starter (Bottom Exit) Latching Contactor Feeder to Transformer “TX-1” (Bottom Exit) “MVMCC-2” Starter Pump No.5 Across-the-line starter (Bottom Exit) Starter Pump No.6 Across-the-line starter (Bottom Exit) Starter Backwash Pump Across-the-line starter (Bottom Exit) Latching Contactor Feeder to Transformer “TX-2” (Bottom Exit) 2. All sections shall be a minimum of 36” wide. 3. The equipment shall be designed for the protection and control of power circuits on a 2400 volt, 3 phase, 3 wire, 60 Hertz solidly grounded wye system. Main bus for the 2400V MCC shall be tin plated copper rated for 1200A continuous duty. 4. MCC manufacturer shall coordinate with metal-clad switchgear equipment to provide transition section between switchgear and MCC. Switchgear and MCC shall be from the same manufacturer. No exceptions. D. FACTORY INSPECTION AND TESTS E. FACTORY TESTS 1. Switchgear sections shall be completely assembled, wired, adjusted, and tested at the factory. 2. Factory tests shall include electrical tests as described by American National Standards Institute Standard C 37.20. 3. The switchgear shall be assembled and shipped in sections of the largest size practicable to be unloaded and handled at the job. 4. The manufacturer shall perform all tests required by the applicable standards and shall be responsible for testing all control and relaying circuits within the switchgear to ensure proper function performance and operable condition. 5. The switchgear shall be tested and certified in accordance with the applicable requirements of ANSI/IEEE C37.20.2 and ANSI C37.55. 6. All instrument transformers furnished for metering and relaying service shall be tested and certified in accordance with the applicable requirements of ANSI/IEEE C57.13. 7. All busses shall undergo a one-minute, 60 Hz dielectric withstand test. All control circuits shall undergo a one-minute insulation resistance test. 8. Components manufactured in different factories shall be shipped to the main switchgear assembly point for testing at the manufacturer’s expense. Additional testing of components is limited to those tests associated with test of completed equipment. 9. Each unit shall be tested for operating sequence to assure accuracy of wiring correctness of control scheme and functioning of the equipment. 10. Factory tests for medium voltage motor controllers shall include electrical tests as described by NEMA ICS 1-109 and ANSI C19.3. 11. A statement of calibration shall be provided to cover all meters and relays. Medium Voltage Motor Control Center 26 13 23 -3 DTN18104 – Lake Lewisville WTP Phase II Improvements 12. The MCC manufacturer shall provide the actual test data, observations and certification that the tests have been completed prior to shipment to the Engineer for approval. 1.03 SUBMITTALS A. Submittals shall be in accordance with this section, the General Requirements, Section 01 33 00, “Submittal Procedures” and shall include the following minimum information: 1. PRE-AND POST-SUBMITTAL MEETING a. Supplier shall include in the bid the cost of attending a one-day pre-submittal meeting and a one-day post-submittal meeting in the offices of Freese and Nichols, in Fort Worth, Texas or Lake Lewisville Water Treatment Plant in Denton, Texas – exact location to be determined at a later date. A pre-submittal meeting shall be held before any shop drawings are submitted. A post-submittal meeting shall be held after the Engineer’s shop drawing review comments have been submitted. Vendor shall determine the exact number of people attending the meeting per the specification requirements and cover each person’s cost. b. Any shop drawings submitted before the pre-submittal meeting will be rejected and sent back Not Approved, Revise and Re-submit. The Manufacturer/Supplier shall bring with them a detailed list of the items their submittal will include for review by the Engineer or a bootleg copy of the actual submittal. c. As a minimum the following shall attend the meeting: 1) General Contractor (if selected), 2) Electrical Contractor (if selected), 3) Medium Voltage MCC Supplier/Manufacturer and Engineer. Representatives from the Supplier/Manufacturer shall include: a) The Project Manager or Individual who will be responsible for putting together the submittal and who will be responsible for the project at the factory, no exceptions. b) The Project Engineer at the factory who has technical knowledge of the equipment, no exceptions. c) A sales person may attend, but not as a substitute for the Project Manager and/or Project Engineer 2. Shop Drawings a. Any deviations from the specifications should be clearly identified on a separate sheet of paper in the shop drawing submittal. b. Fill out and submit data sheet included in the Attachment at the end of this specification section. c. Complete description of all equipment, including catalogs, cuts and pertinent engineering data. Clearly identify on cut sheets the model number of the equipment being provided. Complete Bill of Material clearly identifying make and model number of all major components. d. Component catalog number and manufacture data sheets, indicating pertinent data and clearly marked to identify each component by the item number and nomenclature specified. e. Manufacturer of equipment f. Manufacturer's type Medium Voltage Motor Control Center 26 13 23 -4 DTN18104 – Lake Lewisville WTP Phase II Improvements g. Outline dimensions of line-up h. Provide overall outline drawing showing medium voltage MCC. Overall outline drawing shall include complete line-up including metal-clad switchgear, transition section, if required, and motor control center. i. One-Line diagram and Three-Line diagram to be submitted with initial submittal, No Exceptions. j. Front View Elevation showing detailed layout of devices, selector switches, lights, pushbuttons, etc. and nameplates and mounting heights. k. Project specific wiring diagrams / interconnection diagrams / terminal strip layout showing customer connections. Terminal strip layout shall be provided as part of initial submittal. l. Project specific schematic diagrams for starters and latching contactors. m. Mimic bus layout n. Nameplate schedule. o. Weight of line-up p. Assembly ratings including: 1) Short-circuit rating 2) Voltage 3) Continuous current 4) Basic impulse level for equipment over 600 volts q. Major component ratings including: 1) Voltage 2) Continuous current 3) Interrupting ratings r. BIL test data on previously tested equipment of the same design s. Power Factor Correction Capacitors Data: 1) Hand calculations verifying motor PF corrected to .95 or better. Hand calculations shall include a copy of the data sheet for each existing motor connected under this contract. The manufacturer shall be responsible for obtaining all information to perform the calculations, no exceptions will be granted. 2) Power factor correction capacitor data – outline drawings including weight, dimensions, cut sheets, one-line diagram, component bill of materials, and spare fuses. t. Back-to-Back Capacitor Switching Study 1) Provide a back-to-back capacitor switching study for the system. The study shall examine the cases that are representative of the various combinations of motors running and starting (assuming that no two motors will ever start simultaneously). Show the resultant capacitor inrush current and frequency. Show that the inrush current will not damage capacitors or cause nuisance tripping of capacitor fuses without additional switching transient mitigating technology. Medium Voltage Motor Control Center 26 13 23 -5 DTN18104 – Lake Lewisville WTP Phase II Improvements 2) If the calculations indicate switching transient mitigating technology be added, the manufacturer shall add the switching transient mitigating technology and calculate the results with additional inductors connected in series with the capacitors. u. Spare parts list v. Where the Supplier's product differs from the specified requirements and/or catalog description, each point of difference shall be clearly stated. This requirement is set forth to facilitate the review of submittals and not to be construed by the Supplier as waiving any of the requirements of the specifications. Setting and foundation plans and dimension sheets for the equipment offered shall be submitted with each submittal. w. Stub-up locations and conduit entry and exit locations. Conduit entry and exit points clearly showing dimensions of entry and exit points. Provide a detailed top and bottom view showing how conduits penetrate the top and bottom of the equipment. 3. Prior to Shipment: The manufacturer shall provide detailed addresses (memory map) for the software I/O points that are communicated over Ethernet, RS485, etc. that are applicable to this project – this would include but not be limited to the data highways associated with the motor protection relays. Coordinate with OWNER/ENGINEER for the list of I/O that will be transmitted over the data highways, the manufacturer shall verify with the Owner if any changes have been made to the lists prior to submitting the memory map. 4. FACTORY TEST DATA a. Submit factory test data to Engineer for approval prior to shipping Switchgear to job site. 5. EQUIPMENT INSTALLATION REPORT a. Submit Equipment Installation Report certifying the equipment is properly installed, is in accurate alignment, is free from undue stress from connecting appurtenances, that it has been operated under full load conditions, and that it is operating satisfactorily. The report shall also include a copy of the field test reports. 6. Field Test Data – Equipment Installation Report: a. Field test data shall include summary of all tests performed in the field specifically identified in this specification and other factory standard tests. 7. NETA Acceptance Testing Specification (ATS) field tests and inspections tests report. 8. Supplier shall submit a training outline for Owner’s/Engineer’s review and comment a minimum of 4 weeks before training is to take place. 9. OPERATION AND MAINTENANCE MANUALS a. Submit Manuals with instructions for installation, adjustment, lubrication, operation and maintenance of the equipment in accordance with the specific conditions. b. List all factory setting relay and provide relay-setting and calibration instructions, including software, where applicable. O&M manuals shall include a hard copy of the power meter settings. Medium Voltage Motor Control Center 26 13 23 -6 DTN18104 – Lake Lewisville WTP Phase II Improvements c. Operation and maintenance manuals shall be prepared by the equipment manufacturer and shall contain the final certified approved shop drawings, submittals, list of manufacturer recommended spare parts, schematics, and maintenance procedures, and field test data. O&M manuals shall include all field changes made during startup and testing. d. Manuals may be manufacturer's standard instructions, but shall be supplemented as necessary to cover any special feature not included in standard material. e. Operation and maintenance manuals shall include warranty information as well as a warranty information page that shall include information on the warranty start and end date as well as contact information for service. f. Submit preliminary manuals for review prior to start-up of equipment. 1.04 STANDARDS The applicable provisions of the following standards shall apply as if written here in their entirety: NEC National Electrical Code U.L. Underwriter’s Laboratories ANSI American National Standards Institute C37.100 Definitions for Power Switchgear C37.20.3 Standard for Metal-Enclosed Interrupter Switchgear C37.20.4 Standard for Indoor AC Medium - Voltage Switches used in Metal-Enclosed Switchgear C37.21 Application Guide for Metal-Enclosed Power Switchgear C37.54 Conformance Testing of Indoor AC High-Voltage Circuit Breakers Applied as Removable Elements in Metal-Enclosed Switchgear Assemblies C37.13 Standard Requirements for Instrument Transformers C37.55 Conformance Testing of Metal-Clad Switchgear C37.24 Guide for Evaluating the Effect of Solar Radiation NEMA National Electrical Manufacturers Association ICS 1 Industrial Control and Systems - General Requirements ICS 3 Industrial Control and Systems - Factory-Built Assemblies SG-5 Power Switchgear Assemblies SG-6 Power Switching Equipment 1.05 DELIVERY, STORAGE AND HANDLING A. The manufacturer shall be responsible for delivery of the equipment, and accessories, f.o.b. to the job site or to such storage site as may be designated by the Contractor, in good condition and undamaged. B. Unloading and storage of the equipment shall be the responsibility of the Contractor who shall inspect the equipment for apparent damage. Equipment which is found to be damaged will not be accepted until properly repaired or replaced by the Vendor. C. Handling and shipment of the equipment shall be in such a manner to prevent internal Medium Voltage Motor Control Center 26 13 23 -7 DTN18104 – Lake Lewisville WTP Phase II Improvements component damage, breakage, and denting and scoring of the enclosure finish. D. Equipment must be delivered and stored in accordance with the manufacturer’s recommendation at all times. Equipment shall be stored indoors in a clean, dry, climate controlled heated and air conditioned environment that is free from dust, No Exceptions. Store equipment indoors in a dry space with uniform temperature to prevent condensation. Protect equipment from exposure to dirt, fumes, water, corrosive substances and physical damage. E. 100 watt incandescent lamps shall be placed in the switchgear enclosure sections as required and energize to prevent the buildup of condensation during extended storage periods. F. Deliver in sections or lengths that can be moved past obstructions in delivery path. 1.06 COORDINATION A. Contractor shall coordinate layout and installation of MCC and components with other construction that penetrates walls or is supported by them, including electrical and other types of equipment, raceways, piping, encumbrances to workspace clearance requirements, and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels. B. Contractor shall coordinate sizes and locations of concrete bases with actual equipment provided. Cast anchor-bolt inserts into bases. 2.00 PRODUCTS 2.01 MOTOR CONTROL CENTER A. GENERAL 1. The ratings for the metal enclosed load interrupter switchgear shall be: a. Nominal system voltage: 2.4 KV, 3 phase, 3 wire, solidly grounded b. Maximum design voltage: 4.76 KV c. Basic impulse level: 60 KV d. Nominal 3-Phase Class: 50KA e. Power frequency withstand: 19 KV f. Rated main bus current: 1200 amps g. Rated momentary current, kA rms Asym.: 61KA h. Rated short time current (2 sec.), kA rms Sym.: 38KA i. Enclosure: NEMA 1 j. The main power bus shall be tin-plated copper rated for 1200A continuous duty. The equipment shall be factory assembled (except for necessary shipping components). The assembly shall be a self-supporting, floor mounted bay. k. The complete assembly shall be constructed in accordance with the applicable provisions of ANSI/IEEE C37.20.3 and the minimum construction standards of the manufacturers of space for fuse handling when applicable. Medium Voltage Motor Control Center 26 13 23 -8 DTN18104 – Lake Lewisville WTP Phase II Improvements l. The integrated MCC assembly shall withstand the effects of closing, carrying and interrupting currents up to the assigned maximum short circuit rating. m. A viewing window shall be installed in the switch enclosure and located so as to enable visible inspection of the switchblades and blown fuse indicators from outside the enclosure. n. The equipment shall be designed and arranged for operation on 2400 volt, 3 phase, 60 hertz solidly grounded wye system. o. The Line-up shall be U.L. Listed. If the Supplier requires that a U.L. representative conduct a field inspection to obtain the U.L. listing, the Supplier shall be responsible for submitting an application to the Underwriters Laboratories, Inc. for inspection and shall be responsible for all costs for U.L. inspection and obtaining the U.L. listing. 2. Power Meter displays, protective relay displays, indication lights, switches, etc. shall be mounted no higher than 5’-6” AFF, which shall include the height of the 4” housekeeping pad. Front panel layout showing exact mounting heights shall be submitted to the Engineer for approval. 3. All 120VAC power for power meters, relays, etc. shall be fused and supplied integral to the MCC. 4. The maximum dimensions for the Switchgear shall be as indicated below, No Exceptions: Maximum Dimensions of “MVMCC” lineups (no exceptions) MVMCC-1: 144”W x 30“D x 92“H MVMCC-2: 108”W x 30”D x 92”H . B. STARTER AND LATCHING CONTACTOR SECTIONS 1. Circuits shall have an interrupting capacity of 50 KAIC. 2. Circuits shall contain all of the wiring and components shown on the one-line and wiring diagrams, including isolation switch with current-limiting fuses, three-phase busses, ground bus, load lugs, phase current transformers, control potential transformers, motor protection relay (MPR), where required, indicating lamps, selector switches, pushbuttons, interposing relays, contactor, etc. 3. The contactor assembly shall consist of the contactor, primary fuses, mechanical interlocks and control transformer with associated wiring. 4. The contactor shall be roll-out, vacuum type and have a rating of minimum of 400 amps. Vacuum contactor shall be three pole, designed for long life in contaminated atmosphere. The vacuum bottles shall have low chop current of 0.3 amperes average to minimize voltage spikes and shall have an interrupting rate of 6000 amperes. Low voltage connections to the contactor shall be made with a quick disconnect plug. Cable terminations shall be easily accessible to disconnect cables. Contactor shall have a dc operating coil through a heavy duty full wave bridge silicon rectifier mounted on the contactor. Auxiliary contacts shall be rated at 10 amperes, 120 volts ac continuous Medium Voltage Motor Control Center 26 13 23 -9 DTN18104 – Lake Lewisville WTP Phase II Improvements 5. Latching contactor sections shall be suitable for top and bottom exit of all cabling. 6. The control transformer shall be mounted in the vertical section and shall be a minimum of 750 VA. Control transformer shall be fused on primary and secondary with proper coordination. 7. Controller shall have a circuit to test the contactor and control circuit when the isolation switch is in the open position. Test circuit shall consist of receptacle and plug mounted in the medium voltage compartment and accessible only when the door is open. Plug shall isolate control transformer and prevent energizing the control transformer secondary from the test voltage source. 8. Power fuses shall be front accessible, vertically mounted for ease of inspection, and removable without special tools. Power fuses shall be current limiting type with three phase symmetrical interrupting rating of 50 KA at 2400 volts and shall have blown-fuse indication. 9. The power isolation switch shall be externally operable, gang operated, non-load break medium voltage isolation switch with quick make quick break action, with viewing window to verify blade position. Switch shall be capable of interrupting the control transformer space heater load and associated power factor correction capacitor. Isolation switch shall isolate the medium voltage contractor and power fuses, disconnect the primary of the control transformer and release the door interlock so that the medium voltage door can be opened. The isolation switch shall be provisioned for padlocking in the open position. 10. Mechanical interlocking shall prevent opening the isolation switch when the contactor is closed, opening the medium voltage compartment door with the isolation switch in ON position and closed, and closing the isolation switch with the contactor placed in its normal operating position and closed while testing the contractor operation. Electrical interlocking shall be provided to assure that the contactor operating coil is de-energized before the isolation switch can be opened. 11. All relays, terminal blocks, etc., shall be mounted on a hinged metal plate. The plate shall be recessed not deeper than necessary to permit closing of the door on the control devices. All terminal blocks including those outgoing shall be installed in the control compartment. All wires leaving the units shall terminate at identified terminal strips in the control compartment. 12. Controls and indicating lights shall be located on the door. The following door mounted pushbuttons, control switches and indicating lights shall be supplied and mounted on the door for the latching contactor sections: a. Open pushbutton b. Close pushbutton c. Red indicating light (contactor closed) d. Green indicating light (contactor open) 13. Refer to starter control schematics in the plans for door mounted devices. C. CABLE REQUIREMENTS 1. NEMA copper compression spade terminals and stress relief terminations for Medium Voltage Motor Control Center 26 13 23 -10 DTN18104 – Lake Lewisville WTP Phase II Improvements terminating 5kV shielded cable shall be provided for outgoing power cable and sized as follows: “SWGR-1” Cable Requirements Pump No.1 Starter 3-1/C #1 (5KV), #6G. (600V) Pump No.2 Starter 3-1/C #2 (5KV), #6G. (600V) Pump No.3 Starter 3-1/C #2 (5KV), #6G. (600V) Pump No.4 Starter 3-1/C #1 (5KV), #6G. (600V) Pump No.5 Starter 3-1/C #1 (5KV), #6G. (600V) Pump No.6 Starter 3-1/C #1 (5KV), #6G. (600V) Backwash Pump Starter 3-1/C #2 (5KV), #6G. (600V) Feeder to Transformer “TX-1” 3-1/C #1/0 (5KV), #4G. (600V) Feeder to Transformer “TX-2” 3-1/C #1/0 (5KV), #4G. (600V) D. POWER FACTOR CORRECTION CAPACITORS 1. Power factor correction capacitors shall be supplied with the medium voltage MCC and be located within the MCC lineup. Capacitors shall be enclosed consisting of a complete assembly including non-PCGB, three phase capacitors, terminal compartment and group fusing with fuses for each phase. Solderless connection shall be provided on each line terminal. a. Each unit shall have discharge resistors to reduce the charge current to 50 volts or less within 5 minutes after de-energization. Capacitor equipment shall be provided with current limiting fuses, inrush reactors, 50,000 ampere interrupting capacity, and a visual indication of blown fuse. Capacitors shall be the required kVAR size, 4800V, 3 phase, 60 hertz, Cooper Power Systems Type EX-D or approved equal. The manufacturer shall coordinate with the contractor to obtain all existing motor information to properly size capacitor banks to correct the power factor to 95% and not overexcite the motor. Provide hand calculations showing this. b. The Manufacturer shall provide the appropriate sized current limiting reactors, filter or other means for limiting the transients caused by capacitor bank switching and the interaction of other starter/capacitors online when the capacitor bank is energized. Provide calculations showing how inrush reactor/filter were sized for the application. If a filter is not required then provide calculations showing when the filter is not needed. 2.02 MISCELLANEOUS A. MOTOR PROTECTION RELAYS: 1. Provide protective relays shown on the one-line as follows: a. Solid state protective relay shall be Multilin 869 Motor Protection Relay for starter sections. Multilin 869 shall have capability for 4-20mA analog outputs. b. Provide GE 515 Blocking and Test Module for testing of Multilin 869 relays. Medium Voltage Motor Control Center 26 13 23 -11 DTN18104 – Lake Lewisville WTP Phase II Improvements c. Communications protocol shall be Ethernet TCP/IP. Manufacturer shall provide all hardware, firmware or software to permit communications using Ethernet communications. Ethernet communications signal shall be wired out to a set of terminals for customer’s use. B. FEEDER PROTECTION RELAYS: 1. Feeder protective relays shall be Multilin 850 Feeder Protection Relay. See one-line diagram for more information. a. Provide GE 515 Blocking and Test Module (both current and voltage inputs) for testing of Multilin 850 relays. b. Communications protocol shall be Ethernet TCP/IP. Manufacturer shall provide all hardware, firmware or software to permit communications using Ethernet communications. Ethernet communications signal shall be wired out to a set of terminals for customer’s use. C. INSTRUMENT CURRENT TRANSFORMERS: Each instrument current transformer shall be indoor wound type, meter class. Insulation shall be equal to that necessary to meet the requirements of the IEEE standards. At normal rated amperes, under usual service conditions, no part of the transformer shall exceed the heating limits specified in the IEEE standards. Each current transformer shall be capable of carrying continuously, its rated primary amperes, under conditions of accidental open secondary circuit, without damage to the primary insulation. Current transformers connected to the power meter shall be ANSI metering accuracy class current transformers. All other current transformers shall have an ANSI accuracy classification of C200. D. INSTRUMENT POTENTIAL TRANSFORMERS: Substantial and well built. Insulation shall meet the requirements of the IEEE standards. At normal ratings under usual service conditions no part of the transformer shall exceed the heating limits specified in the IEEE standards. E. CONTROL RELAYS: Industrial type; contacts rated for 10 amps at 600 VAC; Allen-Bradley Bulletin 700 Type PK, Square D Class 8501 Type X, or approved equal. Relays shall have the capability of having contact decks added in the field. Contacts shall be field convertible to normally open or normally closed. Coils and contacts shall each be replaceable without replacing any other part of the relay. Where control relays are indicated on the Plans, industrial control relays shall be furnished whether the relay coil is operated with 120 VAC or 24 VDC. General purpose “plug-in”/ “ice-cube” type relays are not acceptable. F. TIMING RELAYS: Solid state. Ranges shall be as shown on the Plans. The timing relays shall have both normally open and normally closed contacts by having two sets of form C contacts. Timing relays where shown on the Plans shall be Square D, Class 9050 Type JCK60, time delay relay, Allen-Bradley 700-FS or approved equal model for operation on the control voltage of the equipment it is used in. Timing relay shall be provided with restraining strap. Timing relays shall have blinking indicating light for indication when relay is timing and constant on light when timing relay has timed out. G. ELAPSED TIME METER: The meter shall be of a non-reset type, for totalizing of hours and shall operate on 120 VAC, 60 Hertz. Starter shall be provided with an elapsed time meter; Yokogawa Model 240, 3 ½” New Big Look type elapsed time meter, or approval equal. Digital time meters are not acceptable. H. INDICATING LIGHTS, SWITCHES, PUSHBUTTONS: Heavy duty and oil tight; Square D Class Medium Voltage Motor Control Center 26 13 23 -12 DTN18104 – Lake Lewisville WTP Phase II Improvements 9001 (30.5mm) or approved equal. Pilot lights shall be push to test (LED type) and shall be Square D SK or approved equal. I. NAMEPLATES: Externally visible, permanent nameplates shall be provided to identify each instrument, switch, meter, relay, control switch, indicating light, etc. Equipment and terminal blocks shall be suitably identified. This shall include items on back side of doors and panel-mounted items. Nameplates shall be plastic with white letters on a black background and attached with stainless steel screws. 1. Provide permanent warning signs as follows: a. “DANGER – HIGH VOLTAGE – KEEP OUT” on all enclosure doors. b. “WARNING – HAZARD OF ELECTRIC SHOCK – DISCONNECT POWER BEFORE OPENING OR WORKING ON THIS UNIT” J. EQUIPMENT ACCESSORIES: 1. Furnish the following with the switchgear accessories and testing equipment: a. 1 - Sets of special wrenches for the primary disconnecting devices. b. 1 - Sets of test plugs for meters and relays. K. FINISH: After fabrication, metal structures shall be thoroughly cleaned, bonderized as a unit and then given a primary coat, a coat of rust preventative and a finishing coat of quick- drying lacquer. Unless otherwise specified, the color of the panels and the exteriors of structures shall be gray ANSI-61. Instruments, relays, and meters shall have dull black standard finish. L. CONTROL WIRING: Necessary small wiring, potential busses, fuses, and terminal blocks within each unit shall be furnished installed. Provisions shall be made for Owner’s control conduit to the units. Secondary and control wiring within the high voltage compartment shall be completely shielded in a protective metal covering. 3.00 EXECUTION 3.01 INSTALLATION A. The Manufacturer’s Representative has responsibilities in the installation and field testing of the equipment as described in this Section. Installation of equipment shall be performed by the Contractor who shall be required to assemble the equipment, if required, and install it in accordance with Installation, Operation and Maintenance instructions which shall be furnished by the vendor or manufacturer, and the installation drawings for this project. 1. The Contractor shall furnish all labor, tools, equipment and machinery necessary to receive, inspect, unload, store, protect, and install completely, in proper operating condition, the equipment. Contractor shall protect and store the MCC indoors, as recommended by the manufacturer and as described in section 1.05. 2. He shall also furnish such incidental items not supplied with the equipment, but which may or may not be described in the Plans and Specifications, for complete installation, such as wiring, conduit, ducts, anchors and other appurtenances as necessary. B. The Contractor shall schedule the service of the manufacturer to assist in the installation, adjustment, and acceptance test of the equipment. Medium Voltage Motor Control Center 26 13 23 -13 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.02 INSTALLATION A. Install the switchgear on concrete foundations as indicated. Terminate service and feeder conduits only in the switchgear section containing the lugs or device to which they are to be connected. 3.03 TESTING A. The manufacturer's representative has responsibilities in the field testing of the equipment as described in this section. B. Testing, checkout and start-up of the starter equipment shall be performed under the technical direction of the manufacturer's service engineer from the factory. Under no circumstances are any portions of the starter system to be energized without authorization from the manufacturer's representative. 1. A copy of all tests and checks performed in the field, complete with meter readings and recordings, where applicable, shall be submitted to the Engineer and Owner as an official submittal. C. Testing, checkout and start-up of the Medium Voltage Switchgear shall be performed under the technical direction of the manufacturer’s service engineer from the factory. D. Testing and checkout of the equipment by a non OEM factory representative is not acceptable. Under no circumstances are any portions of the equipment to be energized without authorization from the manufacturer and OEM representative. E. A copy of all tests and checks performed in the field, complete with meter readings and recordings, where applicable, shall be submitted to the Engineer and Owner as an official submittal. F. The tests shall be witnessed by the Owner and Engineer. Provide at least two (2) weeks notice to the Owner and Engineer prior to conducting these tests. Final acceptance of the starter installation will not be considered until the Owner and Engineer have witnessed the test described above and a formal written report has been submitted and approved by the Engineer. G. Provide for the Engineer's review a complete list of test procedures, standards, equipment and calibration reports of the measuring and testing equipment used. H. Any deficiencies with regard to these specifications shall be corrected by the manufacturer at no expense to the Owner. Prior to any corrective action, a plan of correction shall be submitted to the Engineer for approval. I. Adjust the calibration of protective relays according to the schedule and test the settings. Prepare a card index for the relays, the settings, the test results and marked thereon, and submit to the Owner. J. All costs (travel expenses, testing equipment, etc.) required for the start-up, and testing shall be the responsibility of the equipment manufacturer/contractor. 3.04 TRAINING A. The Contractor shall provide a training session for the Owner’s representatives for 8 hours at the jobsite or other office location chosen by the Owner. The one day, eight-hour training Medium Voltage Motor Control Center 26 13 23 -14 DTN18104 – Lake Lewisville WTP Phase II Improvements session shall be broken up into two segments each of 4-hours with a 15 minute break every two hours. Lunch break will be one hour. Training session shall be scheduled and coordinated with the Owner. B. The training session shall be conducted by a manufacturer’s qualified representative. C. A training outline and manual of training course material shall be provided to the Owner two weeks in advance of the course. Training shall be for four members of the Owner's staff. D. Instruct the operating and maintenance personnel in principle of operation of all major devices and the care and maintenance of components included in the switchgear. E. In addition, a Relay Specialist shall be provided from the Relay Manufacturer for a 1-day training class. Training shall be one 8-hour day (excluding travel time). Training sessions for switchgear and relays shall follow the method below: 1. Training shall include theory of operation, application and troubleshooting. A training outline and manual of training course material shall be provided to the Owner two weeks in advance of the course. Training shall be for four members of the Owner's staff. Eight-hour training sessions shall be broken into two segments each of 4-hours with a 15 minute break every two hours. Lunch break shall be one hour. Training session shall be coordinated and scheduled with Owner. F. All costs (travel expenses, testing equipment, etc.) required for the training shall be the responsibility of the equipment manufacturer/contractor. 3.05 FIELD QUALITY CONTROL A. Upon completion of the installation, perform continuity tests and functional checkout to assure the proper operation of all equipment. The manufacturer's representative shall be available to assist the installation Contractor in checking the operation of the switchgear. B. Start-up procedures, testing and troubleshooting of the switchgear shall be performed under the supervision of the manufacturer's representative. Energization of the switchgear shall not be permitted without the manufacturer's representative's permission. C. The manufacturer's representative shall submit an equipment installation report certifying the equipment if properly installed, has been tested and operated under all conditions which may be encountered during operation and is operating satisfactorily. D. Tests shall be conducted to assure proper operation of all circuits. The manufacturer's representative shall assist in correcting any deficiencies at no expense to the Owner. 3.06 WARRANTY A. Manufacturer shall warrant the equipment furnished under this specification for a period of two (2) years against defects in materials and workmanship and operational failure. B. In the event of failure of any part or parts of the equipment during the first 2 years of service, provided that the equipment has been operated and maintained in accordance with good practice, the Manufacturer shall furnish, deliver and install the defective part or parts at his own expense. C. The first 2 years of service shall be interpreted as the 24-month period following the Medium Voltage Motor Control Center 26 13 23 -15 DTN18104 – Lake Lewisville WTP Phase II Improvements installation, adjusting and acceptance testing, and the start of actual operation of the equipment, or 30 months after delivery, whichever occurs first. 3.07 CLEAN AND ADJUST The manufacturer shall furnish sufficient touch-up paint of the same type and color used at the factory to repair damages incurred in installation. Perform touch up painting to achieve the original paint thickness, quality and appearance. 3.08 SPARE PARTS: Equipment accessories shall be furnished as follows for each pump station: A. 6 - spare fuses of each type and size including medium voltage fuses B. 2 - spare lamps of each type and size C. 2 - sets of each type of test cable D. 2 - sets of each type of special wrench or tool for primary disconnecting devices E. 1 - elevating table type lifting device for installation of contactors F. 1 - spare relay and timer of each type Medium Voltage Motor Control Center 26 13 23 -16 DTN18104 – Lake Lewisville WTP Phase II Improvements ATTACHMENT A SUBMITTAL DATA SHEET FOR 26 13 23, MEDIUM VOLTAGE MOTOR CONTROL CENTER Submit the following data with the Shop Drawing: Item No. Description 2400V MCC “MVMCC-1” & “MVMCC-2” 1 Manufacturer: 2 Total Equipment Dimensions for MVMCC-1 Line-up (inches): Width x Depth x Height _________W x _________D x _________H 3 Total Weight for MCCMV-1 Line-up (lbs.): 4 Total Equipment Dimensions for MVMCC-2 Line-up (inches): Width x Depth x Height _________W x _________D x _________H 5 Total Weight for MVMCC-2 Line-up (lbs.): 6 Heat Loss (Watts) MVMCC-1 7 Heat Loss (Watts) MVMCC-2 END OF SECTION Medium Voltage Motor Control Center 26 13 23 -17 DTN18104 – Lake Lewisville WTP Phase II Improvements THIS PAGE INTENTIONALLY LEFT BLANK Low Voltage Distribution Transformers 26 22 13-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 22 13 LOW VOLTAGE DISTRIBUTION TRANSFORMERS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install transformers. Electrical work shall be in accordance with Section 26 05 00, COMMON WORK RESULTS FOR ELECTRICAL. 1.02 QUALITY ASSURANCE A. Transformers shall comply with the specifications and shall be produced by the following Manufacturers: 1. Cutler-Hammer 2. General Electric 3. Square D 4. Siemens B. All others shall submit qualifications to the Owner and the Engineer for review and approval prior to bid submittal no later than one week after bid advertisement date. Any submittals after this time period shall not be evaluated. Qualifications shall include equipment manufacturer who have had at least 10 years of successful experience in providing equipment for similar projects with a generator and pump station configurations. Qualifications shall include a list of similar projects within the last 5 years with the name of the project and contact information of the Owner. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Bill of Material 2. Equipment Data Sheets showing impedance weights, dimensions, etc. for each transformer. 3. Product data on specified product documenting the following: a. Dimensions b. Weight c. KVA d. Voltage e. % Impedance f. Magnetizing current magnitude and duration g. Taps h. Insulation Class Low Voltage Distribution Transformers 26 22 13-2 DTN18104 – Lake Lewisville WTP Phase II Improvements i. Sound Level j. Wiring Diagram k. Installation Instructions 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: ANSI/IEEE C57.96 Distribution and Power Transformers, Guide for Loading Dry-Type appendix to ANSI C57.12 standards ANSI/IEEE C89.2 Dry Type Transformers for General Applications IEEE C57.12.01 General Requirements for Dry-Type Distribution and Power Transformers Including Those with Solid Cast and / or Resin- Encapsulated Windings IEEE C57.12.91 Test Code for Dry-Type Distribution and Power Transformers UL 506, Specialty Transformers NEMA/ANSI ST20 Dry type transformers for General Applications IEEE Institute of Electrical and Electronic Engineers NEMA TR1 Transformers, Regulators and Reactors NEMA TP-1 2002 Guide for Determining Energy Efficiency for Distribution Transformers 2.00 PRODUCTS A. DRY TYPE TRANSFORMERS 1. Provide dry type, 3-phase, delta wye connected transformers with KVA rating as required. 2. Transformers shall be suitable for indoor or outdoor installation as indicated on the plans, or as required by conditions. Transformers 75 KVA and less shall be suitable for floor, wall or trapeze mounting. Transformers larger than 75 KVA shall be suitable for floor or trapeze mounting. 3. Transformer shall be enclosed in a steel enclosure with covers secured with captive type hardware. Transformer shall be cooled by natural convection of air. The transformer enclosure shall be degreased, cleaned, phosphatized, primed and finished with a gray baked on enamel. 4. The average audible sound level shall not exceed 50 DB for transformers rated at 75 KVA and below, nor 60 DB for transformers rated above 75 KVA, when measured in accordance with NEMA Standard TR1. 5. The percent impedance for transformers shall not exceed 4.6 for up to 112 1/2 KVA and 6 for 150 KVA to 750 KVA. 6. The transformers shall have the following characteristics: a. Class H insulation b. 150 degree Centigrade temperature rise rating at 40 degrees C ambient at full rated load. Low Voltage Distribution Transformers 26 22 13-3 DTN18104 – Lake Lewisville WTP Phase II Improvements c. Compartment for primary and secondary connections. d. Transformer coils shall be of continuous copper wound construction with terminations brazed or welded. Coils shall be impregnated with non-hygroscopic, thermosetting varnish. e. The maximum temperature of top of the enclosure shall not exceed 50 degrees C rise above a 40 degrees C ambient. f. The core of the transformer shall be visibly grounded to the enclosure by means of a flexible copper grounding conductor sized in accordance with applicable NEMA, IEEE, or ANSI standards. g. Transformers shall have two (2) 2-1/2% full ampacity taps below and two (2) 2-1/2% taps above rated voltage in primary. h. The basic impulse level shall be 10 KV for transformers less than 30 KVA, 30 KV for transformers 300 KVA and larger. i. Transformer primary and secondary windings shall be copper. Aluminum windings shall not be permitted. j. Transformers shall have efficiencies in accordance with NEMA TP-1. Provide written documentation as part of submittal process stating this and showing actual transformer efficiencies. 7. Three-phase transformer efficiency, total losses, shall not exceed losses @ 35% and 75°C per the NEMA Premium program tested per 10 C.F.R. Part 431 (“Test Procedures for Distribution Transformers”). Shall not exceed: a. 15 kVA: 97.88% 112.30 W; 121.28 W b. 30 kVA: 98.24% 185.52 W; 200.35 W c. 45 kVA: 98.38% 256.42 W; 276.93 W d. 75 kVA: 98.59% 362.89 W; 391.92 W e. 112.5 kVA: 98.73% 500.31 W; 540.33 W f. 150 kVA: 98.80% 576.14 W; 622.22 W g. 225 kVA: 98.95% 764.14 W; 825.26 W h. 300 kVA: 99.02% 1010.010 W; 1090.81 W. 3.00 EXECUTION 3.01 LOCATION A. Electrical Contractor to verify proper location for the unit. B. The transformer shall be installed in a location where the sides with ventilated openings are a minimum distance of six inches from noncombustible structures or equipment to ensure adequate air circulation Low Voltage Distribution Transformers 26 22 13-4 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.02 INSTALLATION A. Set the transformer plumb and level. Provide solderless lug bonding connection on the inside of the transformer enclosure in accordance with the NEC. Make primary and secondary connections with liquid tight flexible metal conduit to isolate transformer noise from the building structure or conduit system. B. When final connection has been made, check secondary voltage at dry transformers and make tap adjustments required to obtain correct voltage. C. Perform the following isolation procedures in addition to those provided by the transformer Manufacturer. Provide pad-type vibration isolators or waffle pads sized to load 50 pounds per square inch. Install one (1) at each corner of the transformer at floor mount or trapeze installations. Locate pads between hanger and wall for wall hung installations D. For critical installations, spring type isolation may be required by the Engineer consisting of steel, spring-type isolators, sized for 1/2" deflection based on the weight of the transformer. Install at each corner or in hanger rods so that vibration is not transmitted to the building structure. E. Secure transformer to concrete base according to manufacturer's written instructions. F. Secure covers to enclosure and tighten all bolts to manufacturer-recommended torques to reduce noise generation. 3.03 CONNECTIONS A. Ground equipment according to Section 26 05 26 GROUNDING & BONDING FOR ELECTRICAL SYSTEMS. B. Tighten electrical connectors and terminals according to manufacturer's published torque- tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A-486B. C. Provide flexible connections at all conduit and conductor terminations and supports to eliminate sound and vibration transmission to the building structure. 3.04 FIELD QUALITY CONTROL A. Inspect installed dry type transformers for anchoring, alignment, grounding and physical damage. B. Check tightness of all accessible mechanical and electrical connections with calibrated torque wrench. Minimum acceptable values are specified in manufacturer's instructions. 3.05 CLEANING A. Repaint scratched or marred exterior surfaces to match original finish. 3.06 TESTING A. Testing: All testing required shall be per Specification 26 01 26 Testing of Electrical Systems. Low Voltage Distribution Transformers 26 22 13-5 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Transformers furnished to this specification shall receive the following production tests: 1. Perform each visual and mechanical inspection and electrical test stated in NETA ATS for dry-type, air-cooled, low-voltage transformers. Certify compliance with test parameters. 2. Applied Potential; 3. Induced Potential; 4. No Load Losses; 5. Voltage Ratio; 6. Polarity; 7. Continuity C. Manufacturer shall perform the following additional tests on units identical to the design type being supplied to this specification. Manufacturer shall provide on request test data sheets to prove performance of these tests. 1. Sound Levels 2. Temperature Rise Tests 3. Full-Load Losses 4. Regulation 5. Impedance 3.07 ADJUSTING A. Record transformer secondary voltage at each unit for at least 48 hours of typical occupancy period. Adjust transformer taps to provide optimum voltage conditions at secondary terminals. Optimum is defined as not exceeding nameplate voltage plus 5 percent and not being lower than nameplate voltage minus 3 percent at maximum load conditions. Submit recording and tap settings as test results. B. Output Settings Report: Prepare a written report recording output voltages and tap settings. END OF SECTION Low Voltage Distribution Transformers 26 22 13-6 DTN18104 – Lake Lewisville WTP Phase II Improvements THIS PAGE INTENTIONALLY LEFT BLANK 600 Volt Switchboards 26 24 13-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 24 13 600 VOLT SWITCHBOARDS 1.00 GENERAL WORK INCLUDED Furnish labor, materials, equipment and incidentals necessary to install a complete 600 volt switchboard. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. Location Equipment Name Lake Lewisville WTP 480V Switchboard “SWBD-1” QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS Products shall comply with the specifications and shall be by the following Manufacturers: ABB/General Electric Eaton Square D Siemens No other manufacturers will be accepted. The manufacturer shall provide the services of factory field engineers for startup, field tests, troubleshooting, Owner training and the supervision of storage and installation. The minimum time required for the manufacturer field services to be on-site shall include a minimum of the following, per site. These times do not include travel time. Provide a minimum of 8 working hours per day. Start up 2 days per site Field Tests 2 days per site Troubleshooting 2 days per site Owner Training 1 day per site SUBMITTALS Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include shop drawings with the following minimum information: Shop Drawings Any deviations from the specifications should be clearly identified on a separate sheet of paper in the shop drawing submittal. Fill out and submit data sheet included in the Attachment at the end of this specification section. Complete rating. Short circuit withstandability of bus and lowest rated device. Overall outline dimensions including the space available for conduit. 600 Volt Switchboards 26 24 13-2 DTN18104 – Lake Lewisville WTP Phase II Improvements Conduit entry and exit points clearly showing dimensions of entry and exit points. Provide a detailed bottom view showing how conduits penetrate the bottom of the switchboard. Coordinate with the Electrical Contractor on this prior to submitting information to the Engineer. Overall weight of line-up and each shipping split. Complete bill of materials with cut sheets on all major equipment clearly identifying exact model numbers of each component. Circuit schedule indicating the circuit number. Device description. One-Line diagram and Three-Line diagram to be submitted with initial submittal, No Exceptions. Product Data Sheets for Switchboard, SPD, Meter, and Circuit Breakers, miscellaneous electrical equipment, etc. Provide a drawing of the front view elevation with designation of equipment and devices on doors, and clearly indicating the maximum mounting height of devices on doors. Project Specific Wiring Diagram: Detail wiring diagram and differentiate between manufacturer-installed and field-installed customer wiring. Show both power and control wiring. Show terminal strip information identifying all customer field terminations. Provide project specific wiring diagrams. Generic wiring diagrams are not acceptable. Time current curves for all circuit breakers. Bill of Material. Nameplate Schedule. Warranty Information. Kirk-key interlock scheme. Main breaker ground fault test data per National Electrical Code requirements. Note: All documentation listed above shall be supplied with the Switchboard’s initial submittal. Incomplete submittals will be returned “NOT APPROVED, REVISE AND RESUBMIT”. Prior to Shipment: The manufacturer shall provide detailed addresses (memory map) for the software I/O points that are communicated over Ethernet, RS485, etc. that are applicable to this project – this would include but not be limited to the data highways associated with the power meter. Coordinate with OWNER/ENGINEER for the list of I/O that will be transmitted over the data highways, the manufacturer shall verify with the Owner if any changes have been made to the lists prior to submitting the memory map. Field Test Data – Equipment Installation Report: Field test data shall include summary of all tests performed in the field specifically identified in this specification and other factory standard tests. NETA Acceptance Testing Specification (ATS) field tests and inspections tests report. Supplier shall submit a training outline for Owner’s/Engineer’s review and comment a minimum of 4 weeks before training is to take place. Operation & Maintenance Manual Data: 600 Volt Switchboards 26 24 13-3 DTN18104 – Lake Lewisville WTP Phase II Improvements Include all features and operating sequences, both automatic and manual. List all factory setting relay and provide relay-setting and calibration instructions, including software, where applicable. Operation and maintenance manuals shall contain the shop drawings, submittals, list of manufacturer recommended spare parts, schematics, equipment installation report, and maintenance procedures. O&M manuals shall include all field changes made during startup and testing. Operation and maintenance manuals shall include warranty information as well as a warranty information page that shall include information on the warranty start and end date as well as contact information for service. Manuals shall be prepared by the Equipment Manufacturer and shall also incorporate appropriate final certified shop drawings. Manuals may be manufacturer's standard instructions, but shall be supplemented as necessary to cover any special feature not included in standard material. Submit preliminary manuals for review prior to start-up of equipment. STANDARDS The applicable provisions of the following standard shall apply as if written here in its entirety: NEMA Std. PB-2 Deadfront Distribution Switchboards NEMA Std. AB-1 Molded Case Circuit Breakers and Molded Case Switches NEMA Std. KS-1 Enclosed Switches U.L. 489 Molded Circuit Breakers U.L. 891 Switchboards NFPA 70 National Electrical Code DELIVERY AND STORAGE Handling and shipment of the equipment shall be in such a manner to prevent internal component damage, breakage, and denting and scoring of the enclosure finish. Equipment must be delivered and stored in accordance with the manufacturer’s recommendation at all times. Equipment shall be stored indoors in a clean, dry, climate controlled heated and air-conditioned environment that is free from dust, No Exceptions. Store equipment indoors in a dry space with uniform temperature to prevent condensation. Protect equipment from exposure to dirt, fumes, water, corrosive substances and physical damage. 100 watt incandescent lamps shall be placed in the switchboard enclosure sections as required and energize to prevent the buildup of condensation during extended storage periods. Deliver in sections or lengths that can be moved past obstructions in delivery path. 600 Volt Switchboards 26 24 13-4 DTN18104 – Lake Lewisville WTP Phase II Improvements COORDINATION Coordinate layout and installation of switchboards and components with other construction that penetrates walls or is supported by them, including electrical and other types of equipment, raceways, piping, encumbrances to workspace clearance requirements, and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels. Coordinate sizes and locations of equipment bases with actual equipment provided. Cast anchor-bolt inserts into bases. 2.00 PRODUCTS SWITCHBOARD The switchboard shall be freestanding front access only and consist of the required number of vertical sections bolted together to form one (1) metal, enclosed, rigid switchboard. The switchboard shall conform to U.L. Standard #UL891 and NEMA Standard PB-2. The U.L. label shall appear on all switchboard sections which contain U.L. devices. The switchboard shall be U.L. listed for service entrance equipment. Enclosure Type 1 General Purpose Sections shall be completely front and rear aligned. Staggered arrangements are not acceptable. The Switchboard shall be of dead-front construction and require front access only. The switchboard frame shall be of formed steel rigidly bolted together to support all cover plates, bussings, and component devices during shipping and installation. The sides, top and rear shall be covered with single tool removable screw-on, code gauge, steel plates. Include all protective devices and equipment, including necessary interconnections. Each switchboard enclosure shall have an open bottom and individually removable top plate for installation and termination of conduit. The switchboard enclosure shall be painted on all exterior surfaces. The paint finish shall be ANSI 61 light gray or approved equal, applied by electro-deposition process over an iron phosphate pre-treatment. Top and bottom conduit areas shall be clearly indicated on shop drawings. The maximum dimensions for the switchboard shall be as follows, No exceptions. Maximum Dimensions of Switchboard lineup (no exceptions) “SWBD-1” 180“W x 40“D x 92“H Enclosure shall be bottom entry and top/bottom exit. See plans for additional information. All feeder device line and load connection straps shall be rated to carry current rating of device frame. The main incoming bus bars shall be rated for the protective frame size or main incoming conductors. 600 Volt Switchboards 26 24 13-5 DTN18104 – Lake Lewisville WTP Phase II Improvements A tin-plated copper bus shall be of the amperage scheduled on the plans. Tin-plating shall be applied continuously to all bus work. Neutral shall be full capacity. Bus bars shall be mounted on supports of high impact, non-tracking, insulation material which is braced to withstand mechanical forces exerted during 65,000 amp RMS symmetrical short circuit conditions. Secure a copper ground bus to each vertical section of the structure and extend it the entire length of the switchboard. Bus arrangement shall be A-B-C type, left-to-right, top-to-bottom and front-to-rear. The switchboard, cables and bus connections shall be entirely accessible from the front, unless specifically indicated otherwise. Furnish ground fault protection on each main device which is rated 1000 amps or larger unless note otherwise on one-line. Device shall be a U.L. listed, ground sensor relay system equal to General Electric GSR. Provide ground break components for each system with coordinated ground sensor (CR) and integral test winding. A solid state relay shall operate the shunt trip circuit on the switch and monitor panel. Use a time relay-type relay with a continuously adjustable current pick-up setting of 100 to 1200 amperes and continuously adjustable time delay setting from instantaneous (.03 seconds) to one (1) second. The relay shall also have a memory function which recognizes and initiates tripping on intermittent ground faults. Install a panel which indicates relay operations, provides a means for testing the system with or without the interruption of electrical service, and does not permit the ground fault system to be inadvertently left in an inactive or "off" state. Use a ground sensor for zero sequence arrangement on the main service entrance devices. Incoming Main Sections and Feeder Devices Main devices and feeder devices 800 amps and above shall be individually mounted circuit breakers (100% rated) Feeder devices shall be group mounted molded case circuit breakers, unless noted otherwise. All circuit protective devices shall have the following minimum symmetrical current interrupting capacity: 65kA. Series rated feeder devices shall not be acceptable. All breakers shall be capable of being locked in the OFF position. Molded Case Circuit Breakers Molded case circuit breakers shall be provided with the following symmetrical current interrupting capacity: 65kA. Group mounted breakers shall be connected to the vertical bus by bolted connection. Individually mounted breakers shall be stationary mounted. Circuit breaker frames shall be constructed of a high-strength, molded, glass-reinforced polyester case and cover. Breakers shall have an overcenter, toggle handle-operated, trip free mechanism with quick make, quick break action independent of the speed of the toggle handle operation. 600 Volt Switchboards 26 24 13-6 DTN18104 – Lake Lewisville WTP Phase II Improvements Breakers shall have ON and OFF position clearly marked on escutcheon. Breakers shall include a trip-to-test means on the escutcheon for manually tripping the breaker and exercising the mechanism and trip latch. Breakers larger than 150 amps shall use digital true RMS sensing trip units and a rating plug to determine the breaker trip rating. Main Breaker, and Feeder Breakers 800 Amps and Above Breakers shall be manually operated, fixed mounted, with the capability of being electrically operated. Breakers shall have solid-state adjustable trip settings with Long time, Short time, Instantaneous and Ground settings (LSIG). Breakers shall have trip indication of Overload, Short Circuit, and Ground Fault trip. Breaker sections shall be suitable for terminating copper conductors using compression type lugs. See electrical one-line diagram for size and number of conductors required per phase for breakers. Metering Metering device on main incoming breaker sections shall be Multilin PQM II Power Quality Meter. Meter shall be able to accept 4CTs (one per phase plus neutral). Meter shall have capability to communicate using Ethernet TCP/IP protocol. Provide all hardware and software as required for Ethernet communications. The metering device shall incorporate the following functions and features: Metering Functions with accuracy of 0.05 percent for A & V and 0.04 percent for power parameters. Meter shall comply with ANSI C12.20.5 class for revenue meters. A, V, VA, W, var, KWH, KVARH, PF, Hz W, var, A VA Demand A, V, Unbalance Total Harmonic Distortion (THD) of each current and voltage Waveform Capture Data Logging Communications (Ethernet TCP/IP connection) User Interface The digital meter shall have the following user interfaces: a) Integrated keypad to access actual values and setpoints. Relay output shall be through alarm, auxiliary and pulse output functions. The meter shall provide a user configurable pulse output base on KWH, KVARH, or KVAH. The meter shall provide a pulse input for demand synchronization. The meter shall include a simulation mode capability for testing the functionality and meter response to programmed conditions without the need for external inputs. INSTRUMENT CURRENT TRANSFORMERS: Capable of carrying continuously its rated primary amperes under conditions of accidental open secondary circuit without damage to the primary insulation. Burden capacity shall be adequate to supply the connected relays, meters and accessories. 600 Volt Switchboards 26 24 13-7 DTN18104 – Lake Lewisville WTP Phase II Improvements INSTRUMENT POTENTIAL TRANSFORMERS: Substantial and well built, insulation meeting the requirements of the standards of ANSI. At normal ratings under usual service conditions, no part of the transformer shall exceed the heating limits specified in the standards of ANSI when serving its connected load. Where the Plans indicate a switchboard to have voltage metering, two (2) instrument potential transformers shall be furnished at the switchboard metering point. SURGE PROTECTION DEVICES Surge Protection Device Description: IEEE C62.41-compliant, integrally mounted, wired- in, solid-state, parallel-connected, modular (with field-replaceable modules) type, with sine-wave tracking suppression and filtering modules, UL 1449, third edition Type 2, short-circuit current rating matching or exceeding the switchboard short-circuit rating, and with the following features and accessories: Fuses, rated at 200-kA interrupting capacity. Fabrication using bolted compression lugs for internal wiring. Redundant suppression circuits. Redundant replaceable modules. Arrangement with wire connections to phase buses, neutral bus, and ground bus. LED indicator lights for power and protection status. Audible alarm, with silencing switch, to indicate when protection has failed. Form-C contacts rated at 5 A and 250-V ac, one normally open and one normally closed, for remote monitoring of system operation, No Exception. Contacts shall reverse position on failure of any surge diversion module or on opening of any current-limiting device. Four-digit, transient-event counter set to totalize transient surges. Peak Single-Impulse Surge Current Rating: 200kA per mode. Withstand Capabilities: 12,000 IEEE C62.41, Category C3 (10 kA), 8-by-20-mic.sec. surges with less than 5 percent change in clamping voltage. Protection modes and UL 1449 3rd edition VPR for grounded wye circuits with 480Y/277V, three-phase, four-wire circuits shall be as follows: Line to Neutral: 1200 V for 480Y/277V. Line to Ground: 1200 V for 480Y/277V. Neutral to Ground: 1200 V for 480Y/277V. Provide switchboard with adequate lifting means, capable of being rolled or moved into installation position and bolted directly to the floor without the use of floor sills. Nameplates Equipment nameplates and designations shall be 2 in. by 5 in. minimum, not less than 1/16 in. thick, engraved laminated plastic fastened with stainless steel screws. Nameplates shall be 1 in. white lettering on black background, and shall indicate equipment designations as shown on the drawings. Provide legend plates or 1 in. by 3 in. engraved nameplates with ¼ in. lettering for identification of all pilot devices and meters. Legend nameplates shall be secured with stainless steel screws. 600 Volt Switchboards 26 24 13-8 DTN18104 – Lake Lewisville WTP Phase II Improvements Provide permanent warning signs as follows: “DANGER – HIGH VOLTAGE – KEEP OUT” on all enclosure doors. “WARNING – HAZARD OF ELECTRIC SHOCK – DISCONNECT POWER BEFORE OPENING OR WORKING ON THIS UNIT” Provide arc flash labeling in accordance with the National Electrical Code Article 110 and per the Arc Flash Hazard Analysis (performed by others). See Section 26 05 73.01, “Electrical Power System Studies” for more information. 3.00 EXECUTION INSTALLATION Install the distribution switchboards on concrete foundations as indicated. Terminate service and feeder conduits only in the switchboard section containing the lugs or device to which they are to be connected. FIELD QUALITY CONTROL Inspect completed installation for physical damage, proper alignment, anchorage, and grounding. Measure, using a Megger, the insulation resistance of each bus section phase-to-phase and phase-to-ground for one minute each, at minimum test voltage of 1000 VDC; minimum acceptable value for insulation resistance is 1 megohms. Check tightness of accessible bolted bus joints using calibrated torque wrench per manufacturer's recommended torque values. Test ground fault systems on service entrance main breakers per the National Electrical Code. Document all tests and furnish to Engineer as formal submittal. ADJUSTING Adjust all operating mechanisms for free mechanical movement per manufacturer’s specifications. Tighten bolted bus connections in accordance with manufacturer's instructions. Adjust circuit breaker trip and time delay settings according to Short Circuit and Relay Coordination Study and program power meter as required. CLEANING Touch up scratched or marred surfaces to match original finish. Provide one quart of touch- up paint. WARRANTY Manufacturer shall warrant equipment to be free of defects in materials and workmanship for twenty four (24) months from date of shipment. 600 Volt Switchboards 26 24 13-9 DTN18104 – Lake Lewisville WTP Phase II Improvements ADJUSTING Adjust moving parts and operable components to function smoothly, and lubricate as recommended by manufacturer. Set field-adjustable circuit-breaker trip ranges as specified in Section 26 05 73.01, “Electrical Power System Studies”. TRAINING The Contractor shall provide a training session for the Owner’s representatives for 8 hours (per site) at the jobsite or other office location chosen by the Owner. Provide separate training sessions for the Morgan Creek PS and the Snyder PS for a total of 16 hours. The training session shall be conducted by a manufacturer’s qualified representative. The training program shall consist of the following: Review of the switchboard one-line drawings and schedules. Review of the factory record shop drawings and placement of the various cells. Review of each type of cell, components within, control, and power wiring. Discuss the maintenance timetable and procedures to be followed in an ongoing maintenance program. Provide three-ring binders to participants complete with copies of drawings and other course material covered. Training shall include theory of operation, application and troubleshooting. A training outline and manual of training course material shall be provided to the Owner two weeks in advance of the course. Training shall be for four members of the Owner's staff. Training session shall be coordinated and scheduled with Owner. All costs (travel expenses, testing equipment, etc.) required for the start-up, testing and training shall be the responsibility of the equipment manufacturer/contractor. 600 Volt Switchboards 26 24 13-10 DTN18104 – Lake Lewisville WTP Phase II Improvements ATTACHMENT A SUBMITTAL DATA SHEET FOR 26 24 13, 600 VOLT SWITCHBOARDS Submit the following data with the Shop Drawing: Item No. Description For 480V Switchboard “SWBD-1” 1 Manufacturer: 2 Total Equipment Dimensions for Switchboard Line-up (inches): Width x Depth x Height _________W x _________D x _________H 3 Total Weight for Switchboard Line-up (lbs.): 4 Heat Loss (Watts): END OF SECTION Lighting and Branch Panelboards 26 24 16.02-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 24 16.02 LIGHTING AND BRANCH PANELBOARDS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install lighting and branch panelboards. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.02 QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS A. Panelboards shall comply with the specifications and shall be by the following Manufacturers: 1. Eaton 2. General Electric 3. Square D 4. Siemens 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Shop Drawings: a. Bill of Material b. Front Elevation with dimensions c. Assembly ratings including short circuit ratings, continuous current and voltage d. Cable terminal sizes e. Cut sheet on circuit breakers and surge protective devices f. Time current curves for circuit breakers. 1.04 STANDARDS A. Circuit breakers, molded case, and branch circuit shall be in accordance with the applicable provisions of the following standards as if written here in their entirety: 1. Fed. Spec. W-C-375 2. NEMA AB1 Molded Case Circuit Breakers and their application. 3. NEMA PB1 Panelboards 1.05 DELIVERY AND STORAGE A. Equipment shall be handled and stored in accordance with the manufacturer’s instructions. Equipment shall be protected from damage. Lighting and Branch Panelboards 26 24 16.02-2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.06 WARRANTY A. The manufacturer shall warrant the equipment to be free from defects. 1.07 QUALITY ASSURANCE A. Manufacturer shall be ISO 9001 2000 or later certified. B. Manufacturer shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement. 2.00 PRODUCTS 2.01 PANELBOARDS A. Panelboards shall consist of a box, front, interior and circuit protective devices and shall be manufactured in accordance with NEMA PB1 and bearing the applicable U.L. labels. B. Panelboards shall be four wire, three phase as scheduled or required. Panelboards shall be NEMA 1 for air-conditioned spaces and 4X, 316 Stainless Steel for all other locations and suitable for surface mounting. Panelboards shall contain sequence style busing and full capacity neutral, composed of an assembly of bolt-on, molded case, automatic breakers with thermal and an instantaneous, magnetic trip in each pole and a trip-free position separate from either the "On" and the "Off" positions. Two (2) and three (3) pole circuit breakers shall simultaneously open all poles. The use of metal clips tying single pole circuit breakers together to make a multi-pole breaker shall not be allowed. Circuit breakers, molded case and branch circuits shall be in accordance with Fed. Spec. W-C-375. C. The voltage rating, phase, number of wires and ampere rating shall be as indicated and scheduled on the plans. D. The panelboard box shall be fabricated of code gauge, steel in accordance with U.L. standards and have turned edges around the front for rigidity and frontal clamping. Provide standard knockouts on the panel enclosures. E. The panelboard front shall be fabricated of sheet steel and finished with a baked on gray enamel over a rust inhibitor. Each front shall have a door mounted on semi-concealed hinges with a cylinder lock, an index card and a card holder. Panelboard locks shall be master keyed, with two (2) keys furnished for each panelboard. Index cards shall be properly typewritten. F. The interior of the panelboard shall consist of a factory-assembled, rigid frame supporting the rectangular bus, the mains and the neutral bar. G. Busings shall be tin-plated copper and arranged for sequential phasing throughout. The bus bar shall be sized so that the temperature rise is limited in accordance with NEMA standards. The insulated neutral bar shall be located at the opposite end of the structure from the mains. H. Panelboards shall have either solderless lugs or a main circuit protective device as scheduled. Each enclosure shall have grounding lugs and uninsulated equipment grounding terminals. Lighting and Branch Panelboards 26 24 16.02-3 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.02 CIRCUIT BREAKERS A. Panelboards shall be equipped with circuit breakers. B. Circuit breakers shall be molded case, bolt in type. C. Single pole circuit breakers serving fluorescent lighting loads shall have the SWD marking. Circuit breakers serving air conditioning branch loads shall be U.L. listed as type HACR. D. Each circuit breaker used in the panelboards shall have an interrupting capacity of not less than the RMS symmetrical rating indicated on the plans for that panelboard. E. Circuit breakers shall be manufactured by the panelboard manufacturer. F. The panelboard and circuit breaker interrupting capacities and rating shall be equal to or greater than the fault currents available to each panelboard and as shown on the panelboard schedules on plans. Series rating of breakers shall not be permitted. 2.03 SURGE PROTECTION DEVICES A. Surge Protection Device Description: IEEE C62.41-compliant, internally mounted, wired-in, solid-state, parallel-connected, modular (with field-replaceable modules) type, with sine- wave tracking suppression and filtering modules, UL 1449, third edition Type2, short-circuit current rating matching or exceeding the switchboard short-circuit rating, and with the following features and accessories: 1. Fuses, rated at 240-kA interrupting capacity. 2. Fabrication using bolted compression lugs for internal wiring. 3. Integral disconnect switch/circuit breaker. 4. Redundant suppression circuits. 5. Redundant replaceable modules. 6. Arrangement with wire connections to phase buses, neutral bus, and ground bus. 7. LED indicator lights for power and protection status. 8. Audible alarm, with silencing switch, to indicate when protection has failed. 9. Form-C contacts rated at 5 A and 250-V ac, one normally open and one normally closed, for remote monitoring of system operation. Contacts shall reverse position on failure of any surge diversion module or on opening of any current-limiting device. Coordinate with building power monitoring and control system. 10. Four-digit, transient-event counter set to totalize transient surges. B. Peak Single-Impulse Surge Current Rating: 240kA per phase, 120kA per mode. C. Protection modes and UL 1449 3rd edition VPR for grounded wye circuits with 480Y/277V, 208Y/120V, three-phase, four-wire circuits shall be as follows: 1. Line to Neutral, Line to Ground, Neutral to Ground: 1200 V for 480Y/277V and 800 V for 208Y/120V. 2. Line to Line: 2000 V for 480Y/277V and 1200 V for 208Y/120V. Lighting and Branch Panelboards 26 24 16.02-4 DTN18104 – Lake Lewisville WTP Phase II Improvements D. Protection modes and UL 1449 3rd edition VPR for 240V, three-phase, three-wire circuits shall be as follows: 1. Line to Line: 1200 V for 240V. 2. Line to Ground: 1200 V for 240V 3.00 EXECUTION 3.01 INSTALLATION A. Install the panelboard in accordance with applicable codes at each location indicated on the plans. Provide filler plates for unused spaces in the panelboard. All labeling shall be in accordance to Section 26 05 00, “Common Work Results for Electrical”. B. Mount panelboard with 1/4” spacers off of walls. C. NAMEPLATES: 1. For indoor applications with Air Conditioning: Plastic, white 1" letters on black background, on the front of each door on the panelboard; identifying the compartment contents for each compartment. 2. All other applications: Plastic, white 1" letters on black background, on the front of each door on the paneboard; identifying the compartment contents for each compartment. 3. Attach nameplates with a stainless steel screw and nut at each end of the nameplate. Adhesive backed nameplates shall not be installed. END OF SECTION Wiring Devices 26 27 26-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 27 26 WIRING DEVICES 1.00 GENERAL 1.01 WORK INCLUDED Furnish labor, materials, equipment and incidentals necessary to install wiring devices. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.02 QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS 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. D. Products shall comply with the specifications and shall be by the following Manufacturers: 1. Hubbell 2. Leviton 3. Pass & Seymour 1.03 SUBMITTALS Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: A. Shop Drawings for Wiring Devices: Cut sheets of all devices indicating model being provided, NEMA configuration, rating, color, etc. 1.04 STANDARDS The applicable provisions of the following standard shall apply as if written here in its entirety: NEMA WD-1 General Color Requirements for Wiring Devices NEMA WD-6 Wiring Devices – Dimensional Requirements UL 943 Ground-Fault Circuit-Interrupters NFPA 70 National Electrical Code Wiring Devices 26 27 26-2 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.00 PRODUCTS 2.01 MANUFACTURED PRODUCTS A. WALL SWITCHES: For general use, totally enclosed industrial type, specification grade, rated for 120/277 VAC and 20 amps. Approved wire connection to switches shall consist of inserting wire into back wiring hole and tightening terminal screw until wire is tightly griped by clamping mechanism inside switch body. Side wiring shall not be allowed. Switches installed in hazardous areas shall be explosion proof type in accordance with the NEC. B. MOTOR RATED SWITCHES: HP rated switches approved for motor control or disconnect service when controlling or disconnecting motor loads in excess of 1/4 HP; 20 amp switches for loads exceeding 10 amps. C. WEATHERPROOF SWITCHES: Fitted with a single switch as specified, and weatherproof cover with spring door cover; gray in color for all areas. D. RECEPTACLES: For general use shall be U.L. approved, hospital grade heavy duty duplex grounding type 20 ampere 125 volt heavy duty phosphor bronze contacts. Terminal screws shall be large head, deep slotted #8-32 brass, backed out, color coded for polarity identification, and shall accept up to 10 AWG wire. Side wiring shall not be allowed. 1. GROUND FAULT CIRCUIT INTERRUPTING, INDOOR: GFCI receptacle shall include visible indication of ground fault condition. Feed-through feature shall not be used. Install GFCI device at each location indicated. GFCI circuit breaker shall not be permitted. 2. ISOLATED-GROUND RECEPTACLES: Isolated-ground receptacles shall be listed and labeled as isolated-ground type. Receptacle body shall be orange in color. Isolation- ground shall be integral to the receptacle construction and not dependent on removable parts. 3. WEATHER RESISTANT RECEPTACLES: Weather resistant receptacles shall be listed as weather resistant type in accordance with the National Electrical Code. 4. WEATHERPROOF RECEPTACLES: a. Weatherproof receptacles shall be hospital grade, 20 ampere, 125 volt and shall be listed as weather resistant type in accordance with the National Electrical Code and shall include a weatherproof device cover. 1). Weatherproof Duplex Receptacle: Provide GFCI duplex receptacle with weatherproof cover. 2). Weatherproof Single Receptacle: Provide a cast box fitted with a single receptacle and threaded cap with a weatherproof cover. b. Weatherproof device covers shall have a NEMA 3R rating while receptacle is in use Heavy Duty rating with die cast metal construction as manufactured by Taymac Corporation, Tempe, Arizona or Thomas & Betts E. SWITCH AND RECEPTACLE COVER PLATES: The cover plate color shall be stainless steel for all areas, unless otherwise indicated or required by the NEC. Screw heads shall have color to match plate, 302/304 stainless steel. Provide telephone cover plates which are the same as above, except with a single bushed pole for the telephone cable. Wiring Devices 26 27 26-3 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.00 EXECUTION 3.01 INSTALLATION A. Comply with NECA 1, including the mounting heights listed in that standard, unless otherwise noted. B. Coordination with Other Trades: 1. Take steps to insure that devices and their boxes are protected. Do not place wall finish materials over device boxes and 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 NFPA 70, Article 300, without pigtails. D. Existing Conductors: 1. Cut back and pigtail, or replace all damaged conductors. 2. Straighten conductors that remain and remove corrosion and foreign matter. E. Pigtailing all conductors is required. Outlet boxes shall be oversized to allow pigtailing. All wiring devices shall be wired using pigtails. F. Terminate stranded wire with crimp on connectors. G. Install receptacles and switches only in electrical boxes which are clean, free from excess building materials, dirt and debris. H. Install switches, wall-mounted duplex receptacles and telephone outlets at the heights specified in Section 26 05 33.03, “Outlet Boxes”, unless indicated otherwise on the plans. I. Switches installed at one (1) location shall be ganged together under one (1) cover plate. J. Sharing of neutrals is not allowed. K. Through on wiring at receptacles is not allowed. Wiring Devices 26 27 26-4 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.02 FIELD QUALITY CONTROL A. Test wiring devices to insure electrical continuity of grounding. Energize the circuit to demonstrate compliance with the requirements. B. Tests for Convenience Receptacles: 1. Line Voltage: Acceptable range is 108 to 132 V. 2. Percent Voltage Drop under 15-A Load: A value of 6 percent or higher is not acceptable. 3. Ground Impedance: Values of up to 2 ohms are acceptable. 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 Fuses 26 28 13 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 28 13 FUSES 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. Section Includes: 1. Cartridge fuses rated 600-Vac and less for use in control circuits, enclosed switches and enclosed controllers. 1.03 SUBMITTALS A. Product Data: For each type of product indicated. Include construction details, material, dimensions, and descriptions of individual components. Include the following for each fuse type indicated: 1. Ambient Temperature Adjustment Information: If ratings of fuses have been adjusted to accommodate ambient temperatures, provide list of fuses with adjusted ratings. a. For each fuse having adjusted ratings, include location of fuse, original fuse rating, local ambient temperature, and adjusted fuse rating. b. Provide manufacturer's technical data on which ambient temperature adjustment calculations are based. 2. Dimensions and manufacturer's technical data on features, performance, electrical characteristics, and ratings. 3. Current-limitation curves for fuses with current-limiting characteristics. 4. Time-current coordination curves (average melt) and current-limitation curves (instantaneous peak let-through current) for each type and rating of fuse. 5. Coordination charts and tables and related data. B. Operation and Maintenance Data: For fuses to include in emergency, operation, and maintenance manuals. In addition to items specified in Division 01 Section "Operation and Maintenance Data," include the following: 1. Ambient temperature adjustment information. 2. Current-limitation curves for fuses with current-limiting characteristics. 3. Time-current coordination curves (average melt) and current-limitation curves (instantaneous peak let-through current) for each type and rating of fuse. 4. Coordination charts and tables and related data. Fuses 26 28 13 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.04 QUALITY ASSURANCE A. Source Limitations: Obtain fuses, for use within a specific product or circuit, from single source from single manufacturer. B. 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. C. Comply with NEMA FU 1 for cartridge fuses. D. Comply with NFPA 70. 1.05 COORDINATION A. Coordinate fuse ratings with utilization equipment nameplate limitations of maximum fuse size and with system short-circuit current levels. 1.06 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 percent of quantity installed for each size and type, but no fewer than two of each size and type. 2.00 PRODUCTS 2.01 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Cooper Bussmann, Inc. 2. Edison Fuse, Inc. 3. Mersen 4. Littelfuse, Inc. 2.02 CARTRIDGE FUSES A. Characteristics: NEMA FU 1, nonrenewable cartridge fuses with voltage ratings consistent with circuit voltages. 3.00 EXECUTION 3.01 EXAMINATION A. Examine fuses before installation. Reject fuses that are moisture damaged or physically damaged. B. Examine holders to receive fuses for compliance with installation tolerances and other conditions affecting performance, such as rejection features. Fuses 26 28 13 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements C. Examine utilization equipment nameplates and installation instructions. Install fuses of sizes and with characteristics appropriate for each piece of equipment. D. Evaluate ambient temperatures to determine if fuse rating adjustment factors must be applied to fuse ratings. E. Proceed with installation only after unsatisfactory conditions have been corrected. 3.02 FUSE APPLICATIONS A. Cartridge Fuses: 1. Motor Branch Circuits: Class RK1, time delay. 2. Other Branch Circuits: Class J, time delay. 3. Control Circuits: Class CC, time delay. 3.03 INSTALLATION A. Install fuses in fusible devices. Arrange fuses so rating information is readable without re- moving fuse. 3.04 IDENTIFICATION A. Install labels complying with requirements for identification specified in Division 26 Section "Identification for Electrical Systems" and indicating fuse replacement information on inside door of each fused switch. END OF SECTION Enclosed Switches and Circuit Breakers 26 28 16-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 28 16 ENCLOSED SWITCHES AND CIRCUIT BREAKERS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install disconnects. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.02 QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS A. Disconnects shall comply with the specifications and shall be by the following Manufacturers: 1. Eaton 2. General Electric 3. Square D 4. No Approved Equal 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Shop Drawings: a. Product Data Sheets for Disconnects and Circuit Breakers. b. Complete rating. c. Short circuit withstand ability of bus and lowest rated device. d. Overall outline dimensions including the space available for conduit. e. Conduit entry and exit points clearly showing dimensions of entry and exit points. Provide a detailed bottom view showing how conduits penetrate the bottom of the enclosure. Coordinate with the Electrical Contractor on this prior to submitting information to the Engineer. f. Cutsheets on fuses complete with time current curves clearly identifying fuse being provided. g. Overall weight of line-up and each shipping split. h. Complete bill of materials with cut sheets on all major equipment clearly identifying exact model numbers of each component. i. Device description. 2. O&M Manual a. Operation and maintenance manuals shall contain the shop drawing submittals, final drawings with any changes made during start-up and maintenance procedures. Enclosed Switches and Circuit Breakers 26 28 16-2 DTN18104 – Lake Lewisville WTP Phase II Improvements b. Operation and maintenance manuals shall include warranty information as well as a warranty information page that shall include information on the warranty start and end date as well as contact information for service. 1.04 STANDARDS A. The applicable provisions shall apply as if written here in their entirety: 1. ANSI/UL - 198E 2. NEMA RS1 3. Fed. Spec. FS-WS-865 2.00 PRODUCTS 2.01 MANUFACTURED PRODUCTS A. DISCONNECT SWITCHES: 1. Class "R" or non-fusible; of the required ampere rating, or as indicated on the plans; heavy duty, either single throw or double throw (as indicated in the plans) quick-make, quick-break, 3-phase, 3-pole switches, unless otherwise indicated. 2. Enclosure: NEMA 4X, 304 for Stainless Steel for exterior installations not exposed to a hazardous location. NEMA 4X, 316 stainless steel for chemical room. Furnish enclosures with interlocking covers with maintenance defeat feature and external front- operated flange-mounted switch levers. Disconnects shall have provisions for the use of three (3) safety padlocks in the "Off" position. Furnish horsepower rated switches for motor circuits. The fuse interrupting rating shall be 65,000 rms amperes. 3.00 EXECUTION 3.01 INSTALLATION A. Install disconnect switches as required by the National Electrical Code. Install fuses in fusible disconnect switches. END OF SECTION Enclosed Controllers 26 29 13 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 29 13 ENCLOSED CONTROLLERS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals to install combination motor starters. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. Section includes the following enclosed controllers rated 600 V and less. 1.02 QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS Enclosed Controllers shall comply with the specifications and shall be by the following Manufacturers: A. Allen Bradley B. Eaton C. General Electric D. Square D E. No Approved Equal 1.03 QUALITY ASSURANCE A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in and marked for intended location and application. B. Comply with NFPA 70. C. Coordinate with equipment suppliers for actual motor data – HP, voltage, amps, etc, to properly size controller (starter) and overloads. 1.04 SUBMITTALS Submittals for 26 29 13, “Enclosed Controllers” shall not be combined with any other submittals. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: A. Shop Drawings: For each enclosed controller. 1. Include dimensioned plans, elevations, sections, details, and required clearances and service spaces around controller enclosures. 2. Catalog cut sheets of major components. Include manufacturer's technical data on features, performance, electrical characteristics, ratings, and enclosure types and finishes. Data sheets shall clearly identify the make and model number of the equipment being provided. 3. Drawings shall show the following: a. Each installed unit's type and details. b. Factory-installed devices. c. Nameplate legends. d. Short-circuit current rating of integrated unit. Enclosed Controllers 26 29 13 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements e. Features, characteristics, ratings, and factory settings of individual overcurrent protective devices in combination controllers. f. Project specific wiring diagrams/control schematics: For power, signal, and control wiring. Labels on the control schematic for control relays, timing relays, level instruments, indication lights, etc. shall correspond to equipment tag/labels indicated on the Control Schematic included in the plans. Include a label above each timing relays indicating the range and set points for that timing relay. g. Project specific layout of front of controller clearly identifying the location of all panel mounted devices, and clearly indicating the maximum mounting height of devices on doors. h. Terminal strip layout clearly showing all field connections. The terminal strip layout shall also include a label next to each connection indicating signal description. i. Conduit entry and exit locations. Conduit entry and exit points clearly showing dimensions of entry and exit points. Provide a detailed view showing how conduit penetrate the bottom/side of panel. j. Installation weights. k. Cable terminal sizes. l. Internal component layout diagrams showing the front view of inside the panel (with the doors off) clearly identifying all devices and power equipment. 4. Complete bill of materials with model numbers listed for individual components. 5. Data sheets of miscellaneous electrical equipment clearly identifying make and model being provided. 6. Warranty Information. 7. Spare Parts List. 8. Any deviations from the specifications should be clearly identified on a separate sheet of paper in the shop drawing submittal. 1.05 OPERATION AND MAINTENANCE MANUALS: A. Operation and maintenance manuals shall contain the shop drawings, submittals, spare parts lists, schematics, and maintenance procedures. B. Manuals shall also incorporate appropriate final certified shop drawings. Manuals may be manufacturer's standard instructions, but shall be supplemented as necessary to cover any special feature not included in standard material. C. Manufacturer's written instructions for testing, adjusting, and reprogramming reduced- voltage solid-state controllers. D. 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. Enclosed Controllers 26 29 13 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements E. Load-Current and List of Settings of Adjustable Overload Relays: Compile after motors have been installed, and arrange to demonstrate that switch settings for motor running overload protection suit actual motors to be protected. 1.06 DELIVERY, STORAGE, AND HANDLING A. Store enclosed controllers indoors in clean, dry space with uniform temperature to prevent condensation. Protect enclosed controllers from exposure to dirt, fumes, water, corrosive substances, and physical damage. B. If stored in areas subject to weather, cover enclosed controllers to protect them from weather, dirt, dust, corrosive substances, and physical damage. Remove loose packing and flammable materials from inside controllers. 1.07 PROJECT CONDITIONS A. Environmental Limitations: Rate equipment for continuous operation under the following conditions unless otherwise indicated: 1. Ambient Temperature: Not less than minus 22 deg F (minus 30 deg C) and not exceeding 122 deg F (50 deg C). 2. Altitude: Not exceeding 3300 feet. B. HORSEPOWER RATING: 1. The motor size indicated on the Plans is the maximum size horsepower expected at each of the sites. The Contractor shall furnish properly sized motor control equipment suitable for use with the maximum expected motor horsepower for each site. Field verify exact motor horsepower for each site and properly size overloads and MCP accordingly. If actual motor horsepowers differ from the Plans, the Contractor shall obtain assistance from the Engineer in determining whether or not hardware and wiring changes are necessary. The Contractor shall provide all components and wire of the proper size. C. OPERATING VOLTAGE: The equipment shall be designed and arranged for operation on 480 Volt, 3 phase, 60 Hertz or 120V, 60 Hertz. See plans for more details. Enclosed Controllers 26 29 13 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements D. CONTROL POWER: Control power shall be 120 VAC from a control transformer located in each combination starter. Extra control transformer VA capacity shall be furnished for powering the motor space heater in the motor which the combination starter serves. This extra VA capacity shall be in addition to the VA required for the other control components powered by the control transformer. The following is the amount of extra VA capacity which shall be furnished: COMBINATION NEMA SIZE CONTROL TRANSFORMER EXTRA VA CAPACITY size 1 100 size 2 200 size 3 300 size 4 500 size 5 750 size 6 1000 This extra VA capacity shall be furnished in each combination starter regardless of where the motor space heater received its power and regardless of whether the motor has a space heater or not. E. INTERRUPTING RATING: Both circuit breakers and combination starters as complete units shall be rated for 65,000 Amps Interrupting Capacity (AIC). F. ENCLOSURES: NEMA 4X 304 stainless steel for all locations. 1.08 COORDINATION A. Coordinate layout and installation of enclosed controllers with conduit, equipment, and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels. 1.09 SPARE PARTS A. Furnish spare parts that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Control Power Fuses: Equal to 10 percent of quantity installed for each size and type, but no fewer than two of each size and type. 2. Indicating Lights: One of each type and color installed. 3. Five spare relays and timers of each type used. Enclosed Controllers 26 29 13 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.00 PRODUCTS 2.01 COMBINATION STARTER A. The combination starter shall include a motor circuit protector (MCP) type circuit breaker or a thermal magnetic type circuit breaker as indicated on the Plans. MCP's shall be magnetic trip only with adjustable magnetic trip limited to 1300% of motor nameplate full load current to comply with NEC requirements. Devices shown on the schematic and not specifically designated as being elsewhere shall be installed inside the combination starter. B. Combination starter doors shall be interlocked mechanically with the circuit breaker operator mechanism to prevent unintentional opening of the door while the circuit breaker is in the closed position. The circuit breaker operator mechanism shall be mounted on the stationary part of the enclosure and not on the door of the enclosure. The circuit breaker operator mechanism shall indicate "ON" and "OFF" with the door open or closed. The circuit breaker shall be manually operated, resettable after trip from the operator mechanism handle. The operating handle shall clearly indicate whether the circuit breaker is "ON" or "OFF", or "TRIPPED". Means shall be provided to lock each operator mechanism handle in the "OFF" position and to close the door. Means shall be provided for releasing the interlock for intentional access to the interior at any time and intentional application of power, if desired, while door is open. Padlocking arrangements shall permit locking the disconnect device "OFF" with at least three padlocks with door closed or open. C. The combination starter shall have a magnetic starter contactor. The magnetic starter contactor shall be NEMA rated and NEMA 1 magnetic starter contactors shall be the minimum size allowed. Magnetic starter contactors shall have renewable contacts and a renewable coil which shall allow each to be replaced without replacing other parts of the magnetic starter contactor. Magnetic starter contactors shall have a maximum pick up voltage of 71% of nominal coil voltage and a maximum drop out voltage of 59% of nominal coil voltage. D. Each magnetic starter shall have three (3) external manual reset thermal overload relays of either the bimetallic type or the melting alloy type. Overload relays shall be either ambient compensated or ambient insensitive. Overload relay heaters shall be Class 10 for submersible pump motors and hermetically sealed motors and shall be Class 20 for all other motors. Overload relay heaters shall be selected to produce an overload trip at no more than the following percent of the motor nameplate full load current rating: Motors with a marked service factor not less than 1.15 125% Motors with a marked temperature rise of not over 40°C 125% All other motors 115% E. Overload relays shall be reset from outside the enclosure with an insulated bar or button. Auxiliary contacts shall be furnished on the circuit breaker operating mechanism, the starter contactor and on the overload sensing unit as shown on the plans. Enclosed Controllers 26 29 13 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements F. Controls and lights shall be heavy duty oil tight construction. Devices installed in the combination starter or on the door of the combination starter shall be completely factory wired with connections to external devices brought to a terminal strip installed in the starter. No field wiring shall be permitted except for connections to remote devices from the terminal strip. A physical wiring diagram shall be provided on each enclosure door and shall be protected to remain intact and legible for the service life of the equipment. Control devices shall be identified as to type and manufacturer. G. Control relays, timing relays, control transformers, control circuit fuse blocks, etc., shall be grouped in the corresponding combination starter with control wiring kept as short as possible. Ample space shall be allowed between devices so that each component is completely accessible without removing any other device. H. Wiring in the combination starter shall terminate on numbered terminal strips or power distribution blocks. No other wire connecting devices, including but not limited to wirenuts and split bolts, shall be allowed in the combination starter. Each combination starter shall be provided with an individual terminal strip for control wiring. Terminal strip metallic materials shall be tinned copper. Power distribution blocks shall be tinned copper which is rated for termination of copper conductors. I. Combination starter control wiring shall be 14AWG. Power wiring shall have black insulation and control wiring shall have purple insulation for ungrounded conductors and white insulation for grounded conductors. Combination starter wiring shall have copper conductors with MTW insulation only. J. Where control transformers are indicated and unless shown otherwise, each starter shall contain a 480 to 120 volt fused control transformer with sufficient capacity for all the devices shown in the schematic. The control transformer shall have two (2) primary fuses, one in each primary lead and one secondary fuse in one of the secondary leads. The unfused secondary lead shall be grounded. K. Each combination starter shall have an engraved plastic nameplate fastened to the outside of the unit door. Engraved plastic nameplates shall have .33" high black letters on a white background and attached with stainless steel screws. Wiring diagrams shall be provided on the inside of each compartment door and shall be protected so that they remain attached and legible for the service life of the equipment. L. If any circuit breaker operating handle is more than 6'6" above the floor surface immediately in front of the combination starter, a supplementary operating device shall be attached to the operating handle. This supplementary device shall require a person to reach no more than 6'6" above the floor surface at any point of opening or closing the circuit breaker. 2.02 FULL-VOLTAGE CONTROLLERS A. General Requirements for Full-Voltage Controllers: Comply with NEMA ICS 2, general purpose, Class A. B. Magnetic Controllers: Full voltage, across the line, electrically held. 1. Configuration: Nonreversing. Enclosed Controllers 26 29 13 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Contactor Coils: Pressure-encapsulated type with coil transient suppressors. a. Operating Voltage: Depending on contactor NEMA size and line-voltage rating, manufacturer's standard matching control power or line voltage. 3. Power Contacts: Totally enclosed, double-break, silver-cadmium oxide; assembled to allow inspection and replacement without disturbing line or load wiring. 4. Control Circuits: 120V ac; obtained from integral CPT, with primary and secondary fuses of sufficient capacity to operate integral devices and remotely located pilot, indicating, and control devices. a. CPT Spare Capacity: 100 VA minimum. . 5. Bimetallic Overload Relays: a. Inverse-time-current characteristic. b. Class 20 tripping characteristic. c. Heaters in each phase matched to nameplate full-load current of actual protected motor and with appropriate adjustment for duty cycle. d. Ambient compensated. e. Automatic resetting. 6. Solid-State Overload Relay: a. Switch or dial selectable for motor running overload protection. b. Sensors in each phase. c. Class 10/20 selectable tripping characteristic selected to protect motor against voltage and current unbalance and single phasing. d. Class II ground-fault protection, with start and run delays to prevent nuisance trip on starting. e. Analog communication module. 7. External overload reset push button. C. Combination Magnetic Controller: Factory-assembled combination of magnetic controller, overcurrent protective device, and disconnecting means. 1. MCP Disconnecting Means: a. UL 489, NEMA AB 1, and NEMA AB 3, with interrupting capacity to comply with available fault currents, instantaneous-only circuit breaker with front-mounted, field-adjustable, short-circuit trip coordinated with motor locked-rotor amperes. b. Lockable Handle: Accepts three padlocks and interlocks with cover in closed position. c. Auxiliary contacts "a" and "b" arranged to activate with MCP handle. d. Current-limiting module to increase controller short-circuit current (withstand) rating to 65 kA. Enclosed Controllers 26 29 13 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.03 ACCESSORIES A. General Requirements for Control Circuit and Pilot Devices: NEMA ICS 5; factory installed in controller enclosure cover unless otherwise indicated. B. IEC or dual rated NEMA/IEC equipment shall not be acceptable. C. CONTROL RELAYS: Industrial type; contacts rated for 10 amps at 600 VAC; Square D Class 8501 Type X, Allen-Bradley Bulletin 700 type PK, or approved equal. Relays shall have the capability of having contact decks added in the field. Contacts shall be field convertible to normally open or normally closed. Coils and contacts shall each be replaceable without replacing any other part of the relay. Where control relays are indicated on the Plans, industrial control relays shall be furnished whether the relay coil is operated with 120 VAC or 24 VDC. D. TIMING RELAYS: Solid state. Ranges shall be as shown on the Plans. The timing relays shall have both normally open and normally closed contacts by having two sets of form C contacts. Timing relays where shown on the Plans shall be Square D, Class 9050 Type JCK60, time delay relay, Allen-Bradley 700-FS or approved equal model for operation on the control voltage of the equipment it is used in. Timing relay shall be provided with restraining strap. E. ELAPSED TIME METER: Yokogawa Type 240, or approved equal. The meter shall be of the non-reset type for totalizing of hours and operating on 120 or 240 VAC, 60 Hertz. F. INDICATING LIGHTS, SWITCHES AND PUSHBUTTONS: Heavy duty and oil tight, Square D Class 9001 (30.5 mm) or approved equal. Devices shall match or exceed the rating of the enclosure. Indicating lights shall be push-to-test (LED type) and shall be Square D SKT or approved equal. G. CONTROL TRANSFORMER: Included in combination starter units with sufficient VA capacity for powering the devices shown in the control schematic; 480 to 120 volt transformer with a fuse in each primary leg and one (1) fuse in the secondary leg. The unfused secondary leg shall be grounded. H. PHASE FAILURE RELAY: Phase failure relay shall be a 480VAC, 3-phase and be able to detect phase loss, low voltage and phase reversal with an automatic reset and output contacts. The phase failure relay shall be as manufactured by Time Mark model 258 or approved equal. I. Space heaters, with N.C. auxiliary contacts, to mitigate condensation in Type 4X enclosures installed outdoors or in unconditioned interior spaces subject to humidity and temperature swings. Space heaters shall be thermostatically controlled and be power from internal power inside the enclosure. 3.00 EXECUTION 3.01 EXAMINATION A. Examine areas and surfaces to receive enclosed controllers, with Installer present, for compliance with requirements and other conditions affecting performance of the Work. B. Examine enclosed controllers before installation. Reject enclosed controllers that are wet, moisture damaged, or mold damaged. Enclosed Controllers 26 29 13 - 9 DTN18104 – Lake Lewisville WTP Phase II Improvements C. Proceed with installation only after unsatisfactory conditions have been corrected. 3.02 INSTALLATION A. Make electrical connections to equipment specified. Install equipment in accordance with the Manufacturer's recommendations and the plans. If neither are available, install the equipment using the best practices of the electrical industry and trade. B. Wall-Mounted Controllers: Install enclosed controllers on walls with tops at uniform height unless otherwise indicated, and by bolting units to wall or mounting on lightweight structural-steel channels bolted to wall. For controllers not at walls, provide freestanding racks complying with Section 26 05 29, "Hangers and Supports for Electrical Systems." C. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and temporary blocking of moving parts from enclosures and components. D. Install heaters in thermal overload relays. Select heaters based on actual nameplate full- load amperes after motors have been installed. E. Comply with NECA 1. 3.03 IDENTIFICATION A. Identify enclosed controllers, components, and control wiring in accordance with Section 26 05 53, “Identification for Electrical Systems”. 1. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs. 2. Label each enclosure with engraved nameplate. 3. Externally visible, permanent nameplates shall be provided to identify each switch, indicating light, etc. Equipment and terminal blocks shall be suitably identified. This shall include items on the back side of doors and panel mounted items. Nameplates shall be black with white lettering and attached with stainless steel screws. 4. Factory installed conductors, control relays, timing relays, pilot devices, etc. shall be labeled at the factory. 3.04 CONTROL WIRING INSTALLATION A. Install wiring between enclosed controllers and remote devices. B. Bundle, train, and support wiring in enclosures. C. Connect selector switches and other automatic-control selection devices where applicable. 1. Connect selector switches to bypass only those manual- and automatic-control devices that have no safety functions when switch is in manual-control position. 2. Connect selector switches with enclosed-controller circuit in both manual and automatic positions for safety-type control devices such as low- and high-pressure cutouts, high- temperature cutouts, and motor overload protectors. Enclosed Controllers 26 29 13 - 10 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.05 FIELD QUALITY CONTROL A. Upon completion of the installation, perform continuity tests and functional checkout to assure the proper operation of all equipment. B. Acceptance Testing Preparation: 1. Test insulation resistance for each enclosed controller, component, connecting supply, feeder, and control circuit. 2. Test continuity of each circuit. C. Tests and Inspections: 1. Inspect controllers, wiring, components, connections, and equipment installation. Test and adjust controllers, components, and equipment. 2. Test insulation resistance for each enclosed-controller element, component, connecting motor supply, feeder, and control circuits. 3. Test continuity of each circuit. 4. Verify that voltages at controller locations are within plus or minus 10 percent of motor nameplate rated voltages. If outside this range for any motor, notify Contractor/Owner before starting the motor(s). 5. Test each motor for proper phase rotation. 6. Perform each electrical test and visual and mechanical inspection stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. 7. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest. D. Enclosed controllers will be considered defective if they do not pass tests and inspections. E. Prepare test and inspection reports including a certified report that identifies enclosed controllers and that describes scanning results. Include notation of deficiencies detected, remedial action taken and observations after remedial action. 3.06 ADJUSTING A. Set field-adjustable switches, auxiliary relays, time-delay relays, timers, and overload-relay pickup and trip ranges. B. Adjust overload-relay heaters or settings if power factor correction capacitors are connected to the load side of the overload relays. C. Adjust the trip settings of MCPs and thermal-magnetic circuit breakers with adjustable instantaneous trip elements. Initially adjust to six times the motor nameplate full-load ampere ratings and attempt to start motors several times, allowing for motor cool down between starts. If tripping occurs on motor inrush, adjust settings in increments until motors start without tripping. Do not exceed eight times the motor full-load amperes (or 11 times for NEMA Premium Efficient motors if required). Where these maximum settings do not allow starting of a motor, notify Owner/Contractor before increasing settings. D. Set field-adjustable circuit-breaker trip ranges. Enclosed Controllers 26 29 13 - 11 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.07 PROTECTION A. Temporary Heating: Apply temporary heat to maintain temperature according to manufacturer's written instructions until enclosed controllers are ready to be energized and placed into service. B. Replace controllers whose interiors have been exposed to water or other liquids prior to Substantial Completion. END OF SECTION Enclosed Controllers 26 29 13 - 12 DTN18104 – Lake Lewisville WTP Phase II Improvements THIS PAGE INTENTIONALLY LEFT BLANK Electrical Control Panels 26 29 87 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 29 87 ELECTRICAL CONTROL PANELS 1.00 GENERAL 1.01 SCOPE OF WORK A. Furnish and install functional control panels to manually or automatically operate control systems as specified in the detailed requirements of this Section, and logic and schematics as shown on the Electrical Drawings. B. Submittals for Electrical Control Panels, specified as Control Panels by the Electrical or Mechanical equipment manufacturer, shall be submitted under this Section of the Specifications. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” B. Submittals shall also contain information on related equipment to be furnished under this Specification. Incomplete submittals not containing the required information on the related equipment will also be returned unreviewed. C. The original equipment manufacturer shall create all equipment shop drawings, including all wiring diagrams, in the manufacturer's Engineering department. All equipment shop drawings shall bear the original equipment manufacturer's logo, drawing file numbers, and shall be maintained on file in the original equipment manufacturer's archive file system. Photocopies of the Engineer's ladder schematics are unacceptable as shop drawings. D. Submit to the Owner/Engineer, shop drawings and product data, for the following: 1. Product data sheets and catalog numbers for overcurrent protective devices, motor starters, control relays, control stations, meters, pilot lights, etc. The manufacturer's name shall be clearly visible on the each cut sheet submitted. List all options, trip adjustments and accessories furnished specifically for this project. Clearly mark each sheet to indicate which items apply and/or those items that do not apply. 2. Provide control systems engineering to produce custom project specific unit elementary drawings showing interwiring and interlocking between components and to remotely mounted devices. Include and identify all connecting equipment and remote devices on the schematics. The notation "Remote Device" will not be acceptable. Show wire and terminal numbers. Indicate special identifications for electrical devices per the Drawings. 3. Equipment outline drawings showing elevation, plan and interior views, front panel arrangement, dimensions, weight, shipping splits, conduit entrances and anchor bolt pattern. Indicate all options, special features, ratings and deviations from this Section. 4. Project Specific Schematic diagram, including manufacturer's selections of component ratings, and CT and PT ratios. 5. Project Specific Power and control schematics including external connections. Show wire and terminal numbers, and color-coding. 6. Instruction and replacement parts books. 7. As-built final drawings. Electrical Control Panels 26 29 87 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 8. Documentation that the panel assembly facility is a UL-508 certified panel shop. 9. Facsimile of the UL label that is to be applied to the completed panel. 10. Furnish complete Bill of Materials indicating manufacturer's name and part numbers. 11. Manufacturer's cut sheets for every component used in the panel assembly adequately marked to show the items being included. The manufacturer's name shall be clearly visible on the each cut sheet submitted. 12. Assembly ratings including: a. Short-circuit rating b. Voltage c. Continuous current 13. Major component ratings including: a. Voltage b. Continuous current c. Interrupting ratings 14. Cable terminal sizes. 15. Instruction and renewal parts books. E. Factory Tests. Submittals shall be made for factory tests specified herein. F. Field Test Reports. Submittals shall be made for field tests specified herein. G. Operation and Maintenance Manuals. 1. Operation and maintenance manuals shall include the following information: a. Manufacturer's contact address and telephone number for parts and service. b. Instruction books and/or leaflets c. Recommended renewal parts list d. Record Documents for the information required by the Submittals par graph above. 1.03 REFERENCE CODES AND STANDARDS A. All products and components shown on the Drawings and listed in this specification shall be designed and manufactured according to latest revision of the following standards (unless otherwise noted): 1. NEMA Standard ICS 2 - 2000 Industrial Control and Systems 2. NFPA 70- National Electrical Code (NEC) 3. NFPA 70E- Standard For Electrical Safety in the Workplace 4. NFPA 79- Electrical Standard for Industrial Machinery 5. UL 508/508A -Industrial Control Enclosures Electrical Control Panels 26 29 87 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements B. All equipment specified in this Section of the Specifications shall bear the appropriate label of Underwriters Laboratories. 1.04 QUALITY ASSURANCE A. The manufacturer of this equipment shall have produced similar equipment for a minimum period of five (5) years. When requested by the Owner/Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement. B. The control panels shall be assembled in a UL-508 certified facility. A submittal of documentation certifying that the panel fabrication facility is a UL-508 certified facility is required. A UL label shall be affixed to the inside of the external door by the panel fabrication assembly. Submit a facsimile of the UL label in the submittal information. 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. E. For the equipment specified herein, the manufacturer shall be ISO 9001 2000 certified. F. Equipment components and devices shall be UL labeled wherever UL standards exist for such equipment. The completed control panel shall be UL Labeled in accordance with UL 508 and 508A and other applicable UL standards. The panel shall also be UL labeled for the environment in which it is to be placed. A UL label shall be affixed to the inside of the external door by the panel fabrication assembly. Submit a facsimile of the UL label in the submittal information. 1.05 JOBSITE DELIVERY, STORAGE AND HANDLING A. Prior to jobsite delivery, the Contractor shall have successfully completed all submittal requirements, and present to the Owner/Engineer upon delivery of the equipment, an approved copy of all such submittals. Delivery of incomplete constructed equipment, onsite factory work, or failed factory tests will not be permitted. B. Equipment shall be handled and stored in accordance with manufacturer's instructions. Two (2) copies of these instructions shall be included with the equipment at time of shipment, and shall be made available to the Contractor and Owner/Engineer. C. Shipping groups shall be designed to be shipped by truck, rail, or ship. Indoor groups shall be bolted to skids. Breakers and accessories shall be packaged and shipped separately. D. Equipment shall be installed in its permanent finished location shown on the Drawings within seven (7) calendar days of arriving onsite. If the equipment cannot be installed within seven (7) calendar days, the equipment shall not be delivered to the site, but stored offsite, at the Contractor's expense, until such time that the site is ready for permanent installation of the equipment. E. Where space heaters are provided in equipment, provide temporary electrical power and operate space heaters during storage, and after equipment is installed in permanent location, until equipment is placed in service. Electrical Control Panels 26 29 87 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.06 WARRANTY A. The Manufacturer shall warrant the equipment to be free from defects in material and workmanship for two years from date of final payment 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. 2.00 PRODUCTS 2.01 MATERIAL MANUFACTURERS A. Subject to compliance with the Contract Documents, the following material Manufacturers are acceptable: 1. General Electric Co. 2. Eaton I Cutler-Hammer 3. Square D Co. 4. Allen Bradley B. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Materials listed above are not relieved from meeting these Specifications in their entirety. 2.02 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 65,000 amperes RMS symmetrical at 480Y/277 Volts and 22,000AIC for 208Y/120 Volts. 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 indicated in Section 26 00 00 of the Electrical Specifications. Electrical Control Panels 26 29 87 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements G. Motor controllers, including associated devices, shall be designed for continuous operation at rated current in a 40 degree C ambient temperature unless noted otherwise. H. For additional ratings and construction notes, refer to 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. 6. Required Personal Protective Equipment Class. 7. Type of Fire Rated Clothing. 2.03 CONSTRUCTION A. General 1. Refer to Drawings for: actual layout and location of equipment and components; current ratings of devices, bus bars, components; protective relays, voltage ratings of devices, components and assemblies; and other required details. 2. Control units shall be arranged as shown on the Drawings. 3. Nameplates a. External 1). Nameplates shall be engraved, laminated impact acrylic, matte finish, not less than 1/16-in thick by 3/4-in by 2-1/2-in, Rowmark 322402. Nameplates shall be 316 SS screw mounted to all enclosures except for NEMA 4 and 4X. Nameplates for NEMA 4 and 4X enclosures shall be attached with double faced adhesive strips, TESA TUFF TAPE 4970, .009 X W', or equal. Prior to installing the adhesive nameplates, the metal surface shall be thoroughly cleaned with 70% alcohol until all residue has been removed. Epoxy adhesive or foam tape is not acceptable. Nameplates shall be black with white letters. 2). There shall be a master nameplate that indicates supply voltage equipment ratings, short circuit current rating, manufacturer's name, shop order number and general information. Cubicle nameplates shall be mounted on the front face, on the rear panel and inside the assembly, visible when the rear panel is removed. 3). Provide permanent warning signs as follows: a). "Danger- High Voltage- Keep Out" on all doors. b). "Warning- Hazard of Electric Shock - Disconnect Power Before Opening or Working On This Unit" on main power disconnect or disconnects. Electrical Control Panels 26 29 87 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements b. Internal 1). Provide the panel with a UL 508A label. 2). Control components mounted within the assembly, such as fuse blocks, relays, pushbuttons, switches, etc., shall be suitably marked for identification, corresponding to appropriate designations on manufacturer's wiring diagrams. c. Special 1). Identification nameplates shall be white with black letters, caution nameplates shall be yellow with black letters, and warning nameplates shall be red with white letters. 4. Control Devices and Indicators a. All operating control devices, indicators, and instruments shall be securely mounted on the panel door. All controls and indicators shall be 30mm, corrosion resistant, reinforced plastic, NEMA 4/4X/13. Auxiliary contacts shall be provided for remote run indication and indication of each status and alarm condition. Additional controls shall be provided as specified herein and as required by the detailed mechanical and electrical equipment requirements. b. Indicator lamps shall be LED type. Unless otherwise shown on the Drawings, lens color shall be Red for ON or OPEN, Green for OFF or CLOSED, Amber for FAIL or ALARM, and White for POWER ON. For all control applications, indicator lamps shall incorporate a push-to-test feature. c. Mode selector switches (HAND-OFF-AUTO, LOCAL-OFF-REMOTE, etc) shall be as shown on the Drawings. Units shall have the number of positions and contact arrangements, as required. Each switch shall have an extra dry contact for remote monitoring. d. Pushbuttons shall be Red for START or OPEN, Green for STOP or CLOSE, mushroom Red for EMERGENCY STOP (Pull to Reset), and Black for RESET. e. Furnish nameplates for each device. All nameplates shall be laminated plastic, black lettering on a white background, attached with stainless steel screws. Device mounted nameplates are not acceptable. 5. Control and Instrument Power Transformers a. Control power transformers shall be provided where shown on the Drawings. Transformer shall be sized for the entire load, including space heaters, plus 25% spare capacity, and shall be not less than 100VA. b. Control power transformers shall be 120 volt grounded secondary. Primary side of the transformer shall be fused in both legs. One leg of the transformer secondary shall be solidly grounded while the other leg shall be fused. 6. A failure alarm with horn and beacon light shall be provided when required or specified. Silence and reset buttons shall be furnished. Alarm horn and beacon shall be by Federal Signal; Crouse-Hinds, or equal, NEMA 4X for all areas except for NEMA 7 areas, which shall be NEMA 7/4X cast aluminum. Electrical Control Panels 26 29 87 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements 7. Where specified or shown on the Drawings, a six digit, non-resettable elapsed time meter shall be installed on the face of each motor starter. B. Enclosure Types 1. NEMA 7/4X, cast aluminum enclosures for indoor/outdoor use in hazardous (classified as Class 1, Division 1, Groups B, C and D), as defined in NFPA 70. a. Enclosures constructed for either indoor or outdoor use in hazardous (classified as Class 1, Division 1, Groups A, B, C, or as defined in NFPA 70. Boxes shall be copper- free aluminum, with stainless steel hinged cover, watertight ne-oprene cover gasket with stainless steel bolts. All penetrations shall be factory drilled and tapped. Enclosures shall be Type EJB Style Cas manufactured by the Crouse-Hinds Co.; Appleton Electric Co. or approved equal. 2. NEMA 4X Aluminum Enclosures where specifically shown on the Drawings. a. Enclosures shall be NEMA Type 4X of aluminum with mounting lugs or brackets made on the enclosure suitable for wall mounting. Enclosures shall not have holes or knockouts. Enclosures shall not be less than .080 in. thick, gauge metal. All enclosures shall have continuous hinged, foam-in-place gasketed, doors with handle latch, 3-point above 20" x 20". All enclosures shall have bonding provisions on door. Enclosures shall be ECL Series with Window Kit, where shown on the Drawings, as manufactured by Hoffman Engineering Co. or equal. 3. NEMA 4X Non-metallic enclosures, of fiberglass reinforced polyester, for Chlorine, Ammonia, Caustic and other Chemical Rooms. Fiberglass enclosures shall not be used in the presence of sodium hypochlorite nor shall they be used in outdoor applications. a. Enclosures shall be NEMA 4X, non-metallic construction. Non-metallic boxes shall have UV inhibitors, but not mounted in direct sunlight. Where clamp type latches are required, provide quick- release luggage type latches. All enclosures shall have foam-in-place gasketed doors with handle latch, 3-point above 20" x 20". All enclosures shall have bonding provisions on door. Enclosures shall be with Window Kit, where shown on the Drawings, as manufactured by Hoffman Engineering Co. or equal. 4. NEMA 4X 316 Stainless Steel enclosures for all areas, unless specifically stated otherwise, or shown on the Drawings. a. Wall Mounted 1). Enclosures shall be NEMA Type 4X of 316 stainless steel with mounting lugs or brackets made on the enclosure suitable for wall mounting. Enclosures shall not have holes or knockouts. Enclosures shall not be less than .080 in. thick, gauge metal. All enclosures shall have continuous hinged, foam-in-place gasketed doors with handle latch, 3-point above 20" x 20". Screw-clamp latches shall not be acceptable. All enclosures shall have bonding provisions on door. Enclosures shall be LHCXXXXXXSS6 Series with Hoffman APWKXXXXNFSS Window Kit, where shown on the Drawings, as manufactured by Hoffman Engineering Co. or equal. Electrical Control Panels 26 29 87 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements b. Free Standing 1). Enclosures shall be NEMA Type 4X of 316 stainless steel, with lifting eyes, without knockouts or holes. Enclosures shall not be less than 12 gauge metal. All enclosures shall have continuous hinged, foam-in-place gasketed doors with handle latch, 3-point. All enclosures shall have bonding provisions on door. Enclosures shall be AXXXXXXFSSS6 Series with Hoffman APWKxxXXNFSS Window Kit, where shown on the Drawings, as manufactured by Hoffman Engineering Co. or equal. 5. NEMA 12 enclosures where specifically shown on the Drawings. a. Wall Mounted 1). Enclosures shall be of factory gray painted aluminum, with mounting lugs suitable for wall mounting. Enclosures shall not have holes or knockouts. Enclosures shall not be less than .080 in. thick, gauge metal. All enclosures shall have continuous hinged, foam-in-place gasketed doors with handle latch, 3- point above 20" x 20". All enclosures shall have bonding provisions on door. Enclosures shall be Comline Series with Hoffman APWKXXXXNFSS Window Kit, where shown on the Drawings, as manufactured by Hoffman Engineering Co. or equal. b. Free Standing 1). Enclosures shall be of factory gray painted steel, with lifting eyes, without knockouts or holes. Enclosures shall not be less than 12 gauge metal. All enclosures shall have continuous hinged, foam-in-place gasketed doors with handle latch, 3-point. All enclosures shall have bonding provisions on door. Enclosures shall be AXXXXXXFS Series with Hoffman APWKXXXXNFSS Window Kit, where shown on the Drawings, as manufactured by Hoffman Engineering Co. or equal. 6. NEMA Types 1 or 1A enclosures will not be permitted, unless specifically stated in the Specification for the equipment, or shown on the Drawings. 7. All panels installed outdoors shall have a factory applied, suitable primer and final coat of weather-proof white paint. 8. Each enclosure shall incorporate a removable back panel, and side panels, on which control components shall be mounted. Back panel shall be secured to the enclosure with collar studs for wall mounted enclosures, and 316 SS hardware for free standing enclosures. The enclosure door shall be interlocked with the main circuit breaker by a door mounted operating mechanism. Back panel shalf be tapped to accept all mounting screws. Self-tapping screws shall not be used to mount any components. 9. All enclosures shall be padlockable. 10. The enclosure outer door shall have a rear mounted pocket, containing laminated copies of the Control schematics. 11. Overload tables shall be laminated and adhered to the inside of the door. Electrical Control Panels 26 29 87 - 9 DTN18104 – Lake Lewisville WTP Phase II Improvements C. Environmental Conditioning 1. Condensation Control a. A self-contained enclosure condensation heater with thermostat and fan shalf be mounted inside the control panel, if panel is mounted outdoors or in a non-air- conditioned space. 1). Enclosure heaters shall be energized from 120 volt, single-phase power supply and sized to prevent condensation within the enclosure. 2). Locate enclosure heaters to avoid overheating electronic hardware or producing large temperature fluctuations on the hardware. 3). Enclosure heaters shall have an internal fan for heat distribution and shall be controlled with adjustable thermostats. The thermostat shall have an adjustment range of 40 degrees Fahrenheit to 90 degrees Fahrenheit. Provide a circuit breaker or fused disconnect switch within the enclosure. 4). Enclosure heaters shall be Hoffman type DAH or equal. b. Strip heaters may be provided if they are 240 volt rated, powered at 120 volts AC and do not have a surface temperature higher than 60°C. Strip heaters and thermostats shall be as manufactured by Chromolox or equal. 1). Strip heaters shall be Chromalox, Type OT, 1.5-in wide, 240 Volts, single phase, 150 watts, energized at 120 volts, with rust resisting iron sheath, Catalog No. OT-715, Product Code No. 129314, or equal. Provide sufficient wattage in heaters to prevent condensation should the interior temperature of the enclosure drop below the dew point. 2). A control thermostat mounted inside the control Panel shall be Chromalox, Type WR, single stage, Catalog No. WR-80, Product Code No.263177, or equal. 3). The strip heater terminals shall be guarded by a protective terminal cover. 4). High temperature connecting lead wire shall be used between the thermostat and the heater terminals. Wire shall be No. 12 AWG stranded, nickel-plated copper with Teflon glass insulation and shall be the product of Chromalox, Catalog No. 6-CFI-12, Product Code No. 263783, or equal. c. Each panel shall have a %" 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 0-Z GedneyDBB-50SS, or equal. 2. Corrosion Control a. Provide corrosion protection in each control panel with a corrosion-Inhibiting vapor capsule as manufactured by Northern instruments; Model Zerust VC, or Hoffman Engineering; Model A-HCI, or equal. Electrical Control Panels 26 29 87 - 10 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Enclosure Fans a. Fans shall be furnished for soft start starters and VFDs, as required by the manufacturer, to provide air circulation and cooling. Fans shall be controlled by a temperature switch. The fan shall operate only when the drive is "ON" and for a cool- down period after the drive has stopped Otherwise the fan shall not run when the drive is "OFF". Louvers, if provided, shall have externally removable filters. The filter shall be metallic and washable. b. Fan motors shall be protected by an input circuit breaker. Metal squirrel cage ball bearing, three phase fan motors with 10-year design life shall be used in the drive design. Plastic muffin fans are not acceptable. Fan power shall be obtained from a tap on the main control power transformer. c. A "loss of cooling" fault shall be furnished. In the event of clogged filters or fan failure, the drive shall produce an alarm and then, in a predetermined time, be shut down safely without electronic component failure by the temperature switch. d. Redundant fans shall be provided in the drive design as backup in the event of fan failure. e. Enclosure fans shall not be allowed on any NEMA 4X Enclosures. D. Internal Wiring 1. Power and control wiring shall be tinned stranded copper, minimum size No. 14 AWG, with 600 Volt, 90 degree C, flame retardant, Type MTW thermoplastic insulation. Line side power wiring shall be sized for the full rating or frame size of the connected device, and as shown on the Drawings. 2. Analog signal wires shall be 600 Volt Class, insulated stranded tinned copper, twisted shielded #16 AWG pair. 3. All interconnecting wires between panel mounted equipment and external equipment shall be terminated at numbered terminal blocks. Field wiring shall not be terminated directly on any panel-mounted device. 4. All wiring shall be tagged and coded with an Identification number as shown on the Drawings. Coding shall be typed on a heat shrinkable tube applied to each end showing origination and destination of each wire. The marking shall be permanent, non- smearing, solvent-resistant type similar to Raychem TMS-SCE, or equal. 5. All wiring shall be enclosed in PVC wire trough with slotted side openings and removable cover. Plan wire routing such that no low twisted shielded pair cable conducting analog 4-20 mA signals or low voltage analog signals are routed in the same wire trough as conductors carrying discrete signals or power. E. Field Installed Internal Wiring 1. Field installed interior wiring shall be neatly grouped by circuit and bound by plastic tie wraps. Circuit groups shall be supported so that circuit terminations are not stressed. In addition, low signal wiring (millivolt and milliamp) shall be bundle separately from the rest of the control wiring. Electrical Control Panels 26 29 87 - 11 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. All field wiring shall be tagged and coded with an identification number. Coding shall be typed on a heat shrinkable tube applied to each end of the wire. The marking shall be a permanent, non-smearing, solvent-resistant type similar to Raychem TMS-SCE, or equal 3. In general, all conduit entering or leaving equipment shall be stubbed up into the bottom of the enclosure directly below the area in which the conductors are to be terminated, or from the top if shown on the Drawings. Conduits shall not enter the side unless approved in writing by the Owner/Engineer. F. Terminal Blocks 1. Terminal blocks shall be DIN-rail-mounted one-piece molded plastic blocks with tubular- clamp-screw type and end barriers. Terminal blocks shall be rated for 600 volts except for control and instrumentation circuits, or 4-20 mA analog signal conductors. 2. Provide 600 volt rated terminal blocks for any conductor carrying any voltage over 120 volts to ground. 3. Provide 600 volt rated strap screw terminal blocks for any power conductors carrying over 20 amps, at any voltage. Terminals shall be double sided and supplied with removable covers to prevent accidental contact with live circuits. 4. Power conductors carrying over 20 amps, at any voltage shall be terminated to strap- screw type terminal blocks with crimp type, pre-insulated, ring-tongue lugs. Lugs shall be of the appropriate size for the terminal block screws and for the number and size of the wires terminated. Do not terminate more than one conductor in any lug, and do not land more than two conductors under any strap-screw terminal point. 5. Terminals shall have permanent, legible identification, clearly visible with the protective cover removed. Each terminal block shall have 20 percent spare terminals, but not less than two spare terminals. 6. Use the manufacturer's provided bridge connectors to interconnect terminal blocks terminating common or ground conductors. 7. Twisted shielded pair or triad cables shall have each individual conductor and shield drain wire landed on individual terminal blocks. Use the manufacturer's provided bridge connectors to interconnect terminal blocks terminating the shield drain wire conductors. 8. Control circuits, 120 volts and below, and 4-20 mA analog signal conductors shall be terminated with manufacturer's recommended insulated connectors. 9. Provide an AC ground bar bonded to the panel enclosure (if metal) with 20 percent spare terminals. 10. Provided ground terminal blocks for each twisted-shielded pair drain wire. G. CONTROL RELAYS: Industrial type; contacts rated for 10 amps at 600 VAC; Allen-Bradley bulletin 700 type PK, Square D Class 8501 type X, or approved equal. Relays shall have the capability of having contact decks added in the field. Contacts shall be field convertible to normally open or normally closed. Coils and contacts shall each be replaceable without replacing any other part of the relay. Where control relays are in dicated on the Plans, industrial control relays shall be furnished whether the relay coil is operated with 120 VAC or 24 VDC. General purpose “plug-in” type relays shall not be acceptable. Electrical Control Panels 26 29 87 - 12 DTN18104 – Lake Lewisville WTP Phase II Improvements H. TIMING RELAYS: Solid state. Ranges shall be as shown on the Plans. The timing relays shall have both normally open and normally closed contacts by having two sets of form C contacts. Timing relays where shown on the Plans shall be Square D, Class 9050 Type JCK60, time delay relay, Allen-Bradley 700-FS or approved equal model for operation on the control voltage of the equipment it is used in. Timing relay shall be provided with restraining strap. I. INDICATING LIGHTS, SWITCHES, PUSHBUTTONS: Heavy duty and oil tight (30mm); Square d Class 9001 or approved equal. Pilot lights shall be push to test (LED type) and shall be Square D SK or approved equal. 2.04 MAIN CIRCUIT PROTECTIVE DEVICE A. Unless otherwise shown on the Drawings, the main circuit protective device shall be a molded case (MCCB), 3 Pole, 600 Volt, fixed type, manually operated with stored energy closing mechanism. Trip device shall be solid state with adjustable long time pickup, and delay; adjustable short time pickup and delay; short time i2t switch. B. Provide a flange mounted main power disconnect operating handle with mechanical interlock having a bypass that will allow the panel door to open only when the switch is in the OFF position. Where panels are shown or specified with inner and outer doors, disconnecting handles and controls shall be located on the inner door. C. The overall short circuit withstand and interrupting rating of the equipment and devices shall be 65,000 amperes RMS symmetrical at 480Y/277 Volts and 22,000AIC for 208Y/120 Volts. 2.05 REMOTE MONITORING AND CONTROL INTERFACE A. General: All control and interconnection points from the equipment to the plant control and monitoring system shall be brought to a separate connection box. No field connections shall be made directly to the equipment control devices. Functions to be brought out shall be as shown on the Drawings B. Discrete control or status functions shall be form C relays with contacts rated at 120 volts AC. Analog signals shall be isolated from each other. C. Equipment functions to be directly interfaced to the Plant Control and Monitoring System shall be designed for operation with an Ethernet Connection. D. The equipment manufacturer shall factory enter the proper IP Address for such connection. Upon request by the Contractor, the Owner/Engineer will provide the proper Internet Protocol Address (IP Address), to be configured by the equipment manufacturer. E. Refer to the Drawings for monitored parameters. F. Communication 1. For remote monitoring, one of the following communication capabilities shall be provided: a. One (1) integral 10/1OOBaseT Ethernet port supporting Modbus TCP, Ethernet IP and SNMP protocols. b. One (1) media protocol converter, interfacing the provided equipment to a 10/100BaseT Ethernet port supporting Modbus TCP, Ethernet IP and SNMP. Electrical Control Panels 26 29 87 - 13 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. The protocol interface shall implement the following: a. All data shall be available and/or mirrored within the Modbus 4x or "Holding Register" memory area. b. Register 4x00001 shall exist and be readable to allow simple, predictable "comm tests". 3. The media protocol converter shall meet the following criteria: a. The converter shall support 10/1OOBase-T Ethernet. The serial port speed (baud rate) shall support 230kbps. The protocol shall support Modbus TCP, Ethernet IP, DF1, and Modbus RTU/ASCII. Protocol shall be Web Browser configurable. b. Operating limits shall be 0-60 degrees C, with humidity range minimum of 5-90 percent. Shock capability on the serial port shall be ESD +15 kV air GAP meeting IEC 1000-4-2. Power requirements shall be 9-30VDC at 0.5A minimum. c. The converter shall have LED status for serial, signals, power, and Ethernet. d. The converter housing shall be UL 1604, Class 1 Div 2, DIN Rail mountable. The converter shall have DB-9M port connection, with screw terminals, to the input. e. Converter shall be Digi One lAP, or approved equal. 2.06 FACTORY TESTING A. The entire control panel shall be completely assembled, wired, and adjusted at the factory and shall be given the manufacturer's routine shop tests and any other additional operational test to insure the workability and reliable operation of the equipment. B. Factory test equipment and test methods shall conform with the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards. C. The operational test shall include the proper connection of supply and control voltage and, as far as practical, a mockup of simulated control signals and control devices shall be fed into the boards to check for proper operation. D. Factory test equipment and test methods shall conform to the latest applicable requirements of ANSI, IEEE, UL, and NEMA standards, and shall be subject to the Owner/Engineer's approval. 3.00 EXECUTION 3.01 INSTALLER'S QUALIFICATIONS 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. 3.02 EXAMINATION A. Examine installation area to assure there is enough clearance to install the equipment. Electrical Control Panels 26 29 87 - 14 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Housekeeping pads shall be included for the floor mounted motor controllers as detailed on the Drawings with the exception of motor controllers which are to be installed adjacent to an existing unit. Housekeeping pads for these (if used) should match the existing installation. 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. 3.03 INSTALLATION A. The Contractor shall install all equipment per the manufacturer's recommendations and Contract Drawings. B. Conduit hubs for use on raceway system pull and junction boxes shall be watertight, threaded aluminum, insulated throat, stainless steel grounding screw, as manufactured by T&B H150GRA Series, or equal. C. Conduits entering a control Panel or box containing electrical equipment shall not enter the enclosure through the top. D. Install required safety labels. 3.04 RACEWAY SEALING A. Where raceways enter junction boxes or control panels containing electrical or instrumentation equipment, all entrances shall be sealed with 3M 1OOONS Watertight Sealant, or approved equal B. This requirement shall be strictly adhered to for all raceways in the conduit system. 3.05 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. 3.06 FIELD ADJUSTING A. Adjust all circuit breakers, switches, access doors, operating handles for free mechanical and electrical operation as described in manufacturer's instructions. 3.07 FIELD TESTING A. Perform all electrical field tests recommended by the manufacturer. Disconnect all connections to solid-state equipment prior to testing. B. Megger and record phase to phase and phase to ground insulation resistance. Megger, for 1 minute, at minimum voltage of 1000 VDC. Measured Insulation resistance shall be at least 100 megohms. In no case shall the manufacturer's maximum test voltages be exceeded. C. Test each key interlock system for proper functioning. D. Test all control logic before energizing the motor or equipment. Electrical Control Panels 26 29 87 - 15 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.08 CLEANING A. Remove all rubbish and debris from inside and around the motor controllers. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air. 3.09 EQUIPMENT PROTECTION AND RESTORATION A. Touch-up and restore damaged surfaces to factory finish, as approved by the manufacturer. If the damaged surface cannot be returned to factory specification, the surface shall be replaced. 3.10 MANUFACTURER'S CERTIFICATION A. A qualified factory-trained manufacturer's representative shall certify in writing that the equipment has been installed, adjusted, including all settings designated in the Power System Study, and tested in accordance with the manufacturer's recommendations. B. The Contractor shall provide three (3) copies of the manufacturer's representative's certification. 3.11 TRAINING A. Provide manufacturer's services for training of plant personnel in operation and maintenance of the soft start starters furnished under this Section. B. The training for each type of equipment shall be for a period of not less than one (1) eight hour day. C. The cost of training program to be conducted with Owner's personnel shall be included in the Contract Price. The training and instruction, insofar as practicable, shall be directly related to the system being supplied. D. Provide detailed O&M manuals to supplement the training course. The manuals shall include specific details of equipment supplied and operations specific to the project. E. The training session shall be conducted by a manufacturer's qualified representative. Training program shall include instructions on the assembly, motor starters, protective devices, metering, and other major components. F. The Owner reserves the right to videotape the training sessions for the Owner's use. END OF SECTION Automatic Transfer Switches 26 36 23 - 1 DTN18104 – Lake Lewisville WTP Improvements Phase II 26 36 23 AUTOMATIC TRANSFER SWITCHES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install a transfer switch. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical.” 1.02 QUALITY ASSURANCE A. Work shall be performed in accordance with quality commercial practices. The appearance of the finished work shall be of equal importance with its operation. Materials and equipment shall be installed based upon the actual dimensions and conditions at the project site. Locations for materials requiring an exact fit shall be measured. B. Obtain automatic transfer switch, remote annunciator and control panels through one source from a single manufacturer. Acceptable manufacturers shall be: 1. Emerson; ASCO Power Technologies. 2. GE Zenith Controls. 3. Russelectric, Inc. 4. Eaton (Cutler-Hammer) 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Shop Drawings: a. Data sheet clearly indicating what features are being provided for each switch. b. Complete bill of materials with cut sheets on all major equipment (transfer switch and the controller) clearly identifying exact model numbers of each component. c. Complete rating d. Device description e. List of all project specific controller and relay settings as to what each will be set to initially in the field and which clearly indicates what options are applicable to the project. Providing a generic list of factory default settings will not be acceptable. f. Warranty Information g. Spare Parts List h. Drawings shall show: 1). Overall outline dimensions, section and details showing minimum clearances, conductor entry provisions, gutter space, etc. 2). Overall weight of each unit Automatic Transfer Switches 26 36 23 - 2 DTN18104 – Lake Lewisville WTP Improvements Phase II 3). Conduit entry and exit points clearly showing dimensions of conduit entry and exit points. 4). Cable Terminal sizes 5). Provide a drawing of the inner front view elevation with designation of equipment and devices on doors, and clearly indicating the maximum mounting height of devices on doors. 6). Show vertical clearance/distance between lugs/terminating pads and bottom/top of equipment on elevation drawings. 7). Terminal strip layout showing customer field connections. The terminal strip layout shall also include a label next to each connection indicating signal description. 8). Project Specific Wiring Diagram: Detail wiring diagram and differentiate between manufacturer-installed and field-installed customer wiring. Show both power and control wiring. Show terminal strip information identifying all customer field terminations. Provide project specific wiring diagrams. Generic wiring diagrams are not acceptable. 2. Field Quality-Control Test Reports. 3. Operation and Maintenance Data: For each type of product to include: a. Features and operating sequences, both automatic and manual. b. List of all project specific setting of relays listing how each setting was set from the manufacturer after testing; provide relay-setting and calibration instructions, including software where applicable. Providing a list of factory default settings that do not reflect changes made during construction and testing will not be acceptable. B. Product Data: For each type of product indicated. Include rated capacities, weights, operating characteristics, furnished specialties, and accessories. 1.04 STANDARDS A. The applicable provisions of the following standard shall apply as if written here in its entirety: 1. National Electrical Manufacturer Association (NEMA) Standards: NEMA ICS 10 AC Transfer Switch Equipment 2. National Fire Protection Association (NFPA) Standards: NFPA 70 National Electric Code NFPA 110 Emergency and Standby Power Systems 3. Underwriters Laboratories (UL) Standards: UL Bulletin No. 1008 Transfer Switches, Automatic Automatic Transfer Switches 26 36 23 - 3 DTN18104 – Lake Lewisville WTP Improvements Phase II 2.00 PRODUCTS 2.01 TRANSFER SWITCH A. Transfer switch shall combine all functions of an automatic transfer switch. The switch shall be three-pole as shown on plans, rated for 400 amps at 208Y/120 V, as shown on plans and be able to withstand and close into a fault current of 22,000 RMS symmetrical amps without any damage or contact welding according to UL-1008. B. The transfer switch shall be suitable for unistrut mounting. Enclosure shall be NEMA 12, steel for indoor use. C. The transfer switch shall be double throw, actuated by a single electrical operator, momentarily energized, and connected to the transfer mechanism by a simple overcenter type linkage with a total transfer time not to exceed 1/2 second. The transfer switch shall be capable of transferring successfully in either direction with 70 percent of rated voltage applied to the switch terminals. D. The Source 1 and Source 2 contacts shall be positively interlocked mechanically and electrically to prevent simultaneous closing. Main contacts shall be mechanically locked in position in both the normal and emergency positions without the use of hooks, latches, magnets or springs; and shall be silver-tungsten alloy. Separate arching contacts with magnetic blowouts shall be provided on transfer switches. Interlocked molded case circuit breakers or contactors are not acceptable. E. The transfer switch shall be equipped with a safe manual operator designed to prevent injury to operating personnel. The manual operator shall provide the same contact-to- contact transfer speed as the electrical operator to prevent a flashover from switching the main contacts slowly. Main contacts shall be capable of carrying the rated current of the switch continuously and shall be capable of opening at the switch’s rated current. F. The transfer switch shall transfer from Source 1 to Source 2 when 90 percent of rated voltage and frequency has been reached. After restoration of Source 1 power on all phases to 90 percent of rated voltage, an adjustable time delay period of 0 to 30 minutes shall delay retransfer to allow stabilization of Source 1 power. If the Source 2 power source should fail during this time delay period, the switch shall automatically return to the Source 1 power source. G. A test switch shall be included to simulate the Source 1 power failure, and pilot lights shall be mounted on the cabinet door to indicate the switch position. Two auxiliary contacts rated 25 amps, 120 volts, shall be mounted on the main shaft; one closed on Source 1, the other closed on Source 2. In addition, one set of relay contacts shall be provided to open upon loss of the Source 1 power supply. Relays, timer control wiring and accessories shall be front accessible. Control wire terminations shall be identified by tubular sleeve-type markers. H. Neutral Connection: Solid and fully rated, unless otherwise indicated. Automatic Transfer Switches 26 36 23 - 4 DTN18104 – Lake Lewisville WTP Improvements Phase II I. DIMENSIONS: Transfer switch shall not exceed a foot print of 36” wide by 20” deep and shall not require rear or side access. Equipment requiring special access or more space shall be addressed with the contractor prior to bidding the project. The contractor shall be responsible to make all the necessary adjustments to the equipment rack and the site to accommodate the changes at no additional cost to the Owner. 2.02 AUTOMATIC TRANSFER SWITCH FEATURES A. Undervoltage Sensing for each Phase of Normal Source: Sense low phase-to-ground voltage on each phase. Pickup voltage shall be adjustable from 85 to 100 percent of nominal, and dropout voltage shall be adjustable from 75 to 98 percent of pickup value. Factory set for pickup at 90 percent and dropout at 85 percent. B. Adjustable Time Delay: For override of Source 1 voltage sensing to delay transfer. Adjustable from zero to 6 seconds and factory set for 1 second. C. Voltage /Frequency Lockout Relay: Pickup voltage shall be adjustable from 85 to 100 percent of nominal. Factory set for pickup at 90 percent. Pickup frequency shall be adjustable from 90 to 100 percent of nominal with a factory set for pickup at 95 percent. D. Time Delay for Retransfer: Adjustable from 0 to 30 minutes, and factory set for 10 minutes to automatically defeat relay on loss of voltage or sustained under-voltage of emergency source, provided normal supply has been restored. E. Test Switch: Simulate both Source 1 and Source 2 failure. F. Source Available Indicating Lights: 1. Green light engraved “Source 1 Available” and 2. Green light engraved “Source 2 Available”. G. Switch-Position Pilot Light: Indicate source to which load is connected. H. Unassigned Auxiliary Contacts: Two Normally Open and Two Normally Closed contacts for each switch rated 10 A at 240 VAC. 2.03 ACCESSORIES A. Auxiliary contacts to indicate the following: 1. Source 1 Power Mode 2. Source 1 Available 3. Transfer Failure 4. Source 2 Power Mode 5. Source 2 Available 6. Common Alarm. B. The ATS shall include Modbus TCP/IP communications for future use. Automatic Transfer Switches 26 36 23 - 5 DTN18104 – Lake Lewisville WTP Improvements Phase II 3.00 EXECUTION 3.01 INSTALLATION A. Make electrical connections to specified equipment. Install equipment in accordance with the Manufacturer’s recommendations and the plans. If neither is available, install the equipment using recognized practices of the electrical industry. 1. Mounting: Each switch shall be unistrut mounted to the wall. 2. Set field adjustable intervals, delays, and relays. 3.02 CONNECTIONS A. Wiring to Remote Components: Match type and number of cables and conductors to control and communication requirements of transfer switches as recommended by manufacturer. Increase raceway sizes at no additional cost to the Owner if necessary to accommodate required wiring. 3.03 FIELD QUALITY CONTROL A. Upon completion of the installation, perform continuity tests and functional checkout to assure the proper operation of equipment. B. Manufacturer’s Field Service: Engage a factory-authorized service representative to inspect, test and adjust components, assemblies, and equipment installations, including connections. Report results in writing. C. Perform tests and inspections and prepare test reports. 1. After installing equipment and after electric circuitry has been energized, test for compliance with requirements. 2. Perform each visual and mechanical inspection and electrical test stated in NETA Acceptance Testing Specification. Comply with test parameters. 3. Measure insulation resistance phase-to phase and phase-to-ground with insulation- resistance tester. Include external annunciation and control circuits. Use test voltages and procedure recommended by manufacturer. Comply with manufacturer’s specified minimum resistance. a. Check for electrical continuity of circuits and for short circuits. b. Inspect for physical damage, proper installation and connection, and integrity of barriers, covers and safety features. c. Verify manual transfer warnings are properly placed. d. Perform manual transfer operation. 4. After energizing circuits, demonstrate interlocking sequence and operational function for each switch at least three times. END OF SECTION Lightning Protection for Structures 26 41 13-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 41 13 LIGHTNING PROTECTION FOR STRUCTURES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, design, materials, equipment and incidentals necessary to install a complete lightning protection system for the new Buildings as shown on the plans and in accordance with UL 96A, NFPA 780. Lightning protection system shall be tied to the grounding system for the building. 1.02 QUALITY ASSURANCE A. The system furnished under this specification shall be the standard product of a manufacturer regularly engaged in the production of lightning protection systems and shall be the manufacturer's latest approved design. Listing of the manufacturer in the lightning protection section of the current edition of Underwriters' Laboratories, Inc., Electrical Construction Materials List will be accepted as compliance with this requirement. B. All materials shall be copper and bronze and of the size, weight and construction to suit the application where used in accordance with UL, NFPA, NEC code requirements for this type structure and as per manufacturer's recommendations. Class I sized components may be utilized on roof levels 75 feet and below in height. Class II sized components are required for roof levels over 75 feet in height. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures”, and shall include: 1. Shop Drawings a. Specifications b. Catalog Sheets for All Products Provided c. Shop drawings showing type, size and location of all equipment, grounds, cable routings, details, etc. 2. Continuity Test Report 3. Copy of U.L. Master Label for the Facility 1.04 STANDARDS AND REFERENCES A. Refer to Section 26 05 00, “Common Work Results for Electrical”, for all standards which apply to this section. NFPA 780 Standard for the Installation of Lightning Protection Systems UL 96A Standard for Installation Requirements for Lightning Protection Systems LPI 175 Lightning Protection Institute Standard of Practice Lightning Protection for Structures 26 41 13-2 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.00 PRODUCTS 2.01 MATERIALS A. Materials used in connection with the installation of the lightning protection systems shall be approved for lightning protection systems by the Underwriters' Laboratories, Inc. No combination of materials shall be used that form an electrolytic couple of such a nature that corrosion is accelerated in the presence of moisture unless moisture is permanently excluded from the junction of such metals. When unusual conditions exist which would cause deterioration or corrosion of conductors, conductors with suitable protective coatings or oversize conductors shall be used. If a mechanical hazard is involved, the conductor size shall be increased to compensate therefore, or suitable protection shall be provided. The conductors may be protected by covering them with molding or tubing preferably made of wood or nonmagnetic material. If metal tubing is used, the conductor shall be electrically connected to it at its upper and lower ends. B. All equipment used shall be new and of a design and construction to suit the application in accordance with UL 96A requirements and shall be so marked. 2.02 MANUFACTURED PRODUCTS A. CONDUCTORS - Copper conductors manufactured of copper grade ordinarily required for commercial electrical work generally designated as being 98 percent conductive when annealed. Down conductors of copper cable for installations other than towers shall weigh not less than 187.5 pounds per thousand feet and the size of any wire of this cable shall not be less than No. 17 AWG (0.045 inch). Down conductors shall be tinned. The thickness of any copper ribbon or strip shall be not less than No. 16 AWG (0.051 inch). B. AIR TERMINALS - Air terminals shall be tapered to a blunt point. The rod shall be of solid copper, 1/2 inch in diameter. Air terminals and support shall be designed over 24 inches to handle a 75 pound per square foot wind load. All air terminals shall be supported by a suitable brace, with guide(s) not less than one-half the height of the air terminal. Air terminals shall be located in accordance with the requirements of NFPA 780 and UL 96A. Air terminals shall extend at least ten inches above the object or area they are intended to protect. Air terminals shall be placed around the perimeter of flat or gently sloping roofs at intervals not exceeding 20 feet. C. FASTENERS - Fasteners shall be of the same material as the conductor base material or bracket being fastened, or other equally corrosion resistant material. Galvanized or plated materials shall not be used. D. FITTINGS - Fittings/bonding devices, cable splicers, and miscellaneous connectors shall be suitable for use with the installed conductor and shall be copper, bronze or aluminum with bolt pressure connections to the cable. Cast or stamped crimp type fittings shall not be used. E. Aluminum material may be used where the installation of dissimilar metals creates problems. The Contractor shall field verify all materials involved in the total installation and shall install system in accordance with all applicable NFPA and U.L. codes and standards. Lightning Protection for Structures 26 41 13-3 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.00 EXECUTION 3.01 INSTALLATION A. The Contract Drawings (shop drawings) shall indicate the extent and general arrangement of the lightning protection system. If any departures from the Contract Drawings (shop drawings) are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted to the Engineer for approval. No such departures shall be made without the prior written approval of the Engineer. Lightning protection systems for all applications shall conform to National Fire Protection Association Code No. 780 and the NEC, whichever is more stringent. B. Installation shall be performed by a certified master installer. Installer shall provide an Underwriters' Laboratories Master Label for the facilities. C. Air terminals shall be provided on the highest projections and at intervals not exceeding 20 feet along the perimeter top surface. Air terminals shall extend at least 10 inches above the object or area that they are intended to protect. Air terminals shall be connected to the lightning protection system when specifically authorized by the Engineer. D. Roof and down conductors shall be stranded and shall meet the requirements given in NFPA 780. Roof and down conductors shall maintain a horizontal or downward course. No bend in a roof or down conductor shall form an included angle of less than 90 degrees, nor shall it have a bend radius of less than eight inches. Conductors shall be routed external to buildings and six feet or more from power or signal conductors. Down conductors shall be routed outside of any structure and shall not penetrate or invade that structure. All down conductors except one may be provided with a screw type connector as described in UL 96 where lightning protection system testing may be required. Down connectors shall be supported from and secured to the building exterior using one hole straps of copper or bronze at maximum intervals of three feet. E. Guards shall be provided for down conductors located in or next to driveways, walkways or other areas where they may be displaced or damaged. Guards shall extend at least six feet above and one foot below grade level. Guards shall be metal pipe. Metal guards shall be bonded to the down conductor at both ends. Bonding jumpers shall be of the same size as the down conductor. Crimp type fittings shall not be used. F. Metallic bodies, on or below roof level, that are subject to induced charges from lightning include exhaust fans, radio towers, HVAC units, ladders, railings, antennas, roof drains, plumbing, vents, metal coping, metal flashing, gutters, downspouts, small metal wall vents, door and window frames, metal balcony railings, and in general any isolated metallic body within six feet of an exposed lightning protection system element. When these metallic bodies have a metal thickness of 3/16 inch or greater, they shall be bonded to the nearest main lightning protection system conductor with UL approved fittings and conductors meeting the requirements of NFPA 780. These bonding fittings shall provide surfaces of not less than three square inches. Provisions shall be made to prevent corrosive effects introduced by galvanic action of dissimilar metals at bonding points. If the metal parts of these units are less than 3/16 inch thick, additional approved air terminals, conductors and fittings, providing a two way path to ground from the air terminals shall be installed. Lightning Protection for Structures 26 41 13-4 DTN18104 – Lake Lewisville WTP Phase II Improvements G. If metallic, the mast of roof mounted antennas and obstruction lightning shall be bonded to the nearest roof or down conductor using UL approved fittings and conductors. The bonding jumpers shall be of the same size and material as the roof or down conductor to which they are connected. Provide as a minimum a path to ground at each corner of the building. H. Aluminum material may be used where the installation of dissimilar metals creates problems. The Contractor shall field verify all materials involved in the total installation and shall install system in accordance with all applicable NFPA and U.L. codes and standards. 3.02 FIELD QUALITY CONTROL A. The lightning protection system will be inspected by the Engineer to determine conformance with the requirements of this specification. No part of the system shall be concealed until so authorized by the Engineer. B. The Contractor shall establish and maintain quality control for the “Lightning Protection System” installation to assure compliance with contract requirements, and shall maintain records of his quality control for all construction operations. A copy of these records and Contractor tests, as well as records of corrective action taken, shall be furnished to Owner’s Representative, as directed by the Engineer. C. Contractor shall obtain an Underwriters' Laboratories Master Label for the facility. 1. Upon completion, an application shall be made to the Underwriters Laboratories, Inc. for inspection and certification. 2. Cost for UL inspection and associated costs to obtain the UL Master Label shall be paid for by the Contractor. D. Testing of Continuity of all Conductors - A copy of these records and tests, as well as the records of corrective action taken, shall be furnished to Owner’s Representative, as directed by the Engineer. END OF SECTION Lighting 26 50 00-1 DTN18104 – Lake Lewisville WTP Phase II Improvements 26 50 00 LIGHTING 1.00 GENERAL 1.01 WORK INCLUDED Furnish labor, materials, equipment and incidentals necessary to install light fixtures, complete with lamps, ballasts and other incidentals. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.02 QUALITY ASSURANCE A. ACCEPTABLE MANUFACTURERS 1. Refer to Lighting Fixture Schedule on contract drawings. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittals Procedures” and shall include Shop Drawings: 1. Refer to the Lighting Fixture Schedule for the manufacturer and model number for each type of fixture. Submittals with alternate manufacturers than those listed in the lighting fixture schedule will not be reviewed and will be returned without review. 2. Bill of Material 3. Product data sheets for each fixture type: a. Product data sheets shall be marked for each fixture type, arranged in the order of the fixture designation. b. Product data for fixtures, lamps, ballasts, drivers and emergency lighting units. c. Outline drawings indicating dimensions and principal features of the fixture. d. Electrical ratings and photometric data provided by certified laboratory tests for the fixture and lamps. e. Provide data on LED Fixture indicating it is rated for maintained 70% lumen output at 60,000 hours. 1.04 DELIVERY AND STORAGE A. Ship light fixtures inside protective cartons and keep packaged until installed. Deliver lamps to the job site in the original packing cases and sleeves. B. Store poles on decay-resistant-treated skids at least 12 inches above grade and vegetation. Support poles to prevent distortion and arrange to provide free air circulation. C. Retain factory-applied pole wrappings on metal poles until right before pole installation. For poles with nonmetallic finishes, handle with web fabric straps. Lighting 26 50 00-2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.05 JOB CONDITIONS A. Provide cold weather ballasts in fixtures which are subject to temperatures below 32 degrees F. B. Provide special mounting, enclosures and fire-safing, as required by the authorities having jurisdiction so that the integrity of the U.L. listed ceiling assembles is maintained. C. Provide U.L. labels where fixtures are subject to moisture. Provide DL or WL label on fixtures required for the location. D. Contractor shall verify voltages with ballasts and power supplies prior to ordering fixtures. 1.06 WARRANTY A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace products that fail in materials or workmanship; that corrode; or that fade, stain, perforate, erode, or chalk due to effects of weather or solar radiation within specified warranty period. Manufacturer may exclude lightning damage, hail damage, vandalism, abuse, or unauthorized repairs or alterations from special warranty coverage. 1. Warranty Period for Luminaires: Five years from date of Substantial Completion. 2. Warranty Period for Metal Corrosion: Five years from date of Substantial Completion. 3. Warranty Period for Color Retention: Five years from date of Substantial Completion. 4. Warranty Period for Lamps: Replace lamps and fuses that fail within 12 months from date of Substantial Completion; furnish replacement lamps and fuses that fail within the second 12 months from date of Substantial Completion. 5. Warranty Period for Poles: Repair or replace lighting poles and standards that fail in finish, materials, and workmanship within manufacturer's standard warranty period, but not less than 5 years from date of Substantial Completion. 2.00 PRODUCTS 2.01 MATERIALS A. LED DRIVERS AND LAMPS: Drivers and LED lamps shall be integral to the fixture. The fixture shall be rated for operating temperatures of -40°C to +60°C, UL wet location rated with frosted impact rated glass lens. Fixture shall be rated for maintained 70% lumen output at 60,000 hours. B. POLES AND SUPPORT COMPONENTS: 1. Luminaire Attachment Provisions: Comply with luminaire manufacturers' mounting requirements. Use stainless-steel fasteners and mounting bolts, unless otherwise indicated. 2. Mountings, Fasteners, and Appurtenances: Corrosion-resistant items compatible with support components. a. Materials: Shall not cause galvanic action at contact points. Lighting 26 50 00-3 DTN18104 – Lake Lewisville WTP Phase II Improvements b. Anchor Bolts, Leveling Nuts, Bolt Caps, and Washers: Hot-dip galvanized after fabrication, unless stainless-steel items are indicated. c. Anchor-Bolt Template: Plywood or steel. 3.00 EXECUTION 3.01 INSTALLATION A. Provide the lighting fixtures, as specified and scheduled on the plans. If a type designation is omitted, verify the fixture selection with the Engineer before installation. B. Check the architectural finishes and provide fixtures with proper trim, frames, support hangers and other hardware required to coordinate with the proper finishes, regardless of the specified or scheduled catalog number, prefixes and suffixes. C. Test and aim flood lights, when dark outside to provide a uniform and widespread, illuminated area. Direct units as indicated or instructed by the Engineer to prevent objectionable glare. D. Furnish and install a complete exterior lighting control system, as indicated on the plans. Provide materials and equipment to properly interface timing devices and photocells with relays and contactors so that a complete and satisfactory operating system is rendered. 3.02 CLEAN AND ADJUST Immediately before final inspection, clean all fixtures, inside and out, including plastics and glassware. Adjust all trim to properly fit adjacent surfaces. Replace broken or damaged parts. Lamp and test all fixtures for electrical, as well as, mechanical operation. 3.03 SPARE PARTS A. LED Driver: Furnish at least one of each type. B. Globes and Guards: Furnish at least one of each type. END OF SECTION Fiber Optic Data Network 27 15 23.01 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 27 15 23.01 FIBER OPTIC DATA NETWORK 1.00 GENERAL 1.01 SCOPE OF WORK A. Furnish labor, materials, equipment and incidentals necessary to install and test fiber optic cables and associated material as indicated in the plans and as specified herein. 1.02 SUBMITTALS Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: Submit for evaluation within one week of Notice to Proceed, the System Installer’s company(s) resumes complete with: 1. Company history, project lists, locations, Owner, costs, type of system installed, and references with phone numbers. 2. Resumes of the certified installation personnel who will actually conduct and supervise the installation, indicating the experience in the work specified under this Section. Shop Drawings: 1. Complete manufacturer’s product data: Product data shall be provided for the fiber optic cables, connectors, patch panels, spares and test equipment. a. Component catalog number and manufacturing data sheet, indicating pertinent data and clearly marked identifying each component by the item number and nomenclature as specified. b. Product data sheets shall include the manufacturer's name and catalog number for each item, the manufacturer's descriptive literature and catalog cuts, clearly marked to indicate the exact item submitted. c. The date of manufacture for each reel of cable shall be submitted. Cable manufactured 12 months or more prior to the date of this Contract will not be acceptable. d. Detailed component bill of material. 2. Component drawings showing dimensions, mounting, and external connection details. Interconnections to existing installed equipment and owner finished equipment shall be included in the drawings/diagram. 3. Certification of compliance in writing stating the fiber optic cable, anticipated layout, and components are compatible, acceptable for use and in compliance with these Specifications. 4. Complete layout and installation proposed which shows cable and conduit routing, materials, cable size and type, pulling lubricant being used, installation details, estimated maximum pulling tensions, overall system losses for each fiber, and any and all patch panel locations. 5. Training plan and schedule for fiber optic cable termination training. Fiber Optic Data Network 27 15 23.01 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 6. Installation Test reports as specified. 7. Provide four samples of each type of cable, and connector termination kit. Four samples of a completed example of each type of connector termination shall be submitted. 8. Manufacturer’s Instructions. Operation and maintenance manuals shall contain the approved shop drawings, submittals, spare part lists, schematics, final wiring diagrams with any changes made during start-up and maintenance procedures. 1. Submit Operation and Maintenance Manuals containing installation and maintenance instructions for splice and termination kits. 2. Letter of Compliance with manufacturer’s installation standards. 3. Operation and Maintenance Manuals: a. Operation and maintenance manuals shall have the following items included in addition to those items specified in other sections: 1). Description of all components 2). Methods of connection 3). Connection diagram 4). OTDR trace plots for all fibers b. Operation and maintenance manuals shall be prepared by the equipment manufacturer and shall contain the final certified approved shop drawings, submittals, list of manufacturer recommended spare parts and field test data. O&M manuals shall include all field changes made during startup and testing. c. Manuals may be manufacturer's standard instructions, but shall be supplemented as necessary to cover any special feature not included in standard material. d. Operation and maintenance manuals shall include warranty information as well as a warranty information page that shall include information on the warranty start and end date as well as contact information for service. The CONTRACTOR shall: 1. Prepare, and keep up-to-date, the Record Drawings and detailed construction drawings which shall be available at each monthly pay application. 2. Record the exact locations of each of these differences, sizes and details of the Construction Work as executed, with cross-references to and other requirements on the Record Drawings. 3. Keep the Record Drawings on the Work Site; 4. Upon completion of the Work, or at such other time as may be determined by the ENGINEER, submit the Record Drawings and copies to the OWNER’s Representative in accordance with the OWNER’s Requirements. Fiber Optic Data Network 27 15 23.01 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 5. Underground Interference drawing showing all underground ducts, ground rods, ground conductors, pipes, piers, vaults, manholes, pull boxes, etc. that clearly identifies the location and routing of these systems. All interferences shall be brought to the ENGINEER’s attention. Provide as a minimum the duct bank dimensions, burial depth and coordinates of terminations and those of any changes of direction. The dimensions of the duct bank shall be measured prior to back filling. 6. For pull boxes located along a pipeline include the location of all pull boxes using Station Number, and the exact Northing and Easting of each pull box using the North American Datum (NAD) 83 coordinate system. 7. Provide revised final shop drawings in AutoCAD format noting any changes made to equipment during start-up. Field Testing 1. After each network has been installed, a technical representative of System Supplier shall test the network and shall provide a written report for each test. 1.03 REFERENCE STANDARDS A. National Fire Protection Association (NFPA) 1. NFPA 70 - National Electrical Code (NEC) Article 770. B. Underwriters Laboratories, Inc. (UL) 1. UL 1581 VW 1 - Vertical Tray Cable Flame Test 2. UL 1666 - UL Standard for Safety Test for Flame-Propagation Height of Electrical and Optical-Fiber Cables Installed in Vertical Shafts. 3. UL 910 - UL Standard for Safety Test for Flame-Propagation and Smoke-Density Values for Electrical and Optical-Fiber Cables Used in Spaces Transporting Environmental Air. C. Institute of Electrical and Electronics Engineers (IEEE) 1. IEEE Standard 383 - Flame Retardant. D. Electronics Industry Association/Telecommunications Industry Association (EIA/TIA) 1. EIA-STD-RS-455 - Standard Test Procedures for Fiber Optic Fibers, Cables, Transducers, Connecting and Terminating Devices E. National Electrical Code Article 770, Optical Fiber Cable 1. NFPA 70 2005 F. Fiber Optic Test Method and Instrumentation 1. DOD-STD-1678 G. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply. Fiber Optic Data Network 27 15 23.01 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.04 QUALITY ASSURANCE A. The fiber optic cabling system materials furnished under this Section shall be provided by Fiber Optic suppliers who have been providing these types of material for the past three years. The Fiber Optic suppliers shall provide personnel capable of providing technical assistance and fiber testing during installation. B. The installation of fiber optic cabling system materials furnished under this Section shall be performed by the fiber manufacturers certified installation contractor who has been installing these types of materials for the past three years. C. All cabled optical fibers shall be 100% attenuated tested. The attenuation of each fiber shall be provided with each cable reel. D. The cable manufacturer shall be ISO 9001 registered. E. Cable with a manufacture date of greater than twelve months previous will not be acceptable. F. Quality Control Procedure: The manufacturer of the fiber-optic cable shall have a written quality control procedure which shall be made available to the Engineer/Owner upon request. G. All cable shall bear the approval of American National Standards Institute and The Fiber Distributed Data Interface. H. Comply with the requirements of the latest edition of the National Electrical Code, as modified by applicable local electrical codes. 1.05 DELIVERY, 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 shall be covered with a three (3) layer laminated protective material. The outer end of the cable shall be securely fastened to the reel head so as to prevent the cable from becoming loose in transit. The inner end of the cable shall project into a slot in the side of the reel or into the housing on the inner slot of the drum, in such a manner and with sufficient length to make it available for testing. C. Test tails shall be at least two meters long. The inner end shall be fastened so as to prevent the cable from becoming loose during shipping and installation. Reels shall be permanently marked with an identification number that can be used by the manufacturer to trace the manufacturing history of the cable and fiber. D. Reels shall be plainly marked to indicate the direction in which it shall be rolled to prevent loosening of the cable on the reel. E. The attenuation shall be measured at 1310 nm and 1550 nm for single-mode fibers and 850 nm and 1300 nm for multimode fibers. The manufacture shall ship the test results along with the fiber optic cable. Fiber Optic Data Network 27 15 23.01 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements F. 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 weather proof reel tag attached identifying the reel and cable. 5. Each cable shall be accompanied by a Cable Data Sheet. 1.06 WARRANTY A. The Contractor shall submit a warranty certificate from the equipment manufacturer. The manufacturer’s warranty period shall be concurrent with the Contractor’s for ten years, commencing at the time of final payment by the Owner. Any warranty work requiring shipping or transporting of the equipment shall be performed by the Manufacturer at no expense to the Owner. 1.07 CONNECTION TO OWNER NETWORKS A. Network hardware and software provided shall be compatible with the Owner’s existing network systems whenever a system interconnection is provided. System Supplier shall verify existing systems to ensure compatibility. B. All connections to the Owner’s existing network shall be fully coordinated between the Owner and the System Supplier. Prior to connecting to the existing network, the System Supplier shall provide a written request to the Owner for an Owner’s representative to be available when existing systems are disconnected and at the time of any new connections. 1.08 COORDINATION WITH OWNER A. The System Supplier shall coordinate all demolitions, installations, and rework on the existing networks with the Owner and the Engineer. No work shall be performed without the written consent of the Owner. The System Supplier shall submit a written request to perform work on the existing network, including date, time, scope of work, length of time, and any Owner’s support that may be required. 2.00 PRODUCTS 2.01 FULLY WATER BLOCKED FIBER OPTIC CABLE OUTSIDE PLANT TYPE A. Acceptable Manufacturers 1. Subject to compliance with the Contract Documents, the following manufacturers are acceptable: a. Corning b. OFS Technologies c. Approved equal Fiber Optic Data Network 27 15 23.01 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety. B. Cable 1. General: Refer to the drawings for the number of fibers that shall be provided for each fiber optic cable. a. Cables shall be of the Outside Plant Loose Tube, single and/or multimode types, as shown on the Drawings and specified herein for all outside locations meeting type OFN. For all inside building locations cable shall be plenum rated meeting type OFNP. Fiber optic cable that is indicated to be routed along power poles shall be suitable for aerial installation and corrugated. b. Each cable shall consist of individual 6 or 12 strand fiber groups, each fiber surrounded with water blocking compound, each individual 6 or 12 strand groups protected with a PBT jacket and cabled around a rigid epoxy fiberglass central member. The cable shall be wrapped with a water swellable tape, aramid yarn and a UV resistant polyethylene jacket. c. Cables shall furnished in reel lengths, each long enough to reach from connection point to connection point without splice, utilizing the manufacturer’s published maximum reel length capability for each type and size to be used on this Project. If any length capability is insufficient to provide without splice, the Shop Drawing submittal shall clearly describe the insufficiency, and explain the location required for such a splice. Such exception must be described in detail, and approved by the Owner/Engineer before the cable is ordered. Installation of such splices without such approval will require removal of such cable and replacement with another manufacturer’s cable meeting the requirements of the location, all at no expense to the Owner/Engineer. d. Cable shall be flame-retardant, UV stabilized, fully water blocked for use in indoor/outdoor applications. Cable shall be suitable for installation in duct environments. Cable shall meet UL OFNR specifications and not require transition splicing upon building entry in order to meet fire codes. 2. Optical fibers shall be placed inside a buffer tube. Each buffer tube shall contain up to 12 fibers. 3. Each fiber shall be distinguishable by means of color coding according to TIA/EIA-598-A, “Optical Fiber Color Coding.” 4. Buffer tubes containing fibers shall be color coded with distinct and recognizable colors according to TIA/EIA-598-A, “Optical Fiber Color Coding.” 5. In buffer tubes containing multiple fibers, the colors shall be stable across the specified storage and operating temperature range and not subject to fading or smearing onto each other or into the water blocking compound material. Colors shall not cause fibers to stick together. 6. Buffer tubes shall be kink resistant within the specified minimum bend radius. Fiber Optic Data Network 27 15 23.01 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements 7. Fillers may be included in the cable core to lend symmetry to the cable cross-Section where needed. 8. The central anti-buckling member shall consist of a glass reinforced plastic rod. The purpose of the central member is to prevent buckling of the cable. 9. The cable core shall contain a water-blocking material. The water blocking material shall be non-nutritive to fungus, electrically non-conductive and homogenous. It shall also be free from dirt and foreign matter and shall be readily removable with conventional nontoxic solvents. Cable shall contain water blocking threads between tubes. 10. The cable shall contain at least one ripcord under the sheath for easy sheath removal. 11. Tensile strength shall be provided by a combination of high tensile strength dielectric yarns. 12. The high tensile strength dielectric yarns shall be helically stranded evenly around the cable core. 13. The jacket or sheath shall be free of holes, splits and blisters. 14. The cable jacket shall contain no metal elements and shall be of a consistent thickness. 15. Cable jackets shall be marked with manufacturers’ name, sequential meter or foot markings, the year of manufacture, and a telecommunication handset symbol, as required by Section 350G of the National Electrical Safety Code (NESC). The actual length of the cable shall be within ±1 % of the length markings. The marking shall be in contrasting color with the cable jacket. The height of the marking shall be approximately 2.5 mm. 16. The maximum pulling tension shall be 2700 N (608 lbf) during installation (short term) and 600 N (135 lbf) long term installed. 17. The shipping, storage, and operating temperature range of the cable shall be -40C to +70C. The installation temperature range of the cable shall be -30C to +70C. 18. Fibers a. All fibers in the cable must be usable fibers and meeting the required specifications. b. Fibers shall conform to the following: 1). Cladding diameter: 125.0 ± 1.0 μm. 2). Core-to-Cladding offset: 0.8 μm. 3). Cladding non-circularity: 1.0 %., defined as: [ 1 - ( min. cladding dia. max. cladding dia. ) ] x 100 4). Coating diameter: 245 ± 10 μm. 5). Colored fiber diameter: nominal 250 μm. 6). Attenuation uniformity: No point discontinuity greater than 0.10 dB at either 1310 nm or 1550 nm. 7). Attenuation at the Water Peak: The attenuation at 1383 ± 3 nm shall not exceed 2.1 dB/km. 8). Cutoff wavelength: The cabled fiber cutoff wavelength (λccf) shall be < 1260 nm. Fiber Optic Data Network 27 15 23.01 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements 9). Mode-Field diameter: 9.30 ± 0.50 μm at 1310 nm10.50 ± 1.00 μm at 1550 nm. 10). Zero dispersion wavelengths (λ0): 1301.5 nm λ0 1321.5 nm. 11). Zero dispersion slope (S0): 0.092 ps/(nm2•km). 12). Fiber polarization mode dispersion (PMD): 0.5 ps/km. 13). The coating shall be a dual layered, mechanically strippable, UV-cured acrylate applied by the fiber manufacturer. 14). Required Fiber Grade - Maximum Individual Fiber Attenuation. 15). (Single-mode testing) The maximum dispersion shall be 3.2 ps/(nm•km) from 1285 nm to 1330 nm and shall be < 18 ps/(nm•km) at 1550 nm. 16). (Multi Mode Testing) The maximum dispersion shall be < 0.097 ps/(nm•km) from 1332 nm to 1354 nm. The maximum attenuation rates shall be 3 dB/kM or less at a wavelength of 850 nm and 1 dB/kM or less at a wavelength of 1300 nm. Bandwidth distance products shall be 220 MHz-kM at a wavelength of 850 nm and 500 MHz-kM at a wavelength of 1300 nm. 17). The fiber manufacturer shall proof-test 100% of the optical fiber to a minimum load of 100 kpsi. 18). Single Mode Mohawk Enhanced SM2: 9/125 Glass Type 19). Multimode Mohawk AdvanceLite OM1 Grade 3: 62.5/125MM Type 19. Aerial fiber optic cable shall have a flame-retardant, polyethylene cable material. Provide a cable outer jacket that is UV inhibited, fungus resistant and flame retardant. Cable to be CFR listed as 1755.900 and suitable for outdoor use in a self-supporting aerial installation. Provide cable unaffected by continuous or intermittent submergence in water. Cable shall be rated as outdoor self-supporting aerial cable. Follow manufacturer’s specifications for distance between supports on which it is mounted. Do not use cable with plastic fiber core construction. Aerial fiber cable shall be suitable for operation temperature of -40 degrees F to 158 degrees F. 2.02 PATCH CABLES, FIBER CONNECTORS A. Acceptable Manufacturers 1. Subject to compliance with the Contract Documents, the following manufacturers are acceptable: a. Corning Corp., Hickory, NC b. AMP, Inc., Harrisburg, PA c. A.P.D., Inc., Brooklyn, CT d. Or approved equal. 2. The listing of specific manufacturers above does not imply acceptance of their products that do not meet the specified ratings, features and functions. Manufacturers listed above are not relieved from meeting these specifications in their entirety. Fiber Optic Data Network 27 15 23.01 - 9 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Connectors: 1. Provide ceramic SC style connectors for all fiber optic fibers. The connectors shall be designed for use with 9/125 micron cable, and shall be capable of operating in a range of minus 40 to 75 degrees F. Each connector shall cause a maximum signal attenuation of 0.5 dB. Connector specifications shall be as follows: a. Insertion loss (typical): 0.5 dB b. Durability (mating cycles): 1000 (minimum) c. Repeatability: Less than 0.2 dB d. Operating Temperature: minus 40 to plus 75 degrees F C. Fiber Optic Patch Cables and Connectors 1. Fiber optic patch cable shall be 2 fiber zip cord 9/125 core/clad micron single mode riser rated cable. 2. Installation of patch cables shall include all spares and observe the minimum fiber bend radius and strain relief. 3. Provide ceramic ST style connectors for all fiber optic connections. The connectors shall be designed for use with 9/125 micron cable, and shall be capable of operating in a range of 0 to 80 degrees C. Each connector shall cause a maximum signal attenuation of 0.5 dB. Connectors shall be provided by Corning. All fiber optic cables shall be tested for performance and loss after termination and installation to verify that at least a 3 dB power safety margin is obtained between all transmitters and receivers. Test data for each fiber and safety margin calculations for each fiber path shall be provided to the Owner and Engineer after installation to verify conformance with this specification. 2.03 CABLE MARKING SYSTEMS A. A 7-mil, flame retardant, cold and weather-resistant vinyl plastic electrical tape shall be used for phase identification, 3M Corp.; Scotch 35 Tape or equal. B. Cable tags shall be heat stamped nylon secured by polypropylene cable ties, Thomas & Betts No. TC228-9 or equal. 2.04 PATCH PANELS AND ENCLOSURE SYSTEMS A. Patch panels shall be used for all cable termination points. All strands shall be terminated to a connecter on a CCH panel. B. Acceptable types are Corning LANscape series or equal. For terminations made in equipment enclosures the WIC type are preferred or as shown on the drawings. C. The cabinets shall meet the following requirements: a. The patch panel shall be the wall rack mounted type, having provisions for terminating multiple fiber optic cables. Splice trays, strain relief cable attachment points, fiber organizers and bend radius hardware shall be furnished with each termination cabinet. Fiber Optic Data Network 27 15 23.01 - 10 DTN18104 – Lake Lewisville WTP Phase II Improvements b. Panel size shall be suited to the number of fibers to be terminated within the cabinet. Bayonet/flanged couplings shall be furnished and mounted for each fiber to be terminated. c. Fiber terminations shall be spliced to pigtail cables having ST connectors. The pigtails shall be terminated in an orderly method. d. Patch panel shall be located in the RTU cabinet located at each site. 2.05 PULLING COMPOUNDS A. Pulling compound shall be nontoxic, nonflammable, noncombustible and non-corrosive. The material shall be UL listed and compatible with the cable insulation and jacket. B. Acceptable manufacturers are Ideal Company; Polywater, Inc.; Cable Grip Co. or equal. 2.06 FACTORY TESTING A. Perform manufacturers standard production testing and inspection in accordance with Section 6 of the referenced ICEA standards. If requested by the Owner/Engineer, the manufacturer shall submit certified proof of compliance with ICEA design and test standards. B. Provide certified test reports indicating that the cable has passed the following tests: 1. Partial Corona Discharge Test in accordance with ICEA S-97-682 Section 9.13. 2. Vertical tray flame test in accordance with IEEE 1202. C. After completion of the factory tests, individual pulling eyes shall be installed on individual lengths of cable. Pulling eyes shall be suitable for maximum allowable pulling tension on the cables and shall be sealed against entrance of water. A common pulling eye shall not be applied. 3.00 EXECUTION 3.01 GENERAL A. Determine the cutting lengths, reel arrangements and total lengths of cable required and shall furnish this data to the cable manufacturer as soon as possible to assure on-time delivery of cable. B. Splicing and terminating shall be performed by experienced workmen having formal training and a minimum of 3 years field experience in this type of fiber termination work. C. The Contractor shall provide a Certificate of Training issued within the last two years. D. General: Installation shall be per manufacturer's recommendation and the National Electrical Code, which defines the minimum requirements. Discrepancies between these requirements and those in the Drawings and Specifications shall be submitted to the ENGINEER for clarification or rectification. Fiber optic connectors shall match the fiber core and cladding diameters. The connector coupler shall be nickel plated, and the alignment ferrule shall be ceramic. The connector shall have a short boot for strain relief. Fiber optic equipment and cable shall have the same type connectors for correct mating. Connector insertion loss shall not exceed .75 dB. Connectors must be capable of mounting on either 0.9mm buffered fiber of 3.0mm cordage. Fiber Optic Data Network 27 15 23.01 - 11 DTN18104 – Lake Lewisville WTP Phase II Improvements E. Installation Company of fiber-optic cable shall be a qualified firm with previous experience of this kind of system. Installation Company shall submit qualifications to the Engineer. Fiber shall be terminated by a qualified installer, certified in the installation practices. Qualified installer shall have a minimum of 5 years’ experience making this kind of terminations. F. The System Supplier shall be responsible for the coordination of the installation of all cable furnished hereunder. The System Supplier shall be responsible for the termination of all cable furnished hereunder. 3.02 MANUFACTURER’S REPRESENTATIVE A. The Contractor shall provide the services of a cable manufacturers certified installation specialist to be present during the installation of all sections of the cable. The manufacturer shall provide a report to the Owner at the conclusion of the installation that the installation tools and termination materials were of types acceptable to the cable manufacturer, and to his knowledge, he observed no procedures that were contrary to the recommended installation procedures recommended by the Manufacturer. The report shall be signed by the manufactures specialist and the Contractor. 3.03 CABLE INSPECTION A. Perform the following inspections in the presence of the Owner/Engineer 1. Verify that fiber optic cable reels have been off-loaded from truck carefully and not damaged. 2. Submit to the Engineer all test data provided by the fiber manufacture. 3. Verify that the optical fibers of the cable assembly are the type and quantity as specified and as recommended by the Instrumentation System Supplier. 4. Verify that cable construction is the type specified. 3.04 INSTALLATION A. General: Installation shall be per manufacturer's recommendation and the National Electrical Code, and aerial conductors shall be installed per the National Electrical Safety Code, which each defines the minimum requirements. Discrepancies between these requirements and those in the Drawings and Specifications shall be submitted to the ENGINEER for clarification or rectification. Fiber optic connectors shall match the fiber core and cladding diameters. The connector coupler shall be nickel plated, and the alignment ferrule shall be ceramic. The connector shall have a short boot for strain relief. Fiber optic equipment and cable shall have the same type connectors for correct mating. Connector insertion loss shall not exceed .75 dB. Connectors must be capable of mounting on either 0.9mm buffered fiber of 3.0mm cordage. Fiber Optic Data Network 27 15 23.01 - 12 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Cable Damage: If the cable becomes damaged during installation, the contractor shall stop work and notify the engineer immediately. The Owner and Engineer will decide whether to replace the entire reel of cable or to install a splice at the damaged section. If the Owner decides to replace the entire reel of cable, the Contractor shall begin the installation at the last designated splice point. The damaged cable between these points shall be removed, coiled, tagged, and given to the Owner. Installation and cost of new cable to replace damaged cable shall not be a basis of extra payment or contract completion time. If the Owner decides to install a splice at the damaged point, and the cable is damaged a second time, the entire reel of damaged cable (and all subsequent damaged reels) shall be replaced with new reels at the Contractor’s expense. C. Cable Installation 1. All cable indoor and outdoor shall be installed in conduits. Cables shall not be direct buried. 2. When temperature is below 50 degrees F, cable reels shall be stored at 70 degrees F for at least 24 hours before installation. 3. Inspect raceway prior to pulling cables. Notify the Owner / Engineer of any conditions which would prevent installation of the specified cables, before proceeding with the installation. Rod and swab out ducts prior to installing cables. 4. Pull cables prior to attachment of connectors. 5. All cable installation shall be installed with tension-monitoring equipment, using a tension monitoring recorder. Where conductors are found to have been installed without tension– monitoring, the cables, including any existing or previously installed in the same raceway under this Contract, shall be immediately removed from the raceways, permanently identified as rejected material, and removed from the jobsite. New cables shall be reinstalled and tagged, all at no expense to the Owner. 6. Lubricate cables with lubricants specially formulated for fiber cabling jackets during installation. Do not exceed cable manufacturer’s specifications for tensile strength and bending radius. Pulleys used to aid in the installation of the fiber optic cable must be sized according to the minimum bending radius. The pulling tension of all fiber cables during installation shall be recorded using a strip recorder. The printout of the strip recorder shall be submitted to the Engineer. 7. Do not exceed manufacturer's recommendations for maximum pulling tensions and minimum bending radii. The Contractor shall furnish such information to the Owner/Engineer, and the information shall be available at the project site. 8. Pull cables by directly pulling only on the strength member. 9. Support cables in riser conduits at intervals as required by National Electric Code. 10. Minimum bend radius restrictions shall be satisfied both during and after cable installation. 11. Horizontal, unsupported cable runs shall be supported at continuous distances of 5 feet or less. 12. Within manholes, protect cable by providing flexible, corrugated, polyethylene slit duct. Connect slit duct to duct bank by using hose clamps. Support duct at ten foot intervals. Fiber Optic Data Network 27 15 23.01 - 13 DTN18104 – Lake Lewisville WTP Phase II Improvements 13. Feed cables into raceway with zero tension and without cable crossover at raceway entrance. 14. Any non-terminating (field) splices shall be documented as to the physical location and cable meter marker (prior to stripping). Field splices shall be OTDR-tested and documented prior to final cable acceptance testing. 15. Fiber optic cable shall be installed in accordance with NECA 301-2004, Installing and Testing Fiber Optic Cables. D. Cable Splicing 1. Do not make splices in cable unless approved by the Owner / Engineer. Splices shall be made in designated enclosures above ground only. Provide adequate put up lengths on cable reels to make termination to termination runs without splices. Where splices are unavoidable, subject to the approval of the Owner / Engineer, provide fusion splices with attenuation losses of 0.3 dB or less. Make splices watertight and provide mechanical protection equal to the cable jacket, or better. a. Fusion splices shall be allowed only when transitioning from one real of fiber optic cable to another. Fusion splicing shall be accomplished by the act of joining two optical fibers end-to-end using heat. The goal shall be to fuse the two fibers together in such a way that light passing through the fibers such that light is not scattered or reflected back by the splice. The splice and the region surrounding it shall be as strong as the virgin fiber itself. The use of optical fiber connectors or mechanical splices shall not be accepted. b. The following steps shall be a minimum necessary to splice optical fiber: 1). The coatings of the two fibers to be spliced together shall be stripped off. 2). The fibers shall be cleaned, coordinate cleaner or solvent to be used with the fiber optic cable manufacturer. 3). Each fiber shall be cleaved so that its endface is perfectly flat and perpendicular to the axis of the fiber. 4). The two endfaces of the fibers shall be aligned. 5). The two fibers shall be fused together using a fiber optic cable manufacturer approved method for fusing the fibers together. 6). The bare fiber area shall be protected either by recoating or with a splice protector. 7). Perform a proof-test to ensure that the splice is strong enough to survive handling and extended use. 2. The work area shall be kept warm, dry and ventilated during splicing and terminating of the cables. E. Cable Terminating 1. Installation tools and termination material shall be as approved by the cable manufacturer. Fiber Optic Data Network 27 15 23.01 - 14 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Install breakout kits, signal transceivers, power supplies, patch panels, pigtails and jumpers as required and as indicated to install a complete data highway communications network. Patch panels and splice enclosures shall be wall mounted. F. Marking and Identification 1. Plastic nameplates shall be installed in each manhole, pull box and at splice and terminating points. These nameplates shall show the phase and feeder designations and the date when the cable was installed or splice or termination was made. The feeder designation shall be as indicated on the Drawings. Nameplates shall be tied to each cable with self-locking nylon tie. 2. Tag each cable in junction boxes, manholes and hand holes. Provide permanent nylon/plastic tie wrap type tags with waterproof markings. 3. Label each cable, buffer tube and fiber with permanent waterproof typewritten tags. 3.05 PHYSICAL CHECKOUT A. General Procedures: 1. Conduct physical checkout of the fiber optic data highway network. 2. Physical checkout shall be performed prior to functional testing. B. Check Procedures: 1. Submit to the Engineer all test data provided by the fiber manufacture. 2. Verify that the optical fibers of the cable assembly are the type and quantity as specified and as recommended by the Instrumentation System Supplier. 3. Verify that cable construction is the type specified. 4. Verify that fiber optic patch panels have been installed plumb and level at locations indicated. 5. Verify that optical fiber connections or terminations within patch panels and splice closures are in accordance with cable manufacturer's recommendations. 6. Verify that fiber optic patch panels have been installed plumb and level at locations indicated. 7. Verify that optical fiber connections or terminations within patch panels and splice closures are in accordance with cable manufacturer's recommendations. 3.06 FIELD AND FUNCTIONAL TESTING A. All fiber-optic cable shall be tested per manufacturer's testing procedure, and be witnessed by the computer system integration Contractor and Owner's representative. B. Make the following site tests before removing cable from cable reels: 1. Determine attenuation losses of each fiber from end to end. Use an optical time domain reflectometer (OTDR) to capture and record. Provide a printout of the captured data. 2. Submit to the Engineer all test data and models of test equipment, calibration standards and tests. Fiber Optic Data Network 27 15 23.01 - 15 DTN18104 – Lake Lewisville WTP Phase II Improvements C. Make the following field tests after cable and connector installation: 1. All fiber optic cables shall be tested for performance and loss after cable installation and connector termination to certify that at least a 3dB power safety margin is obtained between all transmitters and receivers. Test data for each fiber and safety margin calculations for each fiber path shall be provided to the Owner and Engineer after installation to verify conformance with this specification. The following tests shall be performed as a minimum but not limited to: a. Visually, inspect terminal connectors for out of round condition and surface defects such as microchips and cracks using a 200X (minimum) inspection microscope. b. Check optical continuity of each fiber from terminal to terminal. Use test equipment as specified herein and provide typewritten report certifying each fiber in every cable. c. Verify the calculated attenuation power losses of each fiber from both transmit and receive terminals of each data communications loop (both directions). The light source and operating wavelength of the test equipment shall be representative of the actual operating equipment. Use an OTDR. d. Submit to the Engineer all test data and models of test equipment, calibration standard and tests. D. Test Equipment. Unless specified otherwise, all test equipment for the calibration and checking of system components shall be provided by System Supplier for the duration of the testing work and this test equipment and after the project is complete the testing equipment shall be turned over to the Owner. E. Owner / Engineer will observe the testing. Inform Owner/Engineer of testing schedule at least one week prior to start of testing. F. Equipment testing and inspection for all new cables shall be performed in accordance with the manufacturer’s recommendations on a generic form, and shall include the following: G. Fiber Optic cable Installation: 1. The cable manufacturer shall provide installation procedures and technical support concerning the items contained in this specification. Fiber Optic cable installation shall meet the following requirements: a. All fiber optic cable shall be installed, terminated, and tested by the System Supplier or his fiber subcontractor as specified above. b. In pulling the cable, strain-release, or other tension limiting devices shall be used to limit the pull tension to less than 600 lbs. c. Minimum bend radius restrictions shall be satisfied both during and after cable installation. d. Horizontal, unsupported cable runs shall be supported at continuous distances of 5 feet or less. e. All innerduct, conduit and cabinet entrances shall be sealed with RTV or other reenterable sealant material to prevent ingress of water, dust or other foreign materials. Fiber Optic Data Network 27 15 23.01 - 16 DTN18104 – Lake Lewisville WTP Phase II Improvements f. Any non-terminating (field) splices shall be documented as to the physical location and cable meter marker (prior to stripping). Field splices shall be OTDR-tested and documented prior to final cable acceptance testing. H. Fiber optic cable shall be installed in accordance with NECA 301-2004, Installing and Testing Fiber Optic Cables. 3.07 TRAINING A. Provide one-half day training for up to three students on termination techniques and testing prior to installation. B. Training shall be conducted by the Manufacturer of the cable Trained Termination Personnel. C. Provide training as soon as possible following submittal of proposed fiber optic cable. END OF SECTION Soils for Earthwork 31 05 13 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 05 13 SOILS FOR EARTHWORK 1.00 GENERAL 1.01 WORK INCLUDED A. This Section describes the various classes of Earth Fill. All classes of Earth Fill contained in this specification may not be used on this project. The classes of Earth Fill used on this project are shown on the drawings or specified in other sections of the specifications. This Section does not include specifications for placement and compaction of Earth Fill. Specifications for placement and compaction of Earth Fill are included in other Sections of the specifications and/or shown on the drawings. 1.02 STANDARDS A. Soil materials shall be classified into the appropriate class of Earth Fill shown below according to ASTM D2487 “Standard Classification of Soils for Engineering Purposes (Unified Soil Classification System)” or other appropriate methods as designated by the Engineer. 2.00 PRODUCTS 2.01 MATERIALS; CLASSIFICATIONS A. Class 1 Earth Fill: Limited to clays and sandy clays classified as CH material with a liquid limit greater than or equal to 50, a plasticity index greater than or equal to 25, and a minimum of 60 percent passing the No. 200 sieve, which are free of organic materials. B. Class 2 Earth Fill: Limited to clays and sandy clays classified as CH and CL materials with a coefficient of permeability less than or equal to 1.0 x 10-7 cm/sec, a liquid limit greater than or equal to 30, a plasticity index greater than or equal to 15, and more than 50 percent passing the No. 200 sieve, which are free of organic materials. C. Class 3 Earth Fill: Consist of any materials classified as CH, CL, SM, SP, SP-SM, SC, and GC, which have a minimum plasticity index of 4, which are free of organic materials. D. Class 4 Earth Fill: Consist of materials which are classified as SP, SM, SC, CL, or dual classifications thereof, which have a liquid limit less than or equal to 35 and a plasticity index of a minimum of 4 and a maximum of 15, which are free of organic materials. E. Class 5 Earth Fill: Consist of materials classified as SP or SP-SM which have a plasticity index less than or equal to 4 and a maximum of 12 percent passing the No. 200 sieve, which are free of organic materials. F. Class 12 Earth Fill: Consist of soils suitable for topsoil which are relatively free of stones or other objectionable debris, which have sufficient humus content to readily support vegetative growth. The suitability of soils for topsoil shall be subject to the approval of the Engineer. 3.00 EXECUTION (NOT APPLICABLE) END OF SECTION Aggregates for Earthwork 31 05 16 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 05 16 AGGREGATES FOR EARTHWORK 1.00 GENERAL 1.01 WORK INCLUDED A. This Section of the specifications describes the various classes of Aggregate Fill. All of the classes of Aggregate Fill contained in this specification may not be used on this project. The classes of Aggregate Fill used on this project are shown on the drawings or specified in other sections of the specifications. This Section does not include installation. Installation of Aggregate Fill is included in other sections of the specifications and/or on the drawings. 1.02 QUALITY ASSURANCE A. Classification Testing: 1. Contractor Testing: a. Arrange and pay for the services of an independent testing laboratory to sample and test proposed Aggregate Fill materials. b. Submit the test results to the Engineer, and obtain approval prior to providing Aggregate Fill. 2. Owner Testing: The Owner shall arrange and pay for additional testing on the Aggregate Fill after delivery to the project site as determined necessary by the Engineer. B. Contamination Certification: 1. Obtain a written, notarized certification from the Supplier of each proposed Aggregate Fill source stating that to the best of the Supplier’s knowledge and belief there has never been contamination of the source with hazardous or toxic materials. 2. Submit these certifications to the Engineer prior to proceeding to furnish Aggregate Fill to the site. The lack of such certification on a potential Aggregate Fill source shall be cause for rejection of that source. 1.03 STANDARDS A. Aggregate Fill shall be classified into the appropriate class listed below according to ASTM testing procedures as specified for the various classes. 1. American Society for Testing and Materials (ASTM) Standards: ASTM C33 Specification for Concrete Aggregates ASTM C88 Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium sulfate ASTM C125 Terminology Relating to Concrete and Concrete Aggregates ASTM C131 Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM C535 Test Method for Resistance to Degradation of Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM D448 Classification for Sizes of Aggregate for Road and Bridge Construction Aggregates for Earthwork 31 05 16 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2.00 PRODUCTS 2.01 MATERIALS; CLASSIFICATIONS A. Class 1 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable materials and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation in accordance with ASTM D448, size number 57: Sieve Size Square Opening Percent Passing 1-1/2” 100 1” 95-100 1/2” 25-60 No. 4 0-10 No. 8 0-5 B. Class 2 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable materials and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation in accordance with ASTM D448, size number 67: Sieve Size Square Opening Percent Passing 1” 100 3/4” 90-100 3/8” 20-55 No. 4 0-10 No. 8 0-5 C. Class 3 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable materials and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation in accordance with ASTM D448, size number 7: Sieve Size Square Opening Percent Passing 3/4” 100 Aggregates for Earthwork 31 05 16 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 1/2” 90-100 3/8” 40-70 No. 4 0-15 No. 8 0-5 D. Class 4 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable materials and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation in accordance with ASTM D448, size number 467: Sieve Size Square Opening Percent Passing 2” 100 1-1/2” 95-100 3/4” 35-70 3/8” 10-30 No. 4 0-5 E. Class 5 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable materials and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation in accordance with ASTM D448, size number 357: Sieve Size Square Opening Percent Passing 2-1/2” 100 2” 95-100 1” 35-70 1/2” 10-30 No. 4 0-5 F. Class 6 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable materials and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation in accordance with ASTM D448, size number 1: Aggregates for Earthwork 31 05 16 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 Sieve Size Square Opening Percent Passing 4” 100 3-1/2” 90-100 2-1/2” 25-60 1-1/2” 0-15 3/4” 0-5 G. Class 7 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable materials and shall have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation in accordance with ASTM D448, size number 6: Sieve Size Square Opening Percent Passing 1” 100 3/4” 90-100 1/2” 20-55 3/8” 0-15 No. 4 0-5 H. Class 8 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable materials and shall have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation in accordance with ASTM D448, size number 56: Sieve Size Square Opening Percent Passing 1-1/2” 100 1” 90-100 3/4” 40-85 1/2” 10-40 3/8” 0-15 No. 4 0-5 I. Class 9 Aggregate Fill: Aggregates for Earthwork 31 05 16 - 5 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 1. Consist of washed and screened gravel and natural sands or sands manufactured by crushing stones complying with the requirements of ASTM C33, except that the gradation shall be as follows: Sieve Size Square Opening Percent Passing 1/2” 100 3/8” 95-100 No. 4 80-95 No. 8 65-85 No. 16 50-75 No. 30 25-60 No. 50 10-30 No. 100 0-10 2. Class 9 Aggregate Fill shall have not more than 45 percent passing any sieve and retained on the next consecutive sieve of those shown above, and its fineness modulus, as defined in ASTM C125, shall be not less than 2.3 nor more than 3.1. J. Class 10 Aggregate Fill: 1. Consist of washed and screened natural sands or sands manufactured by crushing stones complying with the requirements and tests of ASTM C33. The gradation as included in ASTM C33 is as follows: Sieve Size Square Opening Percent Passing 3/8” 100 No. 4 95-100 No. 8 80-100 No. 16 50-85 No. 30 25-60 No. 50 10-30 No. 100 0-10 2. Class 10 Aggregate Fill shall have not more than 45 percent passing any sieve and retained on the next consecutive sieve of those shown above, and its fineness modulus, as defined in ASTM C125, shall be not less than 2.3 nor more than 3.1. K. Class 11 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable material and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation: Aggregates for Earthwork 31 05 16 - 6 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 Sieve Size Square Opening Percent Passing 1-3/4” 100 7/8” 65-90 3/8” 50-70 No. 4 35-55 No. 40 15-30 No. 100 0-12 (Wet Sieve Method) L. Class 12 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable material and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation: Sieve Size Square Opening Percent Passing 1-1/2” 100 1” 85-100 3/4” 60-95 3/8” 50-80 No. 4 40-65 No. 16 20-40 No. 100 0-12 (Wet Sieve Method) M. Class 13 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable material and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and shall meet the following gradation: Sieve Size Square Opening Percent Passing 1-3/4” 100 7/8” 65-90 3/8” 50-70 No. 4 35-55 No. 40 15-30 No. 100 0-3 (Wet Sieve Method) Aggregates for Earthwork 31 05 16 - 7 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 N. Class 14 Aggregate Fill: Consist of durable particles of crushed stone free of silt, clay, or other unsuitable material and have a percentage of wear of not more than 40 percent when tested in accordance with ASTM C131 or C535. When material is subjected to five cycles of the sodium sulfate soundness test in accordance with ASTM C88, Sodium Sulfate Solution, the weighted percentage of loss shall not exceed 12 percent. The source of the material shall be approved by the Engineer and meet the following gradation: Sieve Size Square Opening Percent Passing 1-1/2” 100 1” 85-100 3/4” 60-95 3/8” 50-80 No. 4 40-65 No. 16 20-40 No. 100 0-3 (Wet Sieve Method) O. Class 15 Aggregate Fill: Consist of durable particles of silica sand, washed clean, chemically inert, and packaged by the Supplier. The material shall meet applicable regulatory requirements for monitor well filter pack. The source of the material shall be approved by the Engineer and shall meet the following gradation requirements: Sieve Size Square Opening Percent Passing No. 20 98-100 No. 40 0-2 3.00 EXECUTION (NOT APPLICABLE) END OF SECTION Clearing and Grubbing 31 11 00 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 11 00 CLEARING AND GRUBBING 1.00 GENERAL 1.01 WORK INCLUDED A. Provide labor, materials, equipment and incidentals necessary to perform operations in connection with clearing, grubbing, and disposal of cleared and grubbed materials. 1.02 QUALITY ASSURANCE; DEFINITIONS A. Clearing: Clearing is defined as the removal of trees, shrubs, bushes, and other organic matter at or above original ground level. B. Grubbing: Grubbing is defined as the removal of stumps, roots, boards, logs, and other organic matter found at or below ground level. 2.00 PRODUCTS (NOT APPLICABLE) 3.00 EXECUTION 3.01 PREPARATION A. Mark areas to be cleared and grubbed prior to commencing clearing operations. The Owner’s Representative shall approve clearing and grubbing limits prior to commencement of clearing operations. B. Trees and shrubs outside of the clearing limits, which are within 10 feet of the clearing limits, shall be clearly marked to avoid damage during clearing and grubbing operations. C. Remove trees and brush outside the clearing limits, but within the immediate vicinity of the work, upon receipt of approval by the Owner’s Representative, when the trees or brush interfere with the progress of construction operations. D. Clearly mark trees and shrubs within the clearing limits, which are to remain, and protect the trees and shrubs from damage during the clearing and grubbing operations. E. The clearing limits shall not extend beyond the project limits. F. Establish the clearing limits as follows: 1. Embankments plus 10 feet beyond the toe of the embankment. 2. Excavations plus 5 feet beyond the top of the excavation. 3. Concrete structures plus 10 feet beyond the edge of the footing. 4. Roadways, runways, taxiways, and parking areas plus 5 feet beyond the edge of pavement or R.O.W. limits. 5. Retaining walls plus 10 feet beyond the edge of the footing. 6. Underground utility trench top width plus 8 feet. G. Establish the grubbing limits as follows: 1. Embankments plus 2 feet beyond the toe of the embankment. Clearing and Grubbing 31 11 00 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2. Concrete structures plus 2 feet beyond the edge of the footing. 3. Roadways, runways, taxiways, and parking areas plus 1 foot beyond the edge of pavement. 4. Retaining walls plus 2 feet beyond the edge of the footing. 3.02 INSTALLATION A. Clearing: Clearing shall consist of the felling, cutting up, and the satisfactory disposal of trees and other vegetation, together with the down timber, snags, brush, rubbish, fences, and debris occurring within the area to be cleared. B. Grubbing: 1. Grubbing shall consist of the removal and disposal of stumps and roots larger than 1 inch in diameter. 2. Extend grubbing to the depth indicated below: In the case of multiple construction items, the greater depth shall apply. a. Footings: 18 inches below the bottom of the footing. b. Walks: 12 inches below the bottom of the walk. c. Roads and Taxiways: 18 inches below the bottom of the subgrade. d. Parking Areas: 12 inches below the bottom of the subgrade. e. Embankments: 24 inches below existing ground. f. Concrete Structures: 18 inches below the bottom of the concrete. g. Retaining Walls: 18 inches below the bottom of the footing. 3.03 FIELD QUALITY CONTROL A. Completely remove timber, logs, roots, brush, rotten wood, and other refuse from the Owner’s property. Disposal of materials in streams shall not be permitted and no materials shall be piled in stream channels or in areas where it might be washed away by floods. Timber within the area to be cleared shall become the property of the Contractor, and the Contractor may cut, trim, hew, saw, or otherwise dress felled timber within the limits of the Owner’s property, provided timber and waste material is disposed of in a satisfactory manner. Materials shall be removed from the site daily, unless permission is granted by the Engineer to store the materials for longer periods. END OF SECTION Structural Excavation and Backfill 31 23 10 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 23 10 STRUCTURAL EXCAVATION AND BACKFILL 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to complete structural excavation, filling, backfilling, and compacting; to provide protection to equipment and cuts; to include backfill material; the construction or installation of cofferdams, and other similar facilities which may be necessary to perform excavations and/or backfilling; to include the necessary pumping, bailing, or associated drainage; to remove and dispose of surplus materials, cofferdams, and debris; and to provide final grading, as required. B. The work does not include excavation, filling, and backfilling for utility lines, manholes, vaults, valve boxes, and related structures. 1.02 QUALITY ASSURANCE; DEFINITIONS A. Cofferdams: Cofferdam designates any temporary or removable structure constructed to hold the surrounding earth and/or water out of the excavation, whether the structure is formed of soil, timber, steel, concrete, or a combination thereof. It shall be understood also to include the use of pumping wells or well points. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Submit qualifications of independent testing laboratory for approval. 2. Backfill material classifications. Provide certification by an approved independent testing laboratory. 3. Compaction test results. Provide compaction test results within 24 hours. 1.04 STANDARDS A. The following publications, referred to hereafter by basic designation only, form a part of this specification as if written herein in their entirety: 1. American Society for Testing and Materials (ASTM) Standards: ASTM D698 Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3)) ASTM D1556 Test Method for Density and Unit Weight of Soil in Place by the Sand- Cone Method ASTM D6938 Standard Test Methods for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth) ASTM D4253 Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table ASTM D4254 Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density Structural Excavation and Backfill 31 23 10 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 B. Any other testing required by these specifications and not specifically referenced to a standard shall be performed under ASTM or other appropriate standards as designated by the Engineer. C. References herein or on the drawings to soil classifications shall be understood to be according to ASTM D2487, “Standard Classification of Soils for Engineering Purposes (Unified Soil Classification System)” unless indicated otherwise. 1.05 DELIVERY AND STORAGE A. Deposit material to be used for backfill in storage piles at points convenient for handling of the material during the backfilling operations. 1.06 JOB CONDITIONS A. Review subsurface investigations. A limited subsurface investigation has been performed by Freese and Nichols, Inc. A geotechnical report from that investigation is available at the Engineer’s office. However, the precise profile of soil and rock strata beneath this site is not known. B. Review the site and determine the conditions which may affect the structural excavation, prior to the commencement of the excavation. 2.00 PRODUCTS 2.01 MATERIALS A. Structural Earth Backfill: Structural backfill shall be Class 4 Earth Fill as specified in Section 31 05 13 “Soils for Earthwork.” B. Lean Concrete Backfill: Lean concrete shall be in accordance with Section 03 30 00 “Cast-In- Place Concrete.” C. Topsoil: Topsoil shall be Class 12 Earth Fill as specified in Section 31 05 13 “Soils for Earthwork.” D. Fine-Graded Granular Material: Clean mixture of crushed stone, crushed gravel, and manufactured or natural sand; ASTM D448, Size 10, with 100 percent passing a 3/8-inch sieve, 10 to 30 percent passing a No. 100 sieve, and 5 to 15 percent passing No. 200 sieve; maximum plasticity index of 7; complying with deleterious substance limits of ASTM C33 for fine aggregates. 2.02 COMPACTION EQUIPMENT A. Compaction equipment shall conform to the following requirements and shall be utilized as specified herein. 1. Pneumatic Rollers: Pneumatic rollers shall have a minimum of four wheels equipped with pneumatic tires. The tires shall be such size and ply as can be maintained at tire pressures between 80 and 100 pounds per square inch for a 25,000-pound wheel load during roller operations. The roller wheels shall be located abreast and be designed so that each wheel will carry approximately equal load in traversing uneven ground. The spacing of the wheels shall be such that the distance between the nearest edges of Structural Excavation and Backfill 31 23 10 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 adjacent tires will not be greater than 50 percent of the tire width of a single tire at the operating pressure of a 25,000-pound wheel load. The roller shall be provided with a body suitable for ballast loading such that the load per wheel may be varied, from 18,000 to 25,000 pounds. The roller shall be towed at speeds not to exceed 10 miles per hour. The character and efficiency of this equipment shall be subject to the approval of the Engineer. 2. Vibratory Rollers: Vibratory rollers shall have a total static weight of not less than 20,000 pounds, with at least 90 percent of the weight transmitted to the ground through a single smooth drum when the roller is standing in a level position. The diameter of the drum shall be between 5 and 5-1/2 feet and the width between 6 and 9 feet. The unsprung weight of the drum, shaft, and internal mechanism shall not be less than 12,000 pounds. The frequency of vibration during operation shall be between 1100 and 1500 i.e., and dynamic force shall not be less than 40,000 pounds at 1400 i.e. No backing of the vibratory roller will be allowed on the embankment unless the vibrating mechanism is capable of being reversed. Self-propelled and towed vibratory rollers shall be operated at speeds not exceeding 3 miles per hour and 1-1/2 miles per hour, respectively. 3. Power Hand Tampers and Vibratory Plate Hand Compactors: Compaction of material in areas where it is impracticable to use a roller or tractor shall be performed with approved power hand tampers, vibratory plate hand compactors, or other approved equipment. Approval shall be based upon performance in a test section. 3.00 EXECUTION 3.01 PREPARATION A. Clear and grub the area to be excavated prior to the start of excavation in accordance with Section 31 11 00 “Clearing and Grubbing [Civil].” 3.02 EXCAVATION A. When footing concrete or masonry is to rest upon rock, remove the rock to a depth sufficient to expose sound rock. Level off or cut the rock to approximate grades, and roughen the area. When footing concrete or masonry is to rest on an excavated surface other than rock, take care not to disturb the bottom of the excavation, and do not make final removal of the foundation material to grade until just before the concrete is placed. Foundation material shall be protected, after exposure, with a concrete seal slab. B. For footings where the soil encountered at established footing grade is an unstable material, use the following procedure unless other methods are specified: Remove unstable soil. Carry the excavation at least 1 foot beyond the horizontal limits of the structure on all sides. Replace the unstable soil with compacted select fill. Place in uniform layers at a suitable depth for compaction. Wet each layer if necessary and compact by rolling or tamping to provide a stable foundation for the structure. C. When unfeasible to construct a stable footing as outlined above, construct footing by the use of special materials, such as flexible base, cement stabilized base, cement stabilized backfill, or other material, as directed by the Engineer. Structural Excavation and Backfill 31 23 10 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 D. Perform excavation to permit surfaces to be brought to final line and grade within plus or minus 0.1 foot. Restore over-break at the Contractor’s expense. In general, perform excavation in open-cut from the surface of the ground and at the line and grade indicated. E. The sides of the excavation, from the bottom of the excavation to the top of the ground shall be supported in accordance with OSHA requirements. Maintain the supports throughout construction. Remove supports after the completion of the work. 3.03 DEWATERING OF SITE A. Pumping or bailing from the interior of any foundation enclosure shall be done in a manner which precludes the possibility of movement of water through or alongside any concrete being placed. No pumping or bailing shall be permitted during the placing of structural concrete, or for a period of at least 24 hours thereafter, unless from a suitable sump separated from the concrete work by a water-tight wall. Pumping or bailing during placement of seal concrete shall be only to the extent necessary to maintain a static head of water within a cofferdam. Do not start pumping or bailing to de-water a sealed cofferdam until the seal has aged at least 36 hours. 3.04 PLACEMENT OF MATERIAL A. General: 1. Backfill excavated spaces and areas not occupied by the permanent structure, except that no backfill shall be placed against any structure until the concrete has reached its 28-day compressive strength or 7 days whichever is longer. Do not place backfill adjacent to support walls until the top slab has been in place at least 4 days. 2. Take care to prevent wedging action when placing backfill around structures. If backfill is to be placed on two or more sides of the structure or facility, simultaneously place the backfill on all sides to avoid uneven loading on the structure. 3. Do not permit rollers to operate within 3 feet of structures. 4. Maximum placement lifts measured in the loose condition are as follows: a. 8 inches when heavy compaction equipment is used. b. 4 inches when hand-directed compaction equipment is used. 5. Subgrade preparation for slab-on-grade: a. Provide a 3-inch layer of compacted Fine-Graded Granular Material. B. Moisture Control: 1. General: The materials in each layer of the fill shall uniformly contain the amount of moisture within the limits specified below necessary to obtain the maximum dry density for the soil. Compact On-sit Soils, Class 1 and Class 2 Earth Fill with a moisture content of at or within 5 percentage points wet of optimum moisture content. Compact Class 3, Class 4, and Class 5 Earth Fill with a moisture content within 2 percentage points dry to 5 percentage points wet of optimum moisture content. The moisture content ranges specified above for the various classes of earth fill represent maximum upper and lower limits of the particular range. Determination of the maximum dry density-optimum moisture shall be by one or more of the following ASTM procedures D 1556 or D 6938. Structural Excavation and Backfill 31 23 10 - 5 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 Completely cohesionless materials which are to be compacted to a specified relative density shall be at a moisture content which will allow use of the specified compaction equipment and consistent achievement of the specified density. 2. Moisture Control During Placement: After spreading the soil, adjust the moisture content of the soil if necessary by either aeration or the addition of water to bring the moisture content within the range specified. Uniformly distribute the moisture content throughout the layer of soil to be compacted. In order to accomplish this distribution, thoroughly mix the layer of soil by disking, harrowing, or by the use of a power-driven pulverizer. Should the surface of a previously compacted layer become dry due to exposure to the elements, appropriately wet surface of the compacted layer prior to placing the succeeding layer of soil, and properly disk or harrow the surface. Should a layer of soil be over wet, allow the layer to dry to a proper moisture content prior to compacting. Should the surface of a layer become smooth and hard, roughen the surface by scarifying, and wet the surface if necessary prior to placing the next layer of soil. Reprocess any layer which becomes damaged by weather conditions to meet the specification requirements. There shall be no additional payment made for such reprocessing. C. Compaction: 1. Compaction shall be by power hand equipment or rubber tired equipment, provided the rubber tired equipment does no damage. Compaction by power hand equipment or rubber tired equipment shall be completed such that there will be a 24-inch overlap by roller compaction. 2. Compact the Class 1 and Class 2 Earth Fill zones by a minimum of eight passes with a tamping roller. Compact the Class 3, Class 4, and Class 5 Earth Fill zones by a minimum of eight passes with a tamping roller or by a minimum of four passes with a tamping roller, followed by a minimum of four passes with a pneumatic roller. A vibratory roller shall be required if the material is sandy and if requested by the Engineer. A pass shall consist of one trip over the area being compacted. The front and rear axle rollers on self-propelled models shall only be considered as one pass per trip. The initial and final area to be rolled shall each have eight passes. Stagger passes between the initial and final area in order to establish overlapping with at least eight passes at all locations. Approve the exact method based upon the test section. Dumping, spreading, sprinkling, and compacting may be performed at the same time at different points along a section where there is sufficient area to permit these operations to proceed simultaneously. 3. Areas of the fill being compacted with power hand tampers or vibratory plate hand compactors shall receive a minimum of eight passes of the equipment with an overlap of 50 percent of the equipment base plate width. 4. The in-place density of On-Site Soils and Class 1 through Class 5 Earth Fill shall not be less than 95 percent of maximum dry density as determined by ASTM D698, Standard Proctor, except compact the top 12 inches of fill underneath roadways and parking areas to not less than 100 percent of maximum dry density as determined by ASTM D698, Standard Proctor. In areas cut underneath roadways and parking areas scarify and re-compact the top 8 inches of the subgrade within the specified moisture content, to not less than 100 percent of maximum dry density as determined by ASTM D698, Standard Proctor. Structural Excavation and Backfill 31 23 10 - 6 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 5. Compact cohesionless materials, on which it is not practical to control the density by proctor methods, to a minimum of 95 percent of the maximum density as determined by ASTM D4253. At the discretion of the Engineer, an alternate method of determining the maximum density may be used which has been correlated with methods ASTM D4253 and ASTM D4254. 6. If necessary, to achieve the specified density, increase the number of passes of the compaction equipment, and/or modify the weight of the compaction equipment. 7. Regardless of the density achieved, the number of passes of the compaction equipment shall not be less than eight. 3.05 FIELD QUALITY CONTROL A. The Owner is responsible for the costs involved in providing an Owner approved testing laboratory to perform quality control testing of backfill operations. The testing laboratory shall make tests of in-place density in accordance with ASTM Standards. The testing laboratory shall monitor backfill operation continuously or at intervals acceptable to the Owner and Engineer at structures. It shall be the responsibility of the Contractor to notify the testing laboratory before backfill operations begin. 1. Unless noted otherwise, in-place density tests shall be conducted at a rate of one test per 3000 square feet for every lift. END OF SECTION Flowable Fill 31 23 23.34 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 23 23.34 FLOWABLE FILL 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment, and incidentals necessary to mix and place flowable fill, consisting of Portland cement, fine aggregate, fly ash, and water in the proper proportions as specified hereinafter. Flowable fill (Controlled Low-Strength Material, CLSM) shall be used to bed and backfill around piping, utilities, and structures where indicated. 1.02 QUALITY ASSURANCE A. Design Criteria – Flowable Fill Proportions and Consistency: Flowable fill shall be proportioned to give the necessary workability, strength, and consistency, and shall conform to the following governing requirements: 1. Permeability: Maximum permeability limit of 1x10-6 cm/sec. This limit shall apply at all locations where flowable fill is used as a utility trench plug (dam) within trench backfill materials. 1. Subsidence: Evaporation of bleed water shall not result in shrinkage of more than 10.4 mm per m (1/8 inch per ft.) of flowable fill depth. Measurement of a Final Bleeding shall be as measured in Section 10 of ASTM C940. 2. Strength for Excavatable Flowable Fill: Unconfined compressive strength at 28-days when tested in accordance with ASTM D4832: 100 psi (+/- 50 psi). a. The 1-year strength shall not exceed 150 psi. b. Where indicated provide Excavatable Flowable Fill around utilities, unless noted otherwise. c. Excavatable Flowable Fill shall be excavatable with hand tools and conventional machinery such as backhoes. 3. Strength for Non-Excavatable Flowable Fill: Unconfined compressive strength at 28- days when tested in accordance with ASTM D4832: 150 psi minimum. a. Where indicated provide Non-Excavatable Flowable Fill below structures and/or around structures, unless noted otherwise. 4. Fluidity: Flowable fill shall be self-consolidating and non-segregating in accordance with ASTM C1611: a. Slump Flow Test: Minimum 20-inch mean spread. b. Visual Stability Index (VSI) Test: Less than or equal to 1. B. Factory Testing: The Contractor shall be responsible for the design of the material. A trial mix shall be designed by an independent testing laboratory, retained by the Contractor. The testing laboratory shall submit verification that the materials and proportions of the trial mix design meets the requirement of the Specifications. In lieu of trial mix design, Contractor may submit historical data for a mix design used successfully in previous similar work. The Contractor shall not make changes in materials, either in gradation, source, or Flowable Fill 31 23 23.34 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 brand, or proportions of the mixture after having been approved, except by specific approval of the Engineer. C. Owner Testing: It is the responsibility of the Contractor to achieve and maintain the quality of material required by this Section. However, the Owner may secure the services of an independent testing laboratory to verify the quality of the flowable fill. The Owner shall have the right to require additional testing, strengthening, or replacement of flowable fill which has failed to meet the minimum requirements of this Section. 1.03 SUBMITTALS A. Submit mix design on each material required. Provide backup data as required below. B. Submit historical or trial mix data and test results as a basis for mix design approval. Required data shall include: 1. Permeability test results if plugs are required on Project. 2. Subsidence test results. 3. Strength test results for Excavatable and Non-Excavatable Flowable Fill if used on Project. 4. Fluidity test results. 1.04 STANDARDS AND REFERENCES A. Materials shall meet recommendation for mix design and placement, as published by National Ready Mixed Concrete Association. B. The applicable provisions of the following references and standards shall apply to this Section as if written herein in their entirety. 1. American Society for Testing and Materials (ASTM) Standards: ASTM C33 Specification for Concrete Aggregates ASTM C40 Test Method for Organic Impurities in Fine Aggregates for Concrete ASTM C150 Specification for Portland Cement ASTM C618 Specification for Fly Ash and Raw or Calcined Natural Pozzolan for Use as Mineral Admixture in Portland Cement Concrete ASTM C 940 Standard Test Method for Expansion and Bleeding of Freshly Mixed Grouts for Preplaced-Aggregate Concrete in the Laboratory ASTM C 1611 Standard Test Method for Slump flow of Self Consolidating Concrete ASTM D 4832 Standard Test Method for Preparation and Testing of Controlled Low Strength Material (CLSM) Test Cylinders 2.00 PRODUCTS 2.01 MATERIALS A. Cement: Portland cement conforming to the specifications and test for Type I or I/II Portland cement of the American Society for Testing and Materials, Designation C-150. Flowable Fill 31 23 23.34 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 B. Fine Aggregate: Fine aggregate consisting of natural, washed and screened sand having clean, hard, strong, durable, uncoated grains complying with the requirements for ASTM C33. The sand shall generally be of such size that all will pass a 3/8-inch sieve, at least 95 percent pass a 1/4-inch screen and at least 80 percent pass a No. 8 sieve. Aggregate shall not contain strong alkali, or organic material which gives a color darker than the standard color when tested in accordance with ASTM Specification Designation C40. C. Fly Ash/Pozzolans: Fly ash shall be an ASTM C618, Class “C” fly ash. The fly ash may be used in controlled low-strength material. D. Water: Water for flowable fill shall be clean and free from oil, acid, alkali, organic matter or other harmful impurities. Water which is suitable for drinking or for ordinary household use will be acceptable for concrete. Where available, water shall be obtained from mains of a waterworks system. E. Performance Additive: As required to meet specification requirements: 1. “Darafill” by Grace Construction Products. 2. Rheocell Rheofill by BASF The Chemical Company. 3. Sika Lightcrete Powder by Sika Corporation. 4. Approved equal. F. Chemical Admixtures for Concrete per ASTM C 494, as required by performance requirements. 2.02 MIXES A. In the determination of the amount of water required for mix, consideration shall be given to the moisture content of the aggregate. The net amount of water in the mix will be the amount added at the mixer; plus the free water in the aggregate; and minus the absorption of the aggregate, based on a 30 minute absorption period. No water allowance shall be made for evaporation after batching. B. The methods of measurement of materials shall be such that the proportions of water to cement can be closely controlled during the progress of the Work and easily checked at any time by the Owner’s representative. To avoid unnecessary or haphazard changes in consistency, the aggregate shall be obtained from sources which will insure a uniform quality and grading during any single day’s operation and they shall be delivered to the Work and handled in such a manner that the variation in moisture content will not interfere with the steady production of flowable fill of reasonable degree of uniformity. Sources of supply shall be approved by the Owner’s representative. C. All material shall be separately and accurately measured. Measurement may be made by weight or by volume, as determined by the Contractor; however; all equipment for measurement of materials shall be subject to approval by the Owner’s representative. Flowable Fill 31 23 23.34 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 3.00 EXECUTION 3.01 INSTALLATION A. Contractor shall give the Owner’s representative sufficient advance notice before starting to place material in any area, to permit inspection of the area, and preparation for pouring. B. Conduct the operation of depositing the material so as to form a compact, dense, impervious mass, and so as not to develop air pockets in confined spaces. C. Unless specified otherwise, flowable fill shall be uniformly placed to the depth shown on the Drawings. The fill shall be brought up uniformly to the top of excavation elevation. Placement of flowable fill shall then cease and the fill protected from traffic for a period of 72 hours. 1. To prevent pipe flotation place material in lifts or provide alternate means. 2. Around structures, material shall be placed in lifts. Lift depth shall not exceed one-tenth of total structure embedment into subgrade nor 5 feet, whichever is less. 3. When multiple lifts are required, material shall be allowed to harden before placing next lift. Hardening time varies with each mix. Verify flowable fill has reached a penetration number of 1500, in accordance with ASTM C 403, but not less than 5 hours. D. The material shall be placed against undisturbed trench walls, and shall not be placed on or against frozen ground. E. At time of placement the ambient temperature shall be 35 F and rising. 3.02 FIELD QUALITY CONTROL A. An Owner approved testing laboratory shall perform the quality control testing of backfill operations. The testing laboratory shall sample material in accordance with ASTM D5971. The testing laboratory shall monitor backfill operation continuously or at intervals acceptable to the Owner and Engineer at structures. It shall be the responsibility of the Contractor to provide sufficient advance notification to the testing laboratory before backfill operations begin. 1. Strength: A strength test is the average of two cylinders per ASTM D4832. 2. Fluidity: A fluidity test is a Slump Flow Test and a VSI Test per ASTM C1611. 3. For all tests required, at a minimum perform one test per day, but not less than one per 150 cubic yards. END OF SECTION Trench Safety 31 23 33.14 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 23 33.14 TRENCH SAFETY 1.00 GENERAL 1.01 WORK INCLUDED A. This specification consists of the basic requirements which the Contractor must comply with in order to provide for the safety and health of workers in a trench. This specification is for the purpose of providing minimum performance specifications, and the Contractor shall develop, design, and implement the trench safety system. The Contractor shall bear the sole responsibility for the adequacy of the trench safety system and providing “a safe place to work” for the workman. B. Should the trench safety protection system require wider trenches than specified elsewhere, the Contractor shall be responsible for the costs associated with determining adequacy of pipe bedding and class, as well as, purchase and installation of alternate materials. 1.02 STANDARDS A. The following standard shall be the minimum governing requirement of this specification and is hereby made a part of this specification as if written in its entirety. 1. Occupational Safety and Health Standards - Excavations (29CFR Part 1926), U.S. Department of Labor, latest edition. B. Comply with the applicable Federal, State, and local rules, regulations, and ordinances. 2.00 PRODUCTS (NOT APPLICABLE) 3.00 EXECUTION (NOT APPLICABLE) END OF SECTION Trenching and Backfill 31 23 33.19 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 23 33.19 TRENCHING AND BACKFILL 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to perform operations in clearing, grubbing and Site preparation; trenching, pipe bedding, and backfilling; handling, storage, transportation and disposal of excavated material; pumping and dewatering; preparation of subgrades; protection of adjacent facilities and property; and other appurtenant work. B. Trenching, backfilling, and pipe embedment procedures shall be in full compliance with Section 31 23 33.14 “Trench Safety.” C. Earth removed from excavations and that is not required for backfill, shall be removed from the Site by the Contractor at his own expense, unless arrangements are made with the Owner through his representative to allow disposal on -Site. If permitted, the Contractor shall dump and spread excess earth in a manner agreed upon by the Contractor and Owner. D. General and structural excavation and backfill shall be as specified in other sections. 1.02 QUALITY ASSURANCE; CLASSIFICATION A. Excavations shall include material of whatever nature encountered, including but not limited to clays, sands, gravels, conglomeritic boulders, weathered clay shales, rock, debris and abandoned existing structures. Excavation and trenching shall include the removal and subsequent handling of materials excavated or otherwise handled in the performance of the Work. B. Bidders must satisfy themselves as to the actual existing subsurface conditions prior to the submittal of a proposal to complete the proposed Work. No extra or separate payments shall be made for rock, dewatering, or any other condition. C. Trench excavation shall consist of excavation to the lines and grades indicated, required for installation of the pipe, pipe bedding, backfill, and to accommodate trench safety systems. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Certified test reports for embedment material, backfill material, coarse gravel, and flexbase. Certified Test Reports shall be from an independent laboratory. Test reports shall include sieve analysis, and Atterburg limits, and other tests as required to demonstrate compliance with Paragraph 2.01. 2. Test results indicating soil resistivity for embedment material used on metal pipe. 3. Field density test reports indicating that the Contractor’s method of backfill meets the requirements of the Contract Documents. The field density testing for granular embedment shall be done in a manner approved by the Owner/Engineer by an independent testing lab in accordance with ASTM D4253. The cost of the field testing Trenching and Backfill 31 23 33.19 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 shall be included in the Bid Price for the Work, with no additional compensation to the Contractor. 1.04 STANDARDS A. The following publications, referred to hereafter by basic designation only, form a part of this specification to the extent indicated by the references thereto: 1. American Society for Testing and Materials (ASTM) Standards: ASTM C33 Standard Specification for Concrete Aggregates ASTM D698 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12 400 ft-lbf/ft3 (600 kN-m/m3 ASTM D1556 Test Method for Density and Unit Weight of Soil in Place by the Sand-Cone Method ASTM D2487 Standard Practice for Classification of Soils for Engineering Purposes (Unified Soil Classification System ASTM D6938 Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth) ASTM D3017 Test Method for Water Content of Soil and Rock in Place by Nuclear Methods (Shallow Depth) ASTM D4253 Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table ASTM D4254 Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density ASTM G57 Test Method for Field Measurement of Soil Resistivity Using the Wenner Four-Electrode Method 2. American Water Works Association (AWWA) Standards: AWWA C151 Ductile Iron Pipe AWWA C200 Steel Water Pipe 6 Inches and Larger AWWA C301 Prestressed Concrete Pressure Pipe - Steel Cylinder Type for Water and Other Liquids AWWA C303 Concrete Pressure Pipe – Steel Cylinder Type for Water and other Liquids 3. Texas Department of Transportation Standard Specifications for Road and Bridge Construction, latest edition. B. Any other testing required by these Specifications and not specifically referenced to a standard shall be performed under ASTM or other appropriate standards as designated by the Engineer. C. Reference herein or on the Drawings to soil classifications shall be understood to be according to ASTM D2487, Classification of Soils for Engineering Purposes (Unified Soil Classification System). Trenching and Backfill 31 23 33.19 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 1.05 DELIVERY AND STORAGE A. Excavated and delivered materials to be used for backfill may be deposited in stockpiles at points convenient for rehandling the material during the backfilling process. If not indicated on the Drawings, the location of stockpiles shall be within the limits of construction easements or public right-of-way. The location of stockpiles is subject to the approval of the Owner or the Owner’s representative. Do not place stockpiles over buried pipelines or utilities unless adequate provisions are made for protection. Roads and driveways must be kept open unless written authorization is granted by Owner. Keep drainage channels clear of stockpiled materials or make other satisfactory provisions for drainage. 1.06 JOB CONDITIONS A. Classification of Excavation: Excavation shall be “unclassified” and involves the removing of the necessary materials to provide the trench/excavation to the required width and depth. The Contractor, prior to submitting a proposal, must satisfy himself as to the actual sub- surface conditions. No extra or separate payments shall be made for rock, dewatering or any other condition. B. City, County, and Private Road Crossings: Where the Work is in the right-of-way of City, County and privately owned roads, the Contractor shall secure Street Cut Permits and all other required permits. Work to be performed within the limits of the public right of way shall be in full accordance with the requirements of the easements and permits and as requested by the City, County, or private owner. Provide temporary access and detours for roads and driveways cut off during pipe laying operations. C. Protection of Existing Structures and Utilities: 1. Prior to the start of construction, communicate with the local representatives of utilities companies, including but not limited to oil, gas, telephone, and communications companies, as well as, local water and sewer utilities operating in the location of the proposed construction area. Obtain the utility companies’ assistance in locating existing facilities to avoid conflicts during construction. The location, number, depth, and owner of utilities indicated are for information purposes only, and all utilities and structures may not be shown or may not be in the location shown. The Contractor is responsible for verifying the actual locations and quantities of utilities and for protecting them during construction. 2. Where construction endangers adjacent structures, utilities, embankments and/or roadways, the Contractor shall carefully support and protect such facilities so that no damage occurs throughout the construction process. The cost of such protection shall be included in the Bid, and will not entitle Contractor to additional compensation. In case damage should occur, the Contractor shall be responsible for restoring the damaged item to a condition acceptable to the owner of that item and shall bear all cost of such reparations. 3. Repair or replace damaged street surfaces, driveways, sidewalks, curbs, gutters, fences, drainage structures, or other such facilities to the satisfaction of the Owner. Facilities shall be returned to a condition equal to or better than the original condition and of same or better material and quality. Trenching and Backfill 31 23 33.19 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 4. Relocate minor utilities as necessary, at no additional cost to the Owner, in order to resolve conflicts with new Work. Minor utilities shall be defined as conduit less than or equal to 2-inch diameter and pressure piping less than or equal to 6-inch diameter. All proposed relocations shall be submitted in writing and approved by Owner or Owner’s representative prior to accomplishing the Work. D. Freezing Weather Condition: Place no embedment or backfill material during freezing weather or upon frozen subgrades. Place no frozen embedment or backfill materials. 2.00 PRODUCTS 2.01 MATERIALS A. Concrete Embedment, Cap, Blocking, and Encasement: Where concrete embedment, cap, blocking, or encasement is indicated or requested by the Engineer, it shall be Class E as specified in Section 03 30 00 “Cast-In-Place Concrete” unless otherwise indicated. B. Granular Embedment and Backfill: Granular embedment material shall be as specified in Section 31 05 16 “Aggregates for Earthwork.” C. Coarse Gravel: Where coarse gravel is required for water drainage, restoration of trench foundation, or other uses, it shall be crushed stone or gravel and in compliance with ASTM C33 for Coarse Concrete Aggregate. Gradation shall be ASTM C33 No. 57, No. 67, No. 357, or as follows: Sieve Size Square Opening Percent Passing 1” 95-100 3/4” 55-85 1/2” 25-50 No. 4 0-5 D. Earth Fill Material: Earth fill materials shall be as specified in Section 31 05 13 “Soils for Earthwork.” E. Flexible Base Course: Complying with Item 247 of the Texas Department of Transportation Standard Specifications for Road and Bridge Construction, latest edition, Type A, Grade 1 or 2, Flexible Base (Crushed Stone). F. Hot Mix Asphalt Concrete (HMAC): Complying with Item 340 of the Texas Department of Transportation Standard Specifications for Road and Bridge Construction, latest edition. G. Controlled Low-Strength Material (Flowable Fill): Controlled low-strength material (flowable fill) shall be provided in accordance with Section 31 23 23.33 “Flowable Fill.” H. Modified Flowable Fill: Modified flowable backfill in areas of possible future excavation shall consist of a mixture of native soils or manufactured materials, cement and/or fly ash, air entraining material and water which produces a material with unconfined compressive strength of between 250 and 450 psi after 28 days. Any materials used shall be primarily granular, with a plasticity index less than 12 and with 100 percent passing a 3/4-inch sieve. The flowable mixture shall be mixed in a pub mill, concrete mixer, or transit mixer and shall have a minimum slump of 5 inches. The flowable mixture must be allowed to set prior to Trenching and Backfill 31 23 33.19 - 5 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 the placement of any overlying materials. Modified flowable backfill in permanent areas such as abandoned pipe closures shall contain the same materials and have an unconfined compressive strength greater than 250 psi after 28 days. I. Embedment Geotextile Material: Embedment geotextile material shall be Mirafi 180N polypropylene or approved equal. J. The mixers used for mixing the soil cement backfill shall be designed and operated so that the soil cement discharged from the mixer is uniform in composition and consistency throughout each batch. 2.02 MIXES; SAND-CEMENT BACKFILL A. A minimum sand and cement mixture of 27 parts sand and 2 parts cement will be required. Fine Sand 1 Cubic Yard Cement 1 Bag (Minimum) Water Optimum Moisture B. Sand shall be free of any cohesive material and shall meet the following gradation and plasticity index requirements: Sieve Size Percent Passing 1” 100 1/2” 95-100 No. 40 80-100 C. PI and LL amounts. Plasticity Index 10 Maximum Liquid Limit 25 or less 3.00 EXECUTION 3.01 PREPARATION A. Site: 1. Clear Site of logs, trees, roots, brush, tree trimmings and other objectionable materials and debris which are to be occupied by pipe trenches, and grub stumps. Designate material not salvaged for reuse as spoil and dispose of material in accordance with Paragraph 3.01.D. 2. Do not remove trees outside of the required working area unless their removal is authorized in writing by the Engineer and with the approval of the local governing authority. Adequately protect the trees left standing from permanent damage by construction operations. Standing trees may be trimmed where necessary to facilitate construction, but only with written authorization from the Engineer. B. Dewatering: Trenching and Backfill 31 23 33.19 - 6 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 1. Provide and maintain adequate dewatering equipment to remove and dispose of surface and ground water entering the excavations, trenches, or other parts of the Work. Keep each excavation dry during subgrade preparation and continually thereafter until the proposed pipe is installed. Maintain the proper procedures necessary to protect against damage to the proposed Work from hydrostatic pressure, flotation, or other water related causes. 2. Dewater excavations which extend down to or below ground water elevation by lowering and keeping the ground water level a minimum of 2 feet below the bottom of the excavation. 3. Divert surface water or otherwise prevent water from entering excavated areas to the extent possible without causing damage to adjacent property. 4. Provide and maintain any piping or conduit necessary to facilitate drainage. Do not alter area drainage patterns to the extent that adjacent property and landowners become threatened with localized flooding and/or water damage. Should such a situation occur, the Contractor shall be responsible for repairing the damage at no additional cost to the Owner. C. Blasting: Blasting shall not be allowed in any instance. D. Disposal of Spoil Material: 1. Suitable material from excavations which meets the requirements for pipe backfill material as indicated, except stripping excavation, may be reused. Designate the remaining excavated materials as spoil material and dispose of material off the Site in accordance with all applicable laws, ordinances, and codes. Contractor shall be responsible for the storage, transportation, and deposition of spoil material and shall be responsible for acquiring the necessary permits, and the payment of fees and duties at no additional cost to the Owner. 2. No burning of materials shall be permitted on the Site. 3.02 TRENCH EXCAVATION A. General: The trenches shall be excavated to the alignment and depth indicated or as necessary for the proper installation of the pipe and appurtenances. Brace and dewater the trench if necessary so that the workmen may work therein safely and efficiently. Any specific requirement listed in Part 3.00, Execution, may be modified as necessary to meet OSHA requirements. However, if trench widths are wider than indicated, the Contractor shall be responsible for determining and furnishing the proper class of embedment and piping and for providing the modified installation with no additional compensation to the Contractor. B. Trench Width: The trench widths shall be as shown on the Drawings. C. Pipe Foundation: 1. Excavate the trench to the line and grade indicated and as directed by the Engineer. Grades shall be uniform between high points and low points to eliminate intermediate “highs and lows”. Trenching and Backfill 31 23 33.19 - 7 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2. For 12-inch diameter and smaller pipe, the trench shall be “rough cut” a minimum of 4 inches below the bottom of the pipe. For 14-inch and larger pipe, the trench shall be “rough cut” a minimum of 8 inches below the bottom of the pipe. The “rough cut” dimension shall be increased as necessary to provide a minimum clearance of 2 inches from the bottom of the trench to the bottom of the bells, flanges, valves, fittings, etc. 3. The entire foundation area in the bottom of all excavations shall be firm, stable material. Loose material shall be removed, leaving a clean, flat trench bottom, and material shall not be disturbed below required sub grade except as hereinafter described. If the subgrade is soft, spongy, disintegrated, or the character of the foundation materials is such that a proper foundation cannot be obtained at the elevation specified, direct the Owner’s attention to such condition. Where directed by the Owner, deepen the excavation to a depth where a satisfactory foundation can be obtained. The sub grade shall then be brought back to the required grade with coarse gravel, thoroughly compacted to 75 percent relative density as determined by ASTM D4253 and D4254. D. Correcting Faulty Grade: If the trench is excavated to a faulty grade (at a lower elevation than indicated), correct the faulty grade as specified below: 1. In uniform, stable, dry soils, correct the faulty grade with granular embedment material thoroughly compacted to 75 percent relative density as determined by ASTM D4253 and D4254. 2. In soft spongy disintegrated soils or where necessary to allow proper drainage, correct the faulty grade with coarse gravel compacted to 75 percent relative density as determined by ASTM D4253 and D4254. 3. Correct faulty grade at no additional cost to Owner. E. Pipe Clearance in Rock: Remove ledge rock, rock fragments, or unyielding shale or marl to provide a clearance of at least 6 inches below the parts of the pipe, valves or fittings. Provide adequate clearance for properly jointing pipe laid in rock trenches at bell holes. Refill the excavation to grade with granular embedment material. F. Bell Holes Required: Bell holes of ample dimension shall be dug in trenches at each joint of pipe to permit the jointing to be made properly, visually inspected, and so that the pipe will rest on the full length of the barrel. G. Care of Surface Material for Reuse: Surface materials such as top soil in its natural state, suitable for reuse in restoring the excavated surface, shall be kept separate from the general excavation material. The top 12 inches of the trench backfill shall be considered topsoil. Save the topsoil to be used as backfill of the top 12 inches of the trench after pipelaying. H. Manner of Piling Excavated Material: Place excavated material in accordance with Paragraph 1.05 so that Work is not endangered and so as not to interfere with public traffic. I. Trenching by Machine or by Hand: The use of any suitable trench digging machinery is permitted except in places where operations of same will cause damage to existing structures above or below ground. Employ hand methods as necessary in those cases. J. Open Trench: The Owner shall have the right to limit the amount of trench which may be opened or partially opened at any time in advance of the completed line; and also the amount of trench left not backfilled. Not more than 150 feet of trench shall be left open Trenching and Backfill 31 23 33.19 - 8 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 unless otherwise permitted in writing by the Owner. Backfill and/or protect trenches as necessary to prevent injury to livestock, adjacent property, Owner’s personnel, and the public. 3.03 BACKFILL A. Time of Backfilling: Backfill operations shall immediately follow pipe jointing, joint coating application, and curing. B. Braced and Sheeted Trenches: Remove sheeting and shoring as backfilling operations progress. Incorporate methods so that a good bond is obtained between the backfill material and the undisturbed trench walls. C. Protection of Pipe During Backfilling Operations: Take the necessary precautions to protect the pipe during backfilling operations. Take care to prevent damage to the pipe or to the pipe coating, and repair any damaged pipe before it is backfilled. Backfill the trench in a method to prevent the deformation or other deflection of the cylindrical shape of the pipe by more than the allowable pipe deflection as specified elsewhere. Use methods such as stulling or ellipsing as necessary. D. Concrete Cradle, Encasement or Concrete Arch: Where indicated, install the pipe in concrete cradle, encasement, or concrete arch. Take precautions to prevent pipe movement or deflection during construction. E. Concrete Blocking: Place blocking to rest against firm undisturbed trench walls. The support area for each block shall be at least as great as that indicated in the Standard Details and shall be sufficient to withstand the thrust, including water hammer, which may develop. Each block shall rest on a firm undisturbed foundation of trench sides and bottom. F. Aggregate Fill Bedding: 1. After the trench has been cut to the depths indicated, bring up the bedding layer to a point slightly above grade in maximum 4-inch lifts and uniformly compact to the density indicated. Form bell holes and scoop out a trough to grade so that the pipe is uniformly supported by the embedment material. Lay and joint the pipe. Bring up the embedment material in maximum 4-inch lifts on either side of the pipe to the elevation above the pipe shown on the plans. Uniformly compact the material as specified below. Water jetting shall not be permitted. G. Compaction Requirements: 1. Compact earth fill and cohesive aggregate fill in maximum 4-inch lifts with pneumatic rollers or power hand tampers and make a minimum of eight passes. 2. Compact cohesionless aggregate fill in maximum 4-inch lifts with vibratory rollers or vibratory plate power hand compactors and make a minimum of eight passes. 3. The acceptability of the compaction equipment shall be based upon the results of a test section. 4. Compact earth fill and cohesive aggregate fill to a minimum of 95 percent of maximum dry density as determined by ASTM D698, Standard Proctor. Trenching and Backfill 31 23 33.19 - 9 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 5. Compact earth fill Class 1 and 2 at a moisture content within minus 0 to plus 5 percentage points of the optimum moisture content. Compact the remaining classes of earth fill and cohesive aggregate fill at a moisture content within minus 2 to plus 5 percentage points of optimum moisture content. The moisture ranges listed above are minimum and maximum limits. A tighter moisture range within these limits may be required to consistently achieve the specified density. 6. Compact cohesionless aggregate fill on which it is not practical to control the density by “Proctor” methods to a minimum of 75 percent relative density as determined by ASTM D4253 and D4254, or at the discretion of the Engineer, by a field compaction mold method correlated to ASTM D4253 and D4254. 7. Compact cohesionless aggregate fill at a moisture content within a range that accommodates consistent placement and compaction to the minimum relative density specified above. 8. The Contractor will arrange and pay for density and moisture testing. The testing frequency and methods shall be as required by the Engineer. The cost of repeating failed tests shall be borne by the Contractor. The Engineer may waive testing requirements on cohesionless bedding where testing is not practical because of limited space between the pipe and trench walls, however, the minimum number of passes of the compaction equipment specified above shall be achieved. H. Backfill Procedure for Public and Private Roads: Backfill material above the pipe zone for existing roads including City Roads, County Roads, paved or improved private roads, driveways, and any proposed roads as indicated shall consist of flexbase material compacted in 6-inch lifts to 95 percent Standard Proctor Density. Replace asphalt paved roads with same thickness HMAC as existing, but not less than 2 inches. Replace concrete roadways with 3000 psi concrete reinforced equal to or better than existing. Saw-cut asphalt roads prior to placement of HMAC. Cut concrete roads back to expose reinforcing prior to replacing concrete paving. I. Surface Material Replacement: 1. The top 12 inches of the trench backfill shall be composed of the original surface material or topsoil excavated from the trench. Place the topsoil over the consolidated trench backfill material and neatly round over the trench to a sufficient height to allow settlement to grade after consolidation. Grade the surface as indicated. If final grade is not shown, grade surface to allow drainage in the same manner as existed prior to construction. 2. Top soil shall not contain clods larger than 2 inches or rocks larger than those adjacent to the trench in the undisturbed condition. 3.04 FINISHING A. Finish the top portion of backfill beneath established sodded (lawn) areas with not less than 6 inches of topsoil corresponding to, or better than, that underlying adjoining sodded areas. Other areas shall be seeded as specified elsewhere. B. Grade and rake areas smooth and even which do not receive any type of paved surface, to allow drainage to drain away from the structures and toward the roads and streets or the natural drainage course. Trenching and Backfill 31 23 33.19 - 10 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 3.05 FIELD QUALITY CONTROL A. Compact backfill and appropriate embedment material to a minimum of 95 percent of maximum density at a moisture content of 0 to 5 percent of optimum for backfill and at optimum for sand-cement embedment as determined by ASTM D698, Standard Proctor. B. Make periodic tests of compaction for conformance with this Section by an approved testing laboratory selected and paid for by Contractor. Contractor shall pay for re-testing until acceptable test results are obtained. 3.06 CLEAN AND ADJUST A. Remove surplus pipeline materials, tools, rubbish and temporary structures and leave the Site clean, to the satisfaction of the Owner. Grade the surface and re-establish drainage. Removal of rock and other excess excavated material and general leveling and grading of the Site shall be part of the bid price and no additional payment shall be made. END OF SECTION Seeding for Erosion Control 31 25 13.13 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 25 13.13 SEEDING FOR EROSION CONTROL 1.00 GENERAL 1.01 WORK INCLUDED A. Provide labor, materials, equipment and incidentals necessary to seed the slopes and other areas as specified. This specification includes seedbed fertilization, watering, mulching, and emulsifying or tacking the mulch and maintenance until final acceptance by the Owner. 1.02 QUALITY ASSURANCE A. Soil Testing: Fertilizer requirements for each planting area and for significantly different soil types within planting areas, will be determined by a qualified laboratory such as the Texas A&M University - Agricultural Extension Service soil testing laboratory. Representative composite soil samples will be collected from the planting areas and submitted to an approved soil testing laboratory. 1.03 STANDARDS A. The seed used on this project will conform to ITEM 164.2 Standard Specifications for Construction of Highways, Streets and Bridges, Texas Department of Transportation. 1.04 DELIVERY AND STORAGE A. Deliver seed with each variety separately bagged. 1.05 OPTIONS A. If dry mechanical methods are used, the fertilizer may be spread at the same time as the seed. After sowing, straw mulch will be mechanically spread over the seeded area. B. When seed and fertilizer are to be distributed as a water slurry, apply the mixture within 30 minutes of mixing. 2.00 PRODUCTS 2.01 MATERIALS A. Seed: From the previous season’s crop, labeled in accordance with the Texas Seed Law. 1. Seed for Fall planting (temporary) shall be one or more of the following small grains as designated by the Engineer: Wheat, oats, rye, or barley. 2. Seed for spring planting (permanent) shall be Bermuda grass. B. Fertilizer: Insert requirements. C. Mulch: 1. Consisting of straw, wood-fiber, mulch nettings, wood chips or other suitable material approved by the Engineer and free of Johnson grass and other noxious weed seeds. 2. Straw mulch shall be oat, wheat or rice straw, prairie hay, Bermuda grass hay, or other hay harvested before seed production and approved by the Engineer. The straw mulch Seeding for Erosion Control 31 25 13.13 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 will be kept dry and shall not be rotted or molded. A minimum of 50 percent by weight of the herbage making up the hay shall be 10 inches in length or longer. D. Topsoil: As specified for Class 12 earth fill in Section 31 05 13 “Soils for Earthwork.” E. Herbicide: Contractor shall be responsible for using herbicides in a manner consistent with label requirements and precautions. Only registered herbicides having a minimal residual effect shall be used. Contractor shall strictly adhere to all Federal, State, and local laws governing herbicide usage. 3.00 EXECUTION 3.01 TOPSOIL PLACEMENT A. Place topsoil as specified for Class 12 earth fill in Section 31 05 13 “Soils for Earthwork.” 3.02 FALL PLANTING A. Fall planting will be temporary only and will be required if construction is completed between May 15 and November 30. The fall planting is to be followed by a spring planting of perennial vegetation. B. Seedbed Preparation: Use a one-way plow, tandem disk, bedder, or equipment which will accomplish similar results. Break or mix the surface of the soil with the tillage equipment. Additional tillage operations will be necessary if required so planting can be on a clean, firm seedbed. Chiseling will be necessary on areas which have been severely compacted. C. Seeding: 1. Seeding will be required on disturbed or excavated areas and on new embankments of whatever nature unless requested otherwise by the Engineer. 2. Optimum fall planting dates are September 1 to November 30. Accomplish the seeding for fall planting within these dates unless approval to do otherwise is obtained from the Engineer. Planting rates when drilled or broadcast are as follows: Seeding lb./acre Wheat 120 lb./acre Oats 128 lb./acre Rye 112 lb./acre Barley 114 lb./acre 3.03 SPRING PLANTING A. Follow procedures for spring planting if construction is completed between November 30 and May 15, or after a temporary fall planting has been made: 1. Seedbed Preparation: Seedbed preparation for Spring planting is the same as that stated in the Fall planting of temporary cover with one addition: Any temporary cover crop must be top killed using an approved contact herbicide or by mechanically undercutting the growing cover crop, leaving residues on or near the soil surface. Seeding for Erosion Control 31 25 13.13 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2. Mulching: a. Spread mulch material on the area to be planted if construction was completed too late for planting a temporary fall crop or if insufficient residues are produced by the fall planting. Mulch the planting areas to control soil erosion and seed loss by wind and water and to promote grass establishment. Apply Mulch hay at the rate of 2 tons per acre and spread uniformly so that about 25 percent of the ground surface is uniformly visible through the mulch. b. Anchor the mulch hay by treading into the soil with a straight disk type mulch tiller. Perform disking across the slope along contours. Other types of mulch such as wood cellulose fiber or cotton bur mulch may be used at recommended rates, if approved by the Engineer. Apply mulch in a manner that will not hinder emergence of seedlings. 3. Seeding: a. Plant Bermuda grass seed between March 1 and May 15. Sow the seed at the rate of 50 pounds of pure live seed (PLS) per acre, or more if required to obtain a complete stand of grass. The PLS content is determined by multiplying the seed package weight by the product of the percent purity and the percent germination, which are contained on the seed label. b. Accomplish seeding by mechanical means using either broadcasting or drilling type equipment to provide uniform distribution of the seed in the planting areas. Cover Bermuda grass seed by 1/4 to 1/2 inch of soil. If seed is drilled, the distance between drill rows shall not exceed 12 inches. Hydro seeding may be used to apply seed, fertilizer, and wood-fiber mulch with the approval of the Engineer. 3.04 MAINTENANCE A. Irrigation: Supply the seeded areas with adequate moisture (3- to 4-inch penetration) at 10- day intervals, if needed, for seed germination and plant growth until acceptance by the Owner. Water the seed in a manner which will prevent erosion of the soil. Furnish all water to be used. B. Repair: Repair washouts and other bare soil areas in a seeded area either by re-seeding, sprigging, or spot sodding, and perform maintenance as needed to establish grass in the area. C. Weed Control: 1. Control competitive weed growth during the establishment period by mowing and/or with herbicides. Chemical usage shall be in accordance with the current recommendations of the Texas Agricultural Experiment Station or local Soil Conservation Service Field Office Technical Guides. Strictly adhere to all Federal, State, and local laws governing herbicides. 2. Weed control shall be the Contractor’s responsibility whether topsoil is from on-site or off-site sources and also for seeded areas which are specified not to receive topsoil. 3.05 SEEDING OF DISTURBED AREAS Seeding for Erosion Control 31 25 13.13 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 A. Disturbed areas will require seeding as specified in this Section unless requested otherwise by the Engineer or shown otherwise on the drawings or in the specifications. B. Any areas which are disturbed by the Contractor which are not shown on the drawings or specified to require disturbance including any approved areas not shown on the drawings, shall be considered as unauthorized disturbed areas. Any such areas shall be seeded as specified in this Section at the Contractor’s expense and shall not be measured or paid under this Section. 3.06 FIELD QUALITY CONTROL; OBSERVATION AND ACCEPTANCE A. Observation: Upon completion of the site preparation, mulching, fertilizing, seeding, and maintenance of seeded areas, the Engineer will observe the seeded areas periodically to determine the establishment success. The Engineer will consider soil coverage, purity of the grass stand, and maturity of the plants. B. Establishment of Stand and Acceptance: 1. The Engineer will determine that a grassed area is established upon fulfillment of the following conditions: 2. The permanent grass stand uniformly covers the planting area, with no exposed soil areas more than 36 inches across in any dimension. 3. The permanent grass stand is free of over-topping weed species which would compete for sunlight, moisture, and nutrients. In addition, no area of pure weed species greater than 36 inches across in any dimension shall occur within a permanent grass stand. 4. The majority of the grass plants in a stand shall have a well-established root system to survive if irrigation is discontinued. 5. Establish the permanent grass stand before October 1 to preclude having to perform a temporary Fall seeding. In the event a fall seeding must be performed, follow-up the temporary seeding with a permanent seeding as specified. Upon final acceptance of the work under this contract, the Owner will assume the responsibility of maintaining the grassed areas. END OF SECTION Drilled Concrete Piers and Shafts 31 63 29 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 31 63 29 DRILLED CONCRETE PIERS AND SHAFTS 1.00 GENERAL 1.01 WORK INCLUDED 1.02 QUALITY ASSURANCE A. Installer’s Qualifications: Shaft driller shall be experienced in this line of work, having performed drilled shafts for similar types of work, and having been in business for at least 5 years. Experience shall be relevant to anticipated subsurface materials, water conditions, shaft sizes and special techniques required. B. Tolerances: Contractor shall provide at his own expense any corrective action required by the Engineer if these tolerances are exceeded. Drilled shafts shall comply with the following tolerances: 1. Casing Diameter: 2 percent of round when installed. 2. Final Shaft Diameter: Sides shall not flair out more than 2 inches at top of shaft. 3. Shaft Vertical Alignment: Shafts shall be drilled to within 1.5 percent of shaft length with a maximum of 6 inches. 4. Variation of Location: The least of either 1/24 of shaft diameter or 2 inches maximum. 5. Concrete cut off elevation: Plus or minus 1/2 inch. C. Furnish labor, materials, equipment and incidentals necessary to drill shafts for concrete foundations, including the placement of reinforcing and concrete. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Shop Drawings: a. Reinforcing bar layout drawings with bar lists clearly marked and referenced to the Drawings. b. Submit Drilled Shaft Inspector qualifications for approval. c. Detailed procedures for placement of concrete by tremie when required for underwater placement. 2. Record Drawings: a. Report of actual location and alignment of shafts along with the final bearing elevation at each shaft. Include any modifications to the information as specified. b. Manufacturers’ literature for spacer products. 3. Certified Test Reports: a. Certified mill reports for reinforcing steel. b. Concrete mix designs and material reports. Drilled Concrete Piers and Shafts 31 63 29 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 1.04 QUALITY ASSURANCE A. Testing Agency Qualifications: 1. An independent testing agency, acceptable to authorities having jurisdiction and the Engineer. The independent testing agency will be approved by the Owner and paid by the Owner. 2. The independent testing agency shall be responsible for testing of materials, ready mix, transit mix or central plant concrete. B. Drilled Shaft Inspector: A drilled shaft inspector shall be designated by the independent testing agency and as approved by the Engineer. The Drilled Shaft Inspector shall have at least 5 years’ experience in similar drilled shaft inspection. C. The following items will be inspected, tested or approved by the Drilled Shaft Inspector: 1. Determination of acceptable bearing elevation. 2. Inspection and approval of drilled shafts. 3. Approval for reinforcement and concrete placement. 4. Other activities listed in this specification. 1.05 STANDARDS A. The applicable provisions of the latest revisions of the following standards shall be considered a part of this Section as if written herein in their entirety, unless otherwise noted in the Contract Documents. 1. American Society for Testing and Materials (ASTM) Standards: ASTM A36 Specification for Carbon Structural Steel ASTM A82 Specification for Steel Wire, Plain, for Concrete Reinforcement ASTM A252 Specification for Welded and Seamless Steel Pipe Piles ASTM A615 Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement 2. American Concrete Institute (ACI) Standards: a. The Contractor shall maintain one copy of each of the following standards at the construction field office: ACI 336.1 Specification for the Construction of Drilled Piers 1.06 DELIVERY AND STORAGE A. Deliver reinforcing to site in bundles marked for proper placement. Store reinforcing steel on wood runners raised above grade. Deliver steel casings in undamaged condition and protect from damage until installed. 1.07 JOB CONDITIONS Drilled Concrete Piers and Shafts 31 63 29 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 A. A subsurface investigation has been made by Freese and Nichols, Inc of Fort Worth ,Texas . Logs of borings and test data are available for Contractor’s information and for his interpretation as to soil and water conditions that may be encountered at the site. Logs and test data are not representative as being a complete description of the site soil and water information, but only provide information for the borings at the indicated locations. If Contractor is of the opinion that the information is not adequate to establish site conditions, he may obtain additional information at his own option. B. Establish grades in relation to the permanent bench marks and finish floors for buildings. Bottom elevation of drilled shafts as shown are estimated from soil boring data. The Drilled Shaft Inspector shall determine the actual bearing level at site during excavation. C. Give notification to the Engineer at least 24 hours in advance of the time shafts shall be drilled. Give the Drilled Shaft Inspector advance notice to obtain approval to place reinforcing and concrete in shafts. D. Inspection and approval of drilled shafts shall be made by the Drilled Shaft Inspector, prior to placement of reinforcing or concrete. 2.00 PRODUCTS 2.01 MATERIALS A. Reinforcing Steel: New billet steel conforming to ASTM A615, Grade 60. B. Steel Casings: Non-corrugated round steel casings fabricated of ASTM A252, Grade 2 or ASTM A36 steel 2.02 MIXES A. Concrete materials, production methods and submittals shall be in accordance with Section 03 30 00 “Cast-In-Place Concrete.” 2.03 SPACERS A. Spacers used to center the reinforcement cage within the hole shall be precast mortar blocks with embedded wires for attachment. 2.04 EQUIPMENT A. Furnish drilling rigs of adequate size and power to perform the excavations required. Rigs shall be maintained in good working condition, shall have stable platforms, and run by qualified operators. 3.00 EXECUTION 3.01 PREPARATION A. The site shall be graded clean and level with excess material removed from the site. Remove obstructions that would interfere with movement of drilling rigs. Drilled Concrete Piers and Shafts 31 63 29 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 B. Accurately locate each shaft and mark with color coded stakes in a manner that the color identifies the type of shaft. In addition, provide permanent off set markers outside the construction area to allow rapid checking of shaft locations from fixed reference points. C. Obtain the services of a qualified surveyor to layout shaft locations and determine elevations. 3.02 INSTALLATION A. Excavate drilled shafts to the dimensions and required elevations. If drawings indicate an allowable service load bearing pressure rather than a depth, extend excavation to suitable material which provides that bearing pressure. B. Shafts shall be drilled accurately with vertical shaft walls. Rigs shall be maintained in a manner that prevents excessive vibration, causing uneven or out of plumb shafts. C. Assign workmen whose responsibility it is to remove dirt away from shaft holes. Dirt shall be moved far enough away from the edges of holes to prevent falling back into shaft. D. Once shafts have been drilled, cover open holes with plywood sheets or other coverings to protect workmen and to prevent debris from entering the hole. 3.03 REINFORCEMENT A. Reinforcing shall be fabricated to the design specified herein. Bars shall be straight and true, without bends or kinks, except where indicated on drawings. Unless otherwise indicated on the Drawings, fabricate cages in a manner to allow a 3-inch clearance around edges of shaft. Make splices as indicated. No welding of steel reinforcing shall be allowed. Unless otherwise indicated on the Drawings, space bars to maintain a clear distance between steel of not less than 1.5 times the bar diameter, nor 3 times the maximum aggregate size. B. The longitudinal bars and spiral hooping shall be assembled into a rigid unit prior to placing. C. Spacers: 1. Spacers shall be used at the lower end of the cage and along the side, placed at suitable intervals, to ensure accurate location on the cage within the shaft diameter. Provide at least four spacers around the cage perimeter at each support interval. 2. Spacers shall be wired securely to the reinforcement cage with four wire attachments as follows: a. Attach wires at the top and bottom of the spacer to the vertical reinforcement. b. Attach wires at each side of the spacer to the ties (or spirals) in such a way as to keep the spacer from rotating sideways. c. Spacers shall be securely wired in place and not subject to movement. Displaced spacers shall be replaced prior to concrete placement. D. Reinforcement shall be free of mud, oil or other coatings that affect the bond. Reinforcement having rust, scale or other contaminants shall be wire brushed to remove such contaminants, except as allowable by ASTM specifications. Drilled Concrete Piers and Shafts 31 63 29 - 5 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 3.04 CONCRETE PLACEMENT A. Start concrete placement within 8 hours after completion of drilling and inspection of shaft. Concrete to be placed in dry openings, with or without casings, shall contain set retarders and water reducing agents. B. Provide a hopper with a minimum 3-foot long drop tube at the top of the shaft to direct concrete vertically down the center of the shaft and prevent unnecessary splashing on the reinforcing steel cage. C. Concrete placement shall be continuous from the beginning of placement in the bottom to the top of shaft or to construction joints. Time intervals are allowed for vibrating or rodding, pulling casing, placing forms and other necessary operations. 1. At a minimum, consolidate the top 5 feet of the drilled shaft with a vibrator. Increase depth as required for consolidation. 2. Insert dowels at top of shaft prior to initial set and prior to consolidating top of shaft. 3. If temporary casing is used, then vibrate top of drilled shaft only after casing is pulled. D. Wherever casing is used, extend it above the grade of the finished shaft to provide excess concrete placement for the anticipated slump from the casing removal. E. Where a cap block or ground line strut is shown to be placed at the top of the drilled shaft, and the cap or strut is shown to be placed monolithically with the drilled shaft, a time interval is allowed for placing the required form and reinforcing after any necessary casing removal. F. After a placement is completed, cure the top surface and treat construction joint area, as specified. G. If it is clearly demonstrated that ground water cannot be sealed off because of the nature of the foundation formation, the shaft concrete may be placed through water using the following procedures: 1. Contact the Engineer for a revised drilled shaft depth design. 2. Clean the bottom of the shaft hole of mud and loose material. Pump water out to ensure that the bottom is in satisfactory condition. Allow water level to reach equilibrium prior to concrete placement. Verify that material was not washed into the hole. Flowing water is not permitted during placement. 3. The procedures for placement of concrete underwater shall conform to the requirements of ACI 336.1. 3.05 STEEL CASINGS A. When soil or water conditions require that shafts be cased, furnish steel casings for each diameter of shaft to be drilled. Casings shall be required when soil is unstable and likely to cave in, and where water conditions are such that dry holes cannot be drilled or maintained without casing. B. When temporary casings are used, the shaft shall be drilled with an auger until a predetermined depth is reached, then the casing shall be placed into the hole and spun until Drilled Concrete Piers and Shafts 31 63 29 - 6 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 it reaches the bearing strata and forms a seal against water pressure. The auger shall be refitted and the remainder of the shaft drilled and cleaned out. C. Concrete shall be placed inside the casing to a depth necessary to create a hydrostatic head. As the casing is removed, additional concrete shall be placed inside the shaft, maintaining a head inside the casing. Special care shall be exercised to prevent separations of concrete during removal. D. Steel casings are intended to be temporary in nature and may be removed or left in place. 3.06 FIELD QUALITY CONTROL A. Determination of acceptable bearing elevation. 1. The Contractor shall provide accommodation to the Drilled Shaft Inspector to monitor drilling operations. 2. Explore bearing stratum to a depth equal to the diameter of the bearing area below the bottom of drilled shaft with probe hole if directed by the Drilled Shaft Inspector or the Owner’s representative. 3. When a minimum penetration is required into the bearing strata, the Contractor shall cease drilling operations to allow the Drilled Shaft Inspector to verify and record the top of bearing strata. Drilling within the bearing strata shall proceed only after the top of bearing strata has been established and recorded. B. Inspection and approval of drilled shafts: 1. The Drilled Shaft Inspector shall verify and document that the bottom of the drilled shaft is free of all loose material. 2. When a minimum penetration is required into the bearing strata, the Drilled Shaft Inspector shall verify that the sides of the excavation, over the length of the penetration, are cleaned of all loose material. 3. The Drilled Shaft Inspector shall inspect the excavation after the placement of the reinforcing cage to ensure no loose material was introduced to the excavation while the reinforcing cage was placed. C. If test results indicate that the stratum is not capable of providing the required service load bearing pressure, the Engineer shall make a determination of adjustments which must be made. D. Provide gas testing equipment, protective cage, temporary casings of proper diameter, length, and thickness; or other safety apparatus as required by law where shafts must be entered by workmen or inspectors. Check shaft for toxic or explosive gases or oxygen deficiency prior to any person entering shafts. Provide portable ventilation equipment to evacuate gases from shafts. END OF SECTION Aggregate Base Courses 32 11 23 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 32 11 23 AGGREGATE BASE COURSES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to perform operations in connection with the construction of flexible base. Flexible base shall consist of a foundation for a road surface or for other courses. Construct the flexible base foundation course as specified herein in one or more courses in conformance with the typical sections, lines, and grades indicated in the plans. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Sieve analysis liquid and plastic limits and plasticity index of the material to be used as record data. 1.03 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American Society for Testing and Materials (ASTM) Standards: ASTM C131 Test Methods for Resistance to Degradation of Small-Size Course Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM D2217 Practice of Wet Preparation of Soil Samples for Particle-Size Analysis and Determination of Soil Constants ASTM D4318 Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils 1.04 DELIVERY AND STORAGE A. Deliver materials in approved vehicles. Stockpile materials in locations that are acceptable to the Owner’s Representative and shape to drain. 2.00 PRODUCTS 2.01 MATERIALS A. Base; General: 1. The materials shall be crushed or uncrushed as necessary to meet the requirements hereinafter specified, and shall consist of durable coarse aggregate particles mixed with approved binding materials. The material shall be approved by the Owner’s Representative. 2. Should the Contractor elect to produce the material from local pits, secure the material from the sources approved by the Owner’s Representative. The pits as utilized shall be Aggregate Base Courses 32 11 23 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 opened in such a manner to immediately expose the vertical faces of the various strata of acceptable material and unless otherwise directed, the material shall be secured in successive vertical cuts extending through the exposed strata, in order that a uniform mixed material will be secured. B. Types: 1. Unless the type of material to be used is specified on the plans, the Contractor may use any one of the following types, provided the material proposed for use by the Contractor meets the requirements set forth in the specification test limits tabulation. 2. Type A: Crushed Limestone: a. The material shall be obtained from approved sources, shall be crushed, and shall consist of durable particles of limestone mixed with approved binding materials. The material shall be approved by the Owner’s Representative at the source. The processed material when properly slaked and tested by standard laboratory methods shall meet the following requirements: Sieve Size Percent Passing 1-3/4” 100 3/8” 40-80 No. 4 25-60 No. 40 15-35 b. The material when tested under “The Wet Ball Method for Determining the Disintegration of Flexible Base Materials” shall not develop more than 50 percent soil binder. c. Materials passing the No. 40 sieve shall be known as “Binder” and shall meet the following requirements: 1). The liquid limit shall not exceed 40 when tested in accordance with ASTM D423. 2). The plastic limit shall be determined by testing in accordance with ASTM D424. 3). The plasticity index shall not exceed 12 nor be less than 4 when calculated in accordance with ASTM D424. 4). The preparation of samples for testing according to ASTM D4318 and shall be in accordance with the requirements of ASTM D2217. 5). Materials retained on the No. 4 sieve shall have a percent wear of not more than 45 percent when tested in accordance with ASTM C131. 3. Type B: Processed Gravel: a. The materials shall be obtained from approved sources and shall consist of durable particles of gravel mixed with approved binding materials. The material shall be approved by the Owner’s Representative at the source. The processed material when properly slaked and tested by standard laboratory methods shall meet the following requirements: Aggregate Base Courses 32 11 23 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 Sieve Size Square Opening Percent Passing 1-3/4” 40-80 No. 4 40-80 No. 4 25-60 No. 40 15-35 b. Materials passing the No. 4 sieve shall be known as “Binder.” The portion of material passing the No. 40 sieve shall be known as “Soil Binder” and shall meet the following requirements: 1). The liquid limit shall not exceed 35 when tested in accordance with ASTM D4318. 2). The plastic limit shall be determined by testing in accordance with ASTM D4318. 3). The plasticity index shall not exceed 10 when calculated in accordance with ASTM D4318. 4). The preparation of samples for testing according to ASTM D4318 and shall be in accordance with the requirements of ASTM D2217. 5). Materials retained on the No. 4 sieve shall have a percent wear of not more than 55 percent when tested in accordance with ASTM C131. 4. Type C: Bank-Run Gravel: a. The materials shall be obtained from approved sources and shall consist of durable particles of gravel mixed with approved binding materials. The material shall be free from thin or elongated pieces, lumps of clay, soil, loam, or vegetable matter. The material shall be approved by the Owner’s Representative at the source. The processed material when properly slaked and tested by standard laboratory methods shall meet the following requirements: Sieve Size Percent Passing 1-3/4” 95-100 No. 4 25-70 No. 40 15-35 b. Materials passing the No. 4 sieve shall be known as “Binder.” The portion of material passing the No. 40 sieve shall be known as “Soil Binder” and shall meet the following requirements: 1). The liquid limit shall not exceed 35 when tested in accordance with ASTM D4318. 2). The plastic limit shall be determined by testing in accordance with ASTM D4318. 3). The plasticity index shall not exceed 10 when calculated in accordance with ASTM D4318. Aggregate Base Courses 32 11 23 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 4). The preparation of samples for testing according to ASTM D4318 and shall be in accordance with the requirements of ASTM D2217. 5). Materials retained on the No. 4 sieve shall have a percent wear of not more than 55 percent when tested in accordance with ASTM C131. 3.00 EXECUTION 3.01 PREPARATION A. In conformance with the typical sections, lines, and grades indicated, excavate and shape the road bed. Remove unstable or otherwise objectionable material from the subgrade and replace with approved material. Fill holes, ruts, and depressions with approved material. Sprinkle the subgrade, if necessary, and reshape and roll to the extent directed in order to place the subgrade in an acceptable condition to receive the base material. The surface of the subgrade shall be smooth and conform to line, grade, and typical sections. Prepare sufficient subgrade in advance to insure satisfactory prosecution of the work. B. Utilize material excavated in the preparation of the subgrade in the construction of adjacent shoulders and slopes or otherwise disposed of as directed. Secure any additional material required for the completion of the shoulders and slopes from sources indicated or designated by the Owner’s Representative. C. Immediately before placing the base course material, check the subgrade for conformance with the grade and typical sections indicated. The surface of the subgrade shall not show deviation in excess of 1/4 inch in 5 feet in cross-section, nor 1/2 inch in 16 inches longitudinally. 3.02 PLACEMENT A. Number of Courses: Where the base course exceeds 6 inches in thickness, construct the base course in two or more courses of equal thickness as indicated on the typical section. B. Placing Types A, B, and C: Spread and shape the material deposited on the subgrade the same day. Move the material at least once from the original position in which it is deposited. In the event of inclement weather or other unforeseen circumstances which render impractical the spreading of the material during the first 24 hour period, scarify and spread the material as directed by the Owner’s Representative. Sprinkle the material, if directed, and then blade, drag, and shape to conform to the typical section as indicated. Correct or replace and remove areas and “nests” of segregated course or fine material with well graded material as directed by the Owner’s Representative. If additional binder is considered desirable or necessary after the material is spread and shaped, furnish and apply material in the amount directed by the Owner’s Representative. Carefully incorporate such binder with the material in place by scarifying, harrowing, brooming, or by other approved methods. C. First Course (Types A, B, and C): Sprinkle the course as necessary and compact to the extent necessary to provide not less than the percent density as hereinafter specified under “Density.” In addition to the requirements specified for density, compact the full depth of the flexible base to the extent necessary to remain firm and stable under construction equipment. After each section and course of flexible base is complete, the independent testing laboratory shall make tests of the material. If the material fails to meet the density Aggregate Base Courses 32 11 23 - 5 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 requirements, rework the material as necessary to meet the requirements. Throughout this entire operation, maintain the shape of the course by blading, and smooth the surface upon completion in conformity with the typical sections, lines, and grades indicated. On the surface of which pavement is to be placed, correct any deviation in excess of 1/4 inch in cross-section and in a length of 16 inches measured longitudinally by loosening, adding, or removing material, reshaping, and re-compacting by sprinkling and rolling. Immediately correct irregularities, depressions, or weak spots which develop by scarifying the areas affected, adding suitable material as necessary, reshaping, and re-compacting by sprinkling and rolling. Should the base course, due to any reason or cause, lose required stability, density, and/or finish before the surfacing is complete, re-compact and refinish the base course at the Contractor’s sole expense. D. Succeeding Courses (Types A, B, and C): Use the same construction methods as prescribed for the first course. Prior to placing the surfacing on the completed base, “dry cure” the base to the extent directed by the Owner’s Representative. E. Density: The density of the flexible base material shall not be less than 95 percent maximum dry density as determined by ASTM D698. Perform testing of densities of compacted base in accordance with a method approved by the Owner’s Representative. F. Curb and Gutter: Place and compact paving types with flexible base under the curb and gutter at the same time and in the same operation as the flexible base under the pavement. Place the flexible base in 6-inch maximum courses. Place and compact the first course under both the curb and gutter and the pavement. END OF SECTION Concrete Paving 32 13 13 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 32 13 13 CONCRETE PAVING 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to construct finished pavement of Portland cement concrete on the prepared subgrade, with reinforcement in conformity with the plans, and as specified herein to the lines and grades as established by the Engineer. 1.02 QUALITY ASSURANCE A. Design Criteria: 1. The concrete shall be designed for a minimum compressive strength as indicated in Paragraph 2.04G. Flexural strength is to be determined as a simple beam with center point loading (ASTM C293). While concrete placing operations are in progress, beam and cylinder specimens, of such dimension and numbers as may be required, shall be made by the Owner’s independent testing laboratory each day. Beams and cylinders shall be continuously cured in water until tested. 2. If the concrete fails to meet the strength requirements, as shown by the failure of any flexural or compressive test specimen on 2 out of 3 consecutive days’ tests, increase the cement factor in the increments of 1/2 sack per cubic yard of concrete until the strength requirements are met and redesign the concrete mix. No increase in price or extra compensation shall be allowed the Contractor for such increase in the cement factor. Failure of all the test specimens, either flexural or compressive, on any day’s run of concrete, may be cause for rejection of that particular section of pavement. In such event, submit a redesign of the concrete mix. 3. Redesign of the concrete mix by the Contractor, when required, shall include the required corrective measures as indicated by the deficiencies in the original design mix. Material samples shall be resubmitted for the laboratory check of the redesign mix. Sources of supply of materials may be changed, if desirable, at this time. B. Concrete Mix Control: Furnish, at the Contractor’s own expense, continuous plant control of the concrete by securing the services of an independent local testing laboratory, sufficiently experienced. The following tests and inspections shall be required: 1. Check incoming aggregates, fine and coarse, for gradations, specific gravity, unit weight, abrasion wear, etc. 2. Determine moisture contents of the aggregates to adjust bin weights to comply with designs. 3. Make all concrete designs in accordance with the applicable specifications. 4. Check scales as needed for accuracy. 5. Help maintain proper slumps, as specified. 6. Send inspection reports for each day’s operations. 7. Check fibrous reinforcement for conformance as specified. Concrete Paving 32 13 13 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 8. If the characteristics of the aggregate furnished in the design are such that when mixed with the minimum allowable amount of cement and the maximum allowable amount of water, the slump and workability requirements are not met or if free water comes to the surface of the slab during finishing operations, as specified, add mineral filler or cement only to the limits provided in Paragraph 2.01D, or may be required to redesign of the concrete mix. When the finishing machine has gone over an area twice and all surface voids are not filled, the workability shall be considered as unsatisfactory, terminate concreting operations and redesign the concrete mix. C. Laboratory Testing: 1. Material samples submitted for approval shall be sufficiently large to permit the Owner’s independent testing laboratory-to-laboratory batch the construction of test beams to check the adequacy of the design. When the design mix has been approved, there shall be no change or deviation from the proportions thereof or sources of supply except as hereinafter provided. No concrete shall be placed on the job site until the mix design has been approved by the Engineer in writing to the Contractor. 2. The concrete shall contain not less than 5 sacks of cement per cubic yard. Total water shall not exceed 7 gallons per sack of cement. The mix shall be uniform and workable. The amount of coarse aggregate (dry-loose volume) shall not be more than 85 percent per cubic yard of concrete. 3. The net amount of water shall be the amount added at the mixer plus the free water in the aggregate or minus the amount of water needed to compensate for absorption by the aggregates. Free water or absorption determinations shall be based on a 30 minute absorption period. No water allowance shall be made for evaporation after batching. 4. When gauged by the standard slump test, the settlement of the concrete shall not be less than 3 inches nor more than 5 inches. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures.” B. Within a period of not less than 10 days prior to the start of concreting operations, submit to the Engineer a design of the concrete mix he proposes to use together with samples of materials to be incorporated into the mix and a full description of the source of supply of each material component. The design of the concrete mix shall conform to the provisions and limitation requirements of these specifications. C. Manufacturer’s Certified Test Reports for each lot of silicone joint sealant shipped to the project site. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American Society for Testing and Materials (ASTM) Standards: ASTM A82 Specification for Steel Wire, Plain, for Concrete Reinforcement Concrete Paving 32 13 13 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 ASTM A184 Specification for Fabricated Deformed Steel Bar Mats for Concrete Reinforcement ASTM A1064 Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete ASTM A615 Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement ASTM C150 Specification for Portland Concrete ASTM C293 Test Method for Flexural Strength of Concrete (Using Simple Beam with Center-Point Loading) ASTM C309 Specification for Liquid Membrane-Forming Compounds for Curing Concrete ASTM C946 Standard Specification for Ready Mix Concrete ASTM C1077 Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for use in Construction and Criteria for Laboratory Evaluation ASTM D1751 Specification for Performed Expansion Joint Fillers for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types) ASTM E329 Standard Specification for Agencies Engaged in Testing and/or Inspection of Materials used in Construction 1.05 JOB CONDITIONS A. Should the Contractor desire to use Type III cement in lieu of Type I, permission to do so must be secured from the Engineer in writing before use. When such use is granted, the concrete produced shall meet the requirements specified herein. B. When Type III cement is used, either as required on the plans or as an option to Type I cement, the average tensile strength of briquettes at the age of 28 days shall be higher than that attained at 3 days. C. Any cement which, for any reason, has become partially set or which contains hard lumps or cakes shall be rejected. D. The following special requirements apply to this work: 1. After a joint has been sealed, promptly remove surplus sealant or other residue on the pavement or structure surfaces. 2. If a primer is recommended by the Manufacturer, use primer in accordance with such recommendations. When required, apply primer before installing backup material. 3. Equipment compressors used for cleaning joints with suitable traps capable of removing surplus water and oil in the compressed air. The Engineer shall check the compressed air daily for contamination. Do not use contaminated air. The compressor shall be capable of delivering compressed air at a continuous pressure of at least 90 psi. 4. Do not permit traffic over sealed joints until the sealant is tack free, cured sufficiently to resist displacement of the sealant due to slab movement or other causes, and until debris from traffic does not imbed into the sealant. Concrete Paving 32 13 13 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 5. Any of the following conditions at the sealed joint shall be cause for rejection and repair of the joint: a. Adhesion or cohesion failure of joint sealant material. b. Unsatisfactory or improper workmanship by Contractor. c. Damage by Contractor’s operations or public traffic. d. Damage to the sealant due to displacement of the sealant from slab movements or insufficient cure before opening to traffic. 1.06 OPTIONS A. Bulk cement meeting the above ASTM specifications may be used provided the manner and method of handling and storing is approved by the Engineer. When cement is delivered in bulk, the brand and the Manufacturer’s name, as contained in the shipping invoices accompanying the shipment, shall be furnished to the Engineer prior to use of the cement. 2.00 PRODUCTS 2.01 MATERIALS A. Cement: 1. Cement shall conform to ASTM C150 for Type I. If high-early-strength Portland cement is required, it shall conform to ASTM C150 for Type III, and current revisions. 2. Cement delivered in bags shall be marked plainly with the brand and name of the Manufacturer on the bag. A bag shall contain 94 pounds net. Bags shall be in good condition at the time of use. Bags of cement varying more than 5 percent from the specified weight shall be rejected, and if the average net weight of bags in any shipment, as shown by weighing 50 bags taken at random, is less than 94 pounds, the entire shipment shall be rejected. Do not use cement salvaged from discarded or used bags. B. Coarse Aggregate: 1. Coarse aggregate shall consist of gravel, crushed gravel, crushed stone, or a combination of these materials of which the maximum permissible percentage of deleterious substances, by weight, shall not exceed the following: Coarse Aggregate – Deleterious Substances Material removed by decantation 1.0% Shale, slate, or similar materials 1.0% Clay lumps 0.25% Soft fragments 3.0% Other deleterious substances including friable, thin elongated, or laminated pieces 3.0% The sum of all deleterious ingredients, exclusive of material removed by decantation, shall not exceed by weight 5.0% Concrete Paving 32 13 13 - 5 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2. The aggregate shall be free from an excess amount of salt, alkali, vegetable matter, or other objectionable matter. At the time of its use the aggregate shall be free from frozen material and all foreign material which may have become mixed with it in the stockpiles. 3. The coarse aggregate shall consist of sound particles having a percent of wear not more than 45 (Test Method TEX-410-A) and shall be mixed so that when tested by standard laboratory sieves, the course aggregate meets the following requirements: Coarse Aggregate Requirements Retained on 1-1/4” sieve 0% Retained on 1-1/2” sieve 0% to 5% Retained on 3/4” sieve 30% to 65% Retained on 3/8” sieve 70% to 90% Retained on No. 4 sieve 95% to 100% Loss by Decantation Test Method TEX-604-A 1% max. 4. Coarse aggregate of different characteristics, though tested and approved, shall not be mixed with other aggregates; but shall be stored, batched, and weighed separately. C. Fine Aggregate: 1. Fine aggregate shall consist of sand or a mixture of sands with or without mineral filler. The sand or mixture of sand comprising one fine aggregate shall consist of clean, hard, durable, uncoated grains and shall be free from lumps. The maximum permissible percentage, by weight, of deleterious substances shall not exceed the following: Fine Aggregate – Deleterious Substances Material removed by decantation 3.0% Other deleterious substances such as coal, shale, coated grains, and soft flaky particles 3.0% 2. An additional loss of 2 percent by decantation may be allowed provided this additional loss is material of the same quality as specified for fine aggregate or mineral filler. a. The fine aggregate shall be free from an excess amount of salt or alkali and at the time of use shall be free from frozen material and foreign material. b. When tested for organic impurities the fine aggregate shall not have a color darker than the standard color. c. The fine aggregate shall be well graded from fine to coarse and when tested by standard laboratory sieves shall meet the following requirements: Fine Aggregate - Gradation Retained on 3/8” sieve 0% Retained on No. 4 sieve 0% to 5% Retained on No. 8 sieve 0% to 20% Concrete Paving 32 13 13 - 6 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 Fine Aggregate - Gradation Retained on No. 16 sieve 15% to 50% Retained on No. 30 sieve 35% to 75% Retained on No. 50 sieve 70% to 90% Retained on No. 100 sieve 90% to 100% Retained on No. 200 sieve 97% to 100% 3. Fine aggregate of different characteristics shall not be mixed prior to batching, but shall be weighed and batched separately. 4. Fine aggregate will be subjected to the sand equivalent test (test method TEX-203-F). The sand equivalent value shall not be less than 80. D. Mineral Filler: Stone dust, crushed sand, or crushed shell may be added as a mineral filler, if so directed by the Engineer, in amounts not to exceed 5 percent of the fine aggregate to improve the workability or plasticity of the concrete mix. Such mineral filler must be of the quality specified for fine or coarse aggregate and when tested by standard laboratory sieves shall meet the following requirements: Mineral Filler - Gradation Retained on No. 30 sieve 0% Retained on No. 200 sieve 0% to 35% E. Mixing Water: Water for use in concrete and for curing shall be free from oil, acids, organic matter or other deleterious substances and shall not contain more than 1000 parts per million of chlorides as Cl nor more than 1000 parts per million of sulfates as SO4. Water from municipal supplies approved by the State Health Department will not require testing, but water from other sources shall be sampled and tested before use. F. Steel Dowel Bars: Steel dowel bars, if shown and required on the plans, shall be of the size and type indicated and shall be open hearth, new billet steel of intermediate or hard grade conforming to the requirements of ASTM A615. The free end of dowel bars shall be smooth and free of shearing burrs. G. Dowel Caps: Provide dowel caps when required by the drawings. Encase one end of each dowel bar with an approved cap having an inside diameter of 1/16 inch greater than the diameter of the dowel bar. The cap shall be of such strength, durability, and design as to provide free movement of the dowel bar and shall be filled with a soft felt plug or shall be void in order to permit free movement of the dowel bar for a distance of 1-1/2 times the width of the expansion joint used. Securely hold the dowel caps and dowel bars in place. H. Bar Coating: When bar coating is required, the material may be any standard grade of oil asphalt and shall be applied hot. I. Steel Bar Reinforcement: Steel reinforcing bars shall be of the size and type indicated and shall be open hearth new billet steel of structural, intermediate, or hard grade, ASTM A615, Grade 60 or shall be rail steel concrete reinforcement bars, ASTM A616, Grade 60. Steel Concrete Paving 32 13 13 - 7 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 shall be bent cold. When tie bars are to be bent they shall be Grade 40 conforming to requirements of ASTM A615. J. Reinforcing Mats: When deformed bars are specified, the forms of the bar shall be such as to provide a net sectional area at all points equivalent to that of a plain square or round bar of equal nominal size. Fabricated steel bar or rod mats shall meet the current requirements of ASTM A184. K. Drainage Course: The crushed stone drainage course shall be Class 1 aggregate fill as specified in Section 31 05 16 “Aggregates for Earthwork.” 2.02 MIXES A. Concrete shall be composed of Type I cement or Type III cement, coarse aggregate, fine aggregate, mineral filler, and water. Type III cement shall be used only when specifically approved by the Engineer in writing and the concrete made therewith shall be subject to all applicable provisions of these specifications. Mix shall comply with approved laboratory design or adjusted mix proportions. 2.03 RELATED MATERIALS A. Pavement Markings: 1. Pavement-Marking Paint: Alkyd-resin type, lead and chromate free, ready mixed, complying with FS TT-P-115, Type I or AASHTO M248, Type N. a. Color: White. 2. Pavement-Marking Paint: Latex, waterborne emulsion, lead and chromate free, ready mixed, complying with FS TT-P-1952, with drying time of less than 45 minutes. a. Color: White. 2.04 MANUFACTURED PRODUCTS A. Reinforcement Chairs: Reinforcing steel, tie bars, dowels, etc., shall be placed and held securely in place during placing of concrete by steel or plastic chairs approved by the Engineer. These chairs shall be placed at every other intersection of longitudinal and transverse bars. B. Joint Filler: 1. Joint filler shall consist of boards or a pre-molded bituminous fiber of the size, shape, and type indicated. 2. Redwood Boards: Boards used as a filler shall be sound heartwood obtained from redwood. Boards shall be of selected stock and shall be free from sapwood, knots, cluster bird’s eye, checks, and splits. Occasional sound or hollow bird’s eye, when not in clusters, shall be permitted, provided the board is otherwise free of any defects that may impair the usefulness as a joint filler. The board, when tested in the condition as used in the pavement, shall have a compressive resistance of not more than 1500 pounds per square inch in compressing to one-half of its original thickness. 3. Fiber Board: Fiber used for filler shall be preformed strips which have been formed of cane or other suitable fibers of a cellulose nature securely bound together and Concrete Paving 32 13 13 - 8 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 uniformly and thoroughly impregnated with a suitable asphaltic binder. Fiber joint fillers shall meet the requirements of ASTM D1751. C. Joint Sealing Material: 1. The sealant shall be furnished in a one-part silicone formulation which does not require a primer for bond to concrete. The compound shall be compatible with the surface to which it is applied. Acid cure sealants are not acceptable for use on concrete. Apply the sealant with a pressure applicator that forces it into the joint. Silicone rubber joint seals shall exhibit an adequate bond to concrete when subjected to testing. 2. The silicone sealant shall meet the requirements of Table I. Sealant may be accepted for immediate use on the basis of Manufacturer’s certified test results which indicate the material meets the requirements of Table I. Each lot of sealant shall be delivered in containers plainly marked with the Manufacturer’s name or trademark and a lot number. The Manufacturer shall furnish certified test results of each lot of joint sealant shipped to the project. The Manufacturer shall also indicate the date of shipment on each lot. Material shall not be used after 6 months from the date of shipment from the manufacturer without first being sampled and tested. Foam back-up rod may be accepted based on visual inspection by the Engineer. D. Membrane Curing Compound: 1. Absorptive Cover: AASHTO M182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 9 oz./sq. yd. dry. 2. Moisture-Retaining Cover: ASTM C171, polyethylene film or white burlap-polyethylene sheet. 3. Water: Potable. 4. Evaporation Retarder: Waterborne, monomolecular film forming; manufactured for application to fresh concrete. a. Available Products: 1). Axim Concrete Technologies; Cimfilm. 2). Burke by Edeco; BurkeFilm. 3). ChemMasters; Spray-Film. 4). Conspec Marketing & Manufacturing Co., Inc.; Aquafilm. 5). Dayton Superior Corporation; Sure Film. 6). Euclid Chemical Company (The); Eucobar. 7). Kaufman Products, Inc.; Vapor Aid. 8). Lambert Corporation; Lambco Skin. 9). L&M Construction Chemicals, Inc.; E-Con. 10). MBT Protection and Repair, ChemRex Inc.; Confilm. 11). Meadows, W. R., Inc.; Sealtight Evapre. 12). Metalcrete Industries; Waterhold. Concrete Paving 32 13 13 - 9 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 13). Nox-Crete Products Group, Kinsman Corporation; Monofilm. 14). Sika Corporation, Inc.; SikaFilm. 15). Symons Corporation; Finishing Aid. 16). Vexcon Chemicals, Inc.; Certi-Vex EnvioAssist. E. Concrete Mixtures: 1. Prepare design mixtures, proportioned according to ACI 301, for each type and strength of normal-weight concrete determined by either laboratory trial mixes or field experience. a. Use a qualified independent testing agency for preparing and reporting proposed concrete mixture designs for the trial batch method. 2. Proportion mixtures to provide normal-weight concrete with the following properties: a. Compressive Strength (28 Days): 3600 psi. b. Maximum Water-Cementitious Materials Ratio at Point of Placement: 0.45 c. Slump Limit: 5 inches, plus or minus 1 inch. 3. Add air-entraining admixture: ASTM C 260 4. Limit water-soluble, chloride-ion content in hardened concrete to 0.15 percent by weight of cement. 5. Chemical Admixtures: Use admixtures according to manufacturer’s written instructions. a. Use water-reducing and retarding admixture when required by high temperatures, low humidity, or other adverse placement conditions. 6. Cementitious Materials: Limit percentage, by weight, of cementitious materials other than Portland cement according to ACI 301 requirements as follows: a. Fly Ash or Pozzolan: 25 percent. b. Ground Granulated Blast-Furnace Slag: 50 percent. c. Combined Fly Ash or Pozzolan, and Ground Granulated Blast-Furnace Slag: 50 percent, with fly ash or pozzolan not exceeding 25 percent. 2.05 EQUIPMENT A. General: The equipment necessary for the construction of this item shall be on the project and shall be approved by the Engineer as to condition before the Contractor is permitted to begin construction operations on which the equipment is to be used. B. Field Laboratory: A field laboratory structure shall be required only when specifically required and provided for in the Special Provisions. C. Cement Weighing and Batching Equipment: Concrete Paving 32 13 13 - 10 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 1. Where bulk cement is used, the method of handling and the handling equipment shall be inspected and approved by the Engineer. Cement shall be fully protected from contamination or damage during handling. 2. Cement shall be batched by weight and scales shall be of the beam or springless dial type and shall be the product of a reputable manufacturer. Scales not accurate to a tolerance of 4 pounds per 1000 pounds net load in the hopper shall not be used. The value of the minimum gradation on any type scale shall not be greater than 5 pounds. 3. The scales shall be so constructed as to indicate to the operator that the required load in the hopper or container is being approached; similarly they shall also indicate when the hopper or container is empty. The indicator shall show at least the last 50 pounds of the load. After cement is weighed, protect cement from damage or loss in handling or in transit. D. Aggregate Weighing Equipment: 1. Aggregate weighing equipment shall conform to the following general requirements and shall be approved by the Engineer prior to use. 2. The storage bins shall be of a suitable size and shape to adequately meet the needs of the weighing and batching equipment. The framework and foundation shall be adequate to support the total imposed loads. 3. The weighing hopper or container shall be of sufficient size and tight enough to hold the entire load without leakage, shall be supported entirely upon the scales, and shall be free of other supports. The hopper or container shall be so constructed as to permit easy and sufficient removal of any overload. The discharge gate shall have a substantial latch which holds tightly in place during introduction of the aggregate into the hopper. When more than one aggregate size is to be weighed in a single hopper there shall be a separate compartment for each size so arranged that each could be discharged separately and the overload of any compartment easily removed. 4. Scales shall conform to the requirements as provided under Paragraph 2.05C of this specification and in addition thereto the indicator requirement (paragraph 2) shall be amended to show at least the last 200 pounds of the load. 5. Aggregate weighing equipment shall be fully loaded for 5 hours before testing and using in order to allow settlement and adjustment under working conditions. E. Planer and Templates: 1. A subgrade planer shall be furnished and shall be operated immediately ahead of the paving operations. The planer shall be equipped with adjustable blades which trim the subgrade to the exact section as shown on the plans. The planer shall be supported on wheels that travel on the side forms and shall be so constructed on wheels that are plainly visible during operations and must be heavy enough to remain on the form at all times. The frame shall be of such strength and rigidity that should the support of the planer be transferred from the wheels to the center, there shall not be a deflection of more than 1/8 inch. 2. A template shall be provided having adjustable rods projecting downward at 1-foot intervals. The bottom of these rods shall be adjusted to the true cross-section of the bottom of the slab when the template rests upon the side forms. The template shall be Concrete Paving 32 13 13 - 11 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 of sufficient strength and rigidity that the deflection at the center shall be no greater than 1/8 inch, should the support be transferred to that point. F. Mixer: 1. Unless otherwise provided for or approved by the Engineer, the paving mixer shall be of a capacity of not less than a 27-E paver; mixer rating to be as established by the Mixer Manufacturer’s Bureau of the Associated General Contractors. The paving mixer shall be provided with a boom and bucket for placing concrete or with a full width mechanical spreading or placing machine of approved design. The motor shall be provided with a governor to regulate the speed of the mixer drum within a limit of 16 to 20 revolutions per minute. The mixer shall be equipped with an automatic attachment for satisfactorily timing the mix and locking the discharging device so as to prevent the discharging of the mixer until the materials have been mixed together for the minimum time required. This attachment shall be operated independently of the drum and shall have a bell in operation at all times to indicate the completion of the mixing time. The bell shall be such that it can be plainly heard at a distance of 50 feet from the mixer. 2. Dual drum mixers may be used provided their operations shall be properly synchronized so as to permit a minimum mixing time of 60 seconds exclusive of the time required to transfer the materials from the first to the second drum. 3. The distribution bucket shall be tightly constructed and of a sufficient capacity to hold an entire batch of concrete. The discharge gate shall be so constructed as to give a uniform distribution of the concrete on the subgrade without segregation. 4. The paver shall be equipped with a water measuring device of sufficient accuracy that it will measure the water within one percent of the amount required per batch. The measuring device shall be so constructed that it opens to atmospheric pressure when the measured amount of water is in it and shall be so placed and constructed that the measured amount of water required for a single batch of concrete can be discharged into a calibrated tank or weighing device. The water measuring device shall be checked daily for accuracy. 5. When the use of a mixer of a capacity less than 27-E paver is permitted, it shall be of an approved type and so designed as to positively insure the uniform distribution of the materials throughout the mass and insure the discharge of the batch without segregation. G. Forms: The side forms shall be metal, of approved cross-section and bracing, of a height not less than the prescribed edge thickness of the concrete section, and a minimum of 10 feet in length for each individual form. Forms shall be of ample strength and shall be provided with adequate devices for secure setting so that when in place forms withstand the impact and vibration of equipment imposed thereupon without appreciable springing or settlement. In no case shall the base width be less than 8 inches for a form 8 feet or more in height. The forms shall be free from warps, bends, or kinks and shall show no variation from the true plane for face or top. Each 10-foot length of forms shall be provided with at least three pins for securely staking in position. Sufficient forms shall be provided for satisfactory prosecution of the work. The 10-foot metal form sections shall be used in forming curves with a 250-foot and larger radius. For curves with a radius of less than 250 feet, acceptable flexible metal forms or wood forms may be used upon approval of the Engineer. Concrete Paving 32 13 13 - 12 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 H. Finishing Equipment: 1. Pavement shall be machine or hand finished except as hereinafter provided. The finishing machine shall be power-driven, equipped with two screeds, and a tamp. The finishing machine shall be so designed, equipped, and operated as to strike off, consolidate, and compact the concrete. Strike-off grade shall be to the flowline of the gutter. 2. Alternate floating and finishing equipment may be substituted for the equipment specified herein, when approved by the Engineer in writing, provided the finished surface conforms to the surface test requirements of Paragraph 3.07. 3. Hand finishing shall not be permitted except in intersections, driveways, and parking areas inaccessible to a finishing machine. Provide a strike template 2 x 6 lumber at least 2 feet longer than the width of the pavement to be finished. The strike template shall be so constructed as to leave a sufficient amount of concrete above the finished surface to allow for tamping. The tamping template shall be cut to the crown section and shall have a 3/8-inch steel face. There shall also be provided a hand operated longitudinal float with wood face, of approved design, 12 to 16 feet in length, or an approved type of mechanical float with not less than 10 feet of longitudinal screed. There shall be furnished a sufficient number of bridges for the operation of the longitudinal float and for finishing all joints. Furnish edging and finishing tools required to complete the slab in accordance with the plans and specifications. 4. Furnish a belt of canvas-rubber composition, two- to four-ply, not less than 8 inches nor more than 10 inches wide, and at least 2 feet longer than the width of the slab, or furnish a burlap drag consisting of not less than two layers of burlap, not less than 3 feet wide, and at least 2 feet longer than the width of the pavement. 5. Furnish and maintain at least two standard 10-foot straightedges on the job at all times. 3.00 EXECUTION 3.01 PREPARATION A. Prepare subgrade to receive the pavement drainage course as specified in Section 31 05 16 Aggregates for Earthwork. Any section of the subgrade which does not meet the requirements of those sections of the specifications immediately prior and following to the placement of the geotextile and drainage course shall be reprocessed and re-compacted to be in full compliance with specification requirements. 3.02 INSTALLATION A. Drainage Course: 1. Install the drainage course on the prepared subgrade in conjunction with the geotextile as indicated and as specified in Section 31 32 19.16 “Geotextile Soil Stabilization.” 2. After being spread to the specified thickness, compact the drainage course by rolling with a minimum of eight passes of a vibratory roller of the type specified in Section 31 23 23.16 “Compacted Earth Fill [Landfills and Heavy Earthwork Projects, Excluding Dams].” The drainage course shall not require specific compaction testing, but shall Concrete Paving 32 13 13 - 13 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 receive not less than eight passes by the specified vibratory roller. Increase the number of passes, if necessary, to fully densify and interlock the aggregate particles. 3. The completed surface of the drainage course shall be within a tolerance of +0.00 and - 0.04 foot of the lines and grade indicated. The minimum thickness of the drainage course at any point in the completed course shall not be less than the thickness indicated on the plans. 4. If regrading or reshaping of the surface of the drainage course is required to meet the specified tolerances, reroll the surface with the vibratory roller as specified. 5. Protect the completed drainage course from all traffic which might loosen, contaminate with soil or otherwise damage the course, until the next course of surface course is installed. If the drainage course should become contaminated with soil from runoff or otherwise, replace those contaminated areas prior to proceeding with the next course. 3.03 PLACING AND REMOVING FORMS A. Set forms to line and grade at least 100 feet, where practicable, in advance of the paving operations. Adequately stake forms with at least three pins per 10-foot section. Forms shall be capable of resisting the pressure of concrete placed against them and the thrust and the vibration of the construction equipment operating upon them without appreciable springing or settlement. Neatly and tightly join the forms and set with exactness to the established grade and alignment. Forms must be in firm contact with the subgrade throughout the length and base width. If the subgrade becomes unstable, reset the forms using heavy stakes or other additional supports as necessary to provide the required stability. B. When forms settle over 1/8 inch under finishing operations, stop paving operations, reset the forms to line and grade, and bring the pavement to the required section and thickness. C. Thoroughly clean forms after each use and oil forms before reuse. D. Forms shall remain in place until the concrete has taken its final set. At the time the forms are removed, bank earth against the sides of the slab and immediately and thoroughly wet. E. Form super-imposed curb from the flow line of the gutter to the top of curb. Expansion joints in the curbs shall conform to the joint locations in the slab. 3.04 PLACING REINFORCING STEEL, TIE, AND DOWEL BARS A. Reinforcing steel, welded wire mesh, tie bars, dowels, etc. shall conform to the provisions set out under Paragraphs 2.01 F-K and 2.04A and shall be placed as shown on the plans. Reinforcing shall be clean, free from rust in the form of loose or objectionable scale, and of the type, size, and dimensions shown on the plans. Securely wire reinforcing bars together at all intersections and splices and securely wire to each dowel and load transmission unit intersected. Install bars in their required position. B. Install reinforcing bars and bar mats in the slab at the required depth below the finished surface and support by and securely wiring to reinforcement chairs installed on prescribed longitudinal and transverse centers as shown by section and detailed drawings on the plans. After the reinforcing steel is securely installed above the subgrade, there shall be no loading imposed upon (or walking upon) the bar mats or individual bars before or during the placing or finishing of the concrete. Concrete Paving 32 13 13 - 14 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 C. Where welded wire fabric reinforcement mats are necessary, place and stuck off the concrete by means of a template to the depth below the finished surface as specified for the location of the mesh. Place welded wire mats, conforming to the specified side lap and end splice requirements upon the struck surface, and place the remainder of the concrete with finishing operations proceeding immediately. There shall be no loading imposed upon the mesh mats after installation in the slab concrete. D. Expansion joints or dummy joints which may require an assembly of parts supported by special devices shall be completely assembled and rigidly supported in the correct position well in advance of the placing of concrete. 3.05 JOINTS A. Expansion Joints: 1. Install expansion joints perpendicular to the surface and to the center line of the pavement at the locations indicated. Joint filler shall be a pre-molded asphaltic type or redwood boards of the size and shape specified. The oven-dry weight of the wood shall not exceed 30 pounds per cubic foot. Board joint material with less than 25 percent of moisture at the time of installation shall be thoroughly wetted on the job. Green lumber of much higher moisture content is desirable and acceptable. 2. Appropriately drill the joint filler to admit the dowel bars. Extend the bottom edge of the filler to or slightly below the bottom of the slab and hold the top edge approximately 1/2 inch below the finished surface of the pavement in order to allow the finishing operations to be continuous. Where the joint filler is of a pre-molded asphaltic type, protect the top edge by a metal cap of at least 10 gauge material having flanges not less than 1-1/2 inches in depth. The channel cap may remain in place during the joint finishing operations to serve as a guide for tooling the edges of the joint. After the removal of the side forms, carefully open the ends of the joints at the edges of the slab for the entire depth of the slab. The joint filler may be composed of more than one length of board in the length of the joint, but no board of a length less than 6 feet may be used unless otherwise shown on the plans. 3. Where a monolithic curb or a separate curb and gutter are used, the expansion joints therein shall coincide and be continuous with the pavement joint and of the same size and type. 4. When the pavement is adjacent to or around existing structures, construct expansion joints in accordance with the details shown on the plans. 5. Install dowel bars through the pre-drilled joint filler and rigidly support in true horizontal and vertical positions by an assembly of bar chairs and dowel holders welded to transverse bars extending across the slab and placed on each side of the joint. B. Contraction Joints: Install contraction joints at the locations and at the intervals indicated. Construct the joints by sawing to the width and to the depth indicated. Saw joints into the completed pavement surface as soon after initial concrete set as possible to control cracking, but with enough lapsed time to prevent any damage by blade action to the slab surface and to the concrete immediately adjacent to the joint. Restore any portion of the curing membrane which has been disturbed by sawing operations by spraying the areas with additional curing compound. In the absence of joint sawing instructions on the plans, Concrete Paving 32 13 13 - 15 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 conduct and complete sawing operations within a time period of 5 to 12 hours after the concrete slab is poured including the sealing operation. C. Construction Joints: Construct construction joints formed at the close of each day’s work or when the placing of concrete has been stopped for 30 minutes or longer by use of metal or wooden bulkheads cut true to the section of the finished pavement and clean and oil. Wooden bulkheads shall have a thickness of not less than 2-1/2 inches. Longitudinal bars shall be continuous through the construction joints. Securely hold the bulkheads in place in a plane perpendicular to the surface and at right angles to the center line of the pavement. Round edges to a 1/4-inch radius. Remove any surplus concrete on the subgrade upon the resumption of the work. In no case shall an emergency construction joint be placed within 8 feet following a regular installation of expansion or contraction joint. If the emergency construction joint should fall within this limitation, remove the concrete back to the previously installed joint. D. Longitudinal Parting Strips: Accurately place longitudinal parting strips or planes of weakness, when required. E. Longitudinal Construction Joints: Longitudinal construction joints shall be of the type indicated. Longitudinal construction joints shall be constructed accurately to the required lines in order to coincide with traffic lane lines. No width between longitudinal construction joints shall exceed 24 feet, unless specifically authorized or directed by the Engineer in writing. Construct concrete curbs as an integral part of the pavement. 3.06 MIXING A. Mix concrete in an approved method conforming to the requirements of this specification. Ready-mix concrete shall be permitted in lieu of the paver-mixer. When ready-mix concrete is used, provisions of ASTM C94 Alternate No. 2 shall govern. Materials for concrete placed in pavements shall conform to the requirements of the governing item of this specification. 1. Batch Mixing including Material Transportation: Mix the concrete in a batch-mixer, as indicated and only in the quantities required for immediate use. The mixing of each batch shall continue for a period of not less than 1 minute after all materials comprising the batch are in the mixer. The mixer discharge gate shall be locked by the automatic timing device until the required time has elapsed. The entire contents of the drum shall be discharged before any materials are placed therein for the succeeding batch. Retempering or remixing shall not be permitted. a. Batch boxes, containers, or vehicle bodies used in transporting material from the proportioning plant to the mixers shall be tight and of a sufficient size to hold a batch of maximum size with a margin of safety to prevent spillage. The batch must be protected when hauling is in progress so as to positively prevent any loss of material and minimize loss of moisture by evaporation. On long length hauls, this may require tarpaulin covers. Partitions intended to separate batches shall be adequate and effective in preventing material spilling from one compartment into another while in transit or when being dumped. b. When cement is transported in the original package, do not empty from the bags at a greater distance from the mixer than 1000 feet. Concrete Paving 32 13 13 - 16 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 c. The mixer shall produce a concrete of uniform consistency and appearance. Correct spilling of the mixer by reducing the size of the batch. When a 27-E mixer is used, a maximum overload of 20 percent above the rated capacity of the mixer shall be permitted. In other size mixers, a maximum overload of 10 percent above the rated capacity of the mixer shall be permitted. Replace pick-up and throw-over blades inside the mixer drum when worn down 3/4 inch. d. When the use of a mixer of a capacity greater than that of a 27-E mixer is used, increase the mixing time to 1-1/2 minutes. e. Do not use concrete which has developed initial set or has been mixed longer than 30 minutes. f. Thoroughly clean the mixer each time when out of operation for more than 30 minutes. 2. Transit Mixing: When transit mixing is used, the transit mixer shall be of an approved revolving drum or revolving blade type so constructed as to produce a thoroughly mixed concrete with a uniform distribution of the materials throughout the mass and shall be equipped with a discharge mechanism which insures the discharging of the mixed concrete without segregation. a. The mixer drum shall be water-tight when closed and equipped with a locking device which automatically prevents the discharging of the mixer prior to receiving the required number of revolutions. b. Accurately measure the entire quantity of mixing water by visible calibrated mechanism. Leaking water valves shall be considered as ample reason for condemnation of the mixer unit by the Engineer and removal from the job. Mix each batch not less than 70 nor more than 100 revolutions at the rate of rotation specified by the Manufacturer as mixing speed. Any additional mixing shall be done at a slower speed specified by the Manufacturer for agitation, and shall be continuous until the batch is discharged. c. Truck mixers shall be equipped with actuated counters by which the numbers of revolutions of the drum may be readily verified. The counters shall be actuated at the time of starting mixing at mixing speeds. d. The rate of delivery of the mixed concrete shall be such that the interval between loads shall not exceed 10 minutes. Deliver the concrete to the site of the work and discharge from the mixer within a period of 90 minutes, or before the drum has been revolved 300 revolutions, whichever comes first, after the introduction of the mixing water with the dry materials. 3. Central Mixing Plant: A central mixing plant shall be allowed provided the method of mixing and handling has first been approved by the Engineer and concrete produced is in conformity with the specification requirements as herein provided. a. Mix the concrete in a batch mixer of approved type and in the same manner as indicated. b. Haul the concrete in vehicles so constructed and operated as to provide continuous mechanical agitation during the transportation period. The rate of delivery of the mixed concrete shall be such that the interval between loads shall not exceed 10 Concrete Paving 32 13 13 - 17 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 minutes. Deliver the concrete to the site of the work and discharge from the transporting vehicle within a period of 90 minutes after the introduction of water into the batch at the central mixing plant. 4. Commercial Concrete Plants: In the event the Contractor elects to use concrete produced by a commercial concrete plant, an agreement shall be drawn and executed by the responsible executive management of said plant granting the Engineer ingress and egress to all parts of the plant with full authority to have any and all required tests of aggregates and to observe all batching plant and/or central mixing plant operations. This regulatory access shall be applicable only to the concrete produced by the commercial plant for the work herein specified. 3.07 CONCRETE PLACEMENT A. Unless otherwise provided for on the plans, the full width of the finished pavement shall be constructed monolithically. Rapidly deposit the concrete on the crushed stone drainage course in successive batches and distribute to the required depth and for the entire width of the pavement by shoveling or other approved methods. Where bar mats or wire mesh reinforcing is specified, see Paragraphs 3.04 A, B and C for method of concrete placement. Do not use rakes in handling concrete. The placing operation shall be continuous. At the end of the day, or in case of unavoidable interruption or delay of more than 30 minutes, place a transverse construction joint at the point of work stoppage, provided the point at which work has been suspended is not less than 8 feet from the last regularly established joint. If the length is less than 8 feet, remove the concrete back to the last regularly established joint (Refer to Paragraph 3.05C). 1. Inspection: Before placing concrete, inspect and complete formwork installation, steel reinforcement, and items to be embedded or cast in. Notify other trades to permit installation of their work. 2. Remove snow, ice, or frost from subbase surface and reinforcement before placing concrete. Do not place concrete on frozen surfaces. 3. Moisten subbase to provide a uniform dampened condition at time concrete is placed. Do not place concrete around manholes or other structures until they are at required finish elevation and alignment. 4. Comply with ACI 301 requirements for measuring, mixing, transporting, and placing concrete. 5. Do not add water to concrete during delivery or at Project site. 6. Do not add water to fresh concrete after testing. 7. Deposit and spread concrete in a continuous operation between transverse joints. Do not push or drag concrete into place or use vibrators to move concrete into place. 8. Consolidate concrete according to ACI 301 by mechanical vibrating equipment supplemented by hand spading, rodding, or tamping. a. Consolidate concrete along face of forms and adjacent to transverse joints with an internal vibrator. Keep vibrator away from joint assemblies, reinforcement, or side forms. Use only square-faced shovels for hand spreading and consolidation. Concrete Paving 32 13 13 - 18 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 Consolidate with care to prevent dislocating reinforcement, dowels, and joint devices. 9. Screed pavement surfaces with a straightedge and strike off. 10. Commence initial floating using bull floats or darbies to impart an open textured and uniform surface plane before excess moisture or bleed water appears on the surface. Do not further disturb concrete surfaces before beginning finishing operations or spreading surface treatments. 11. Curbs and Gutters: When automatic machine placement is used for curb and gutter placement, submit revised mix design and laboratory test results that meet or exceed requirements. Produce curbs and gutters to required cross section, lines, grades, finish, and jointing as specified for formed concrete. If results are not approved, remove and replace with formed concrete. 12. Slip-Form Pavers: When automatic machine placement is used for pavement, submit revised mix design and laboratory test results that meet or exceed requirements. Produce pavement to required thickness, lines, grades, finish, and jointing as required for formed pavement. a. Compact subbase and prepare subgrade of sufficient width to prevent displacement of paver machine during operations. 13. When adjoining pavement lanes are placed in separate pours, do not operate equipment on concrete until pavement has attained 85 percent of its 28-day compressive strength. 14. Cold-Weather Placement: Comply with ACI 306.1 and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures. a. When air temperature has fallen to or is expected to fall below 40 F (4.4 C), uniformly heat water and aggregates before mixing to obtain a concrete mixture temperature of not less than 50 F (10 C) and not more than 80 F (27 C) at point of placement. b. Do not use frozen materials or materials containing ice or snow. c. Do not use calcium chloride, salt, or other materials containing antifreeze agents or chemical accelerators unless otherwise specified and approved in mix designs. 15. Hot-Weather Placement: Comply with ACI 301 and as follows when hot-weather conditions exist: a. Cool ingredients before mixing to maintain concrete temperature below 90 F (32 C) at time of placement. Chilled mixing water or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water. Using liquid nitrogen to cool concrete is Contractor’s option. b. Cover steel reinforcement with water-soaked burlap so steel temperature will not exceed ambient air temperature immediately before embedding in concrete. c. Fog-spray forms, steel reinforcement, and subgrade just before placing concrete. Keep subgrade moisture uniform without standing water, soft spots, or dry areas. Concrete Paving 32 13 13 - 19 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 3.08 FINISHING A. Machine Finishing: 1. When the concrete has been deposited, level and strike off concrete to such elevation that when mechanically screeded and tamped the concrete is thoroughly compacted and finished to the required line, grade, and section with surface voids filled. Where bar mats or wire mesh reinforcing is specified, see Paragraph 3.04 A and B for method of procedure. 2. After the finishing machine has processed the concrete surface, use the longitudinal float on the surface. Operate the float from parallel bridges or float carriages moving on the side forms. Operate the float transversely across the slab with a sawing motion, always maintaining the float parallel to the center line of the pavement, in such a manner as to remove variations in the surface. Add concrete to fill minor depressions, if needed, during the longitudinal floating operation. The longitudinal float shall not be moved ahead more than one-half its length at each time. The longitudinal float must be maintained straight and free from warp at all times. Take care to preserve the true cross-section of the pavement. 3. While the concrete is still workable, test for irregularities with a 10-foot straightedge placed parallel to the center line of the pavement so as to bridge depressions and to touch high spots. Ordinates measured from the face of the straightedge to the surface of the pavement shall at no place exceed 1/16 inch per foot from the nearest point of contact, and in no case shall the maximum ordinate to a 10-foot straightedge be greater than 1/8 inch. Rework and refinish any surface not within the tolerance limits. 4. While the concrete is still workable, give the surface final belting in order to produce a uniform surface of gritty texture. This belting shall be of short, rapid, transverse strokes combined with a longitudinal sweeping motion. When the burlap drag is permitted in lieu of the belting, accomplish the burlap drag finish by drawing a wet drag over the surface in a longitudinal direction to produce a uniform surface of a gritty nature. 5. Carefully tool the edges of slabs and joints requiring edging with an edger, of the radius required by the plans, at the time the concrete begins to set and becomes non- workable. Leave work smooth and true to lines. B. Hand Finishing: 1. Hand finishing shall be permitted only in intersections, driveways, and parking areas inaccessible to a finishing machine. 2. When the hand method of striking off and consolidating is permitted, level and strike off the concrete, as soon as placed, and screed to such elevation above grade that when consolidated and finished the surface of the pavement is at the grade elevation shown on the plans. Vibrate the entire surface to consolidate the concrete so as to insure maximum compaction and a minimum of voids. For the strike off and consolidation, provide both a strike template and tamping template on the work. Once in operation, move the strike template forward with a combined longitudinal and transverse motion and manipulate so that neither end of the template is raised from the forms during the striking off process. Keep a slight excess of material in front of the cutting edge at all times. Concrete Paving 32 13 13 - 20 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 3. The longitudinal floating, straight edging, belting, and joint finishing shall be as specified above. 3.09 CURING A. The curing of concrete pavement shall be thorough and continuous throughout the entire curing period. Failure to provide proper curing as specified herein shall be considered sufficient cause for immediate suspension of the paving operations. The curing method specified herein does not preclude the use of any of the other commonly used methods of curing, and the Engineer may approve them if so requested by the Contractor. If any selected method of curing does not afford the desired results, the Engineer shall have the right to order that another method of curing be instituted. Immediately after the finishing of the surface, cover the pavement with a continuous, uniform, water-impermeable coating. The impermeable coating shall be of the type specified in Paragraph 2.04D. After removal of the side forms, the sides of the slab shall receive a like coating before earth is banked against them. Apply the solution under pressure with a spray nozzle in such a manner as to cover the entire surfaces thoroughly and completely with a uniform film. B. The rate of application shall be such as to ensure complete coverage and shall not exceed 200 square feet per gallon of curing compound when applied mechanically and 150 square feet per gallon of curing compound when applied by hand sprayers. When thoroughly dry, it shall provide a continuous and flexible membrane, free from cracks or pinholes, and shall not disintegrate, check, peel, or crack during the curing period. If for any reason the seal is broken during the curing period, immediately repair the seal with additional sealing solution. C. When tested in accordance with ASTM C156, the curing compound shall provide a film which will have retained within the test specimen the following percentages of the moisture present in the specimen when the curing compound was applied: Curing Compound – Moisture Retained Time Retained Moisture (Min.) After 24 hours 97% After 3 days 95% After 7 days 91% 3.10 CLEANING JOINTS A. Immediately after sawing the joint, completely remove the resulting slurry from the joint and clean the immediate area by flushing with a jet of water under pressure, and by the use of other tools as necessary. After flushing, blow out the joint with compressed air. When the surfaces are thoroughly clean and dry and just before the joint sealer is placed, use compressed air having a pressure of at least 90 psi to blow out the joint and remove traces of dust. Equip air compressors, used for cleaning joints, with suitable traps capable of removing surplus water and oil in the compressed air. B. In the event freshly cut sawed joints become contaminated before they are sealed, reclean the joints as outlined above. Concrete Paving 32 13 13 - 21 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 C. Cleaning methods shall not alter the joint profile, including rounding of the top corners, or alter the texture of the concrete riding surface. Accomplish cleaning of the joint faces by sandblasting. 3.11 INSTALLING BACKER-ROD IN JOINT A. Prior to placing the backer-rod, thoroughly dry and clean the joint. Complete any necessary cleaning, air blasting, or air-drying before placing backer-rod and sealant. If backer-rod specified for applicable joint detail are on joints less than 1 inch wide after cleaning, install a round backer-rod of resilient material, compatible with silicone sealant, and slightly oversized to prevent movement during the sealing operation in the joint at the depth specified on the appropriate joint detail in the plans. The thickness of the backer-rod shall be greater after squeezing it into the joint and some “rebound” may occur allowance must be made for this to ensure placing at correct depth. Backer-rod shall be a readily compressible, non-reactive, non-absorptive type material such as expanded closed cell polyethylene foam rod. 3.12 INSTALLING SILICONE SEALANT A. The installation of the silicone sealant is to be done as soon after cleaning and after placing the backer-rod as reasonably possible to ensure that joint is still clean and dry. In the event the joint does become contaminated, damp, or wet, remove the backer-rod, clean and dry the joint, and reinstall a new backer-rod prior to placing the sealant material. The sealant material used shall be a low modulus silicone sealant material as specified. The temperature of the concrete surface and air at time of placement must be 40 F or higher. Apply the silicone sealant by pumping only. B. The pump shall be of sufficient capacity to deliver the necessary volume of material to completely fill the joint to the specified width and height of sealant in one pass. The nozzle shall be of sufficient size and shape to closely fit into the joint and introduce the sealant inside the joint with sufficient pressure to prevent voids occurring in the sealant and to force the sealant into contact with the joint faces. Tool the sealant, after being placed, to provide the specified recess depth, thickness, and shape of sealant. Apply sufficient force or pressure to the sealant in this tooling operation to force the sealant against the joint faces to ensure satisfactory wetting and bonding of the sealant to the joint faces. The silicone sealant is not self-leveling and will not position itself correctly in the joint under its own weight. Place the sealant to reasonably close conformity with the dimensions and shape shown on the plans. Any unreasonable deviation shall be cause for rejection and necessary corrective action shall be made by the Contractor. 3.13 PAVEMENT TOLERANCES A. Comply with tolerances of ACI 117 and as follows: 1. Elevation: 1/4 inch. 2. Thickness: Plus 3/8 inch, minus 1/4 inch. 3. Surface: Gap below 10-foot long, unleveled straightedge not to exceed 1/4 inch. 4. Lateral Alignment and Spacing of Tie Bars and Dowels: 1 inch. 5. Vertical Alignment of Tie Bars and Dowels: 1/4 inch. Concrete Paving 32 13 13 - 22 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 6. Alignment of Tie-Bar End Relative to Line Perpendicular to Pavement Edge: 1/2 inch. 7. Alignment of Dowel-Bar End Relative to Line Perpendicular to Pavement Edge: Length of dowel 1/4 inch per 12 inches. 8. Joint Spacing: 3 inches. 9. Contraction Joint Depth: Plus 1/4 inch, no minus. 10. Joint Width: Plus 1/8 inch, no minus. 3.14 PAVEMENT MARKING A. Do not apply pavement-marking paint until layout, colors, and placement have been verified with Engineer. B. Allow concrete pavement to cure for 28 days and be dry before starting pavement marking. C. Sweep and clean surface to eliminate loose material and dust. D. Apply paint with mechanical equipment to produce pavement markings of dimensions indicated with uniform, straight edges. Apply at manufacturer’s recommended rates to provide a minimum wet film thickness of 15 mils. 3.15 OPENING PAVEMENT TO TRAFFIC A. Exclude traffic from the pavement for a period of not less than 14 days unless the Engineer directs that sections be opened to traffic at an earlier date. On sections of the pavement where the use of Type III cement is required, or permitted, the pavement may be opened to traffic after 4 days. Should tests of beam specimens show a flexural strength of not less than 500 pounds per square inch, the Engineer may direct that the pavement so represented be opened to traffic in less than 14 days and for Type III cement in less than 4 days. In all cases, clean the pavement and fill and trim the joints before opening to public. B. When it is necessary to provide for traffic across the pavement, construct, at the Contractor’s own expense, suitable and substantial crossings over the concrete which will be adequate for the traffic using same. C. Opening pavement to traffic shall not relieve the Contractor of responsibility for the work and shall not in any way affect the time charge on the entire project. The number of days stated in the contract shall govern for the completion of the entire work covered by the contract. 3.16 FIELD QUALITY CONTROL; TESTING OF MATERIALS A. Samples of all materials for test shall be made at the expense of the Owner. In the event the initial sampling and testing does not comply with the specifications, all subsequent testing of the material in order to determine if the material is acceptable, shall be at the Contractor’s expense at the same rate charged by the commercial laboratories. 1. Testing Agency: Engage a qualified independent testing and inspecting agency to perform field tests and inspections and prepare test reports. 2. Testing Services: Testing of composite samples of fresh concrete obtained according to ASTM C172 shall be performed according to the following requirements: Concrete Paving 32 13 13 - 23 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 a. Testing Frequency: Obtain at least 1 composite sample for each 100 cu. yd. or fraction thereof of each concrete mix placed each day. 1). When frequency of testing will provide fewer than five compressive-strength tests for each concrete mixture, testing shall be conducted from at least five randomly selected batches or from each batch if fewer than five are used. b. Slump: ASTM C143/C143M; one test at point of placement for each composite sample, but not less than one test for each day’s pour of each concrete mix. Perform additional tests when concrete consistency appears to change. c. Air Content: ASTM C231, pressure method; one test for each composite sample, but not less than one test for each day’s pour of each concrete mix. d. Concrete Temperature: ASTM C1064; one test hourly when air temperature is 40 F and below and when 80 F and above, and one test for each composite sample. e. Compression Test Specimens: ASTM C31/C31M; cast and laboratory cure one set of three standard cylinder specimens for each composite sample. f. Compressive-Strength Tests: ASTM C39/C39M; test one specimen at 7 days and two specimens at 28 days. 1). A compressive-strength test shall be the average compressive strength from two specimens obtained from same composite sample and tested at 28 days. 3. Strength of each concrete mix will be satisfactory if average of any three consecutive compressive-strength tests equals or exceeds specified compressive strength and no compressive-strength test value falls below specified compressive strength by more than 500 psi (3.4 MPa). 4. Test results shall be reported in writing to Engineer, concrete manufacturer, and Contractor within 48 hours of testing. Reports of compressive-strength tests shall contain Project identification name and number, date of concrete placement, name of concrete testing and inspecting agency, location of concrete batch in Work, design compressive strength at 28 days, concrete mixture proportions and materials, compressive breaking strength, and type of break for both 7-day and 28-day tests. 5. Nondestructive Testing: Impact hammer, sonoscope, or other nondestructive device may be permitted by Engineer but will not be used as sole basis for approval or rejection of concrete. 6. Additional Tests: Testing and inspecting agency shall make additional tests of concrete when test results indicate that slump, air entrainment, compressive strengths, or other requirements have not been met, as directed by Engineer. 7. Remove and replace concrete pavement where test results indicate that it does not comply with specified requirements. 8. Additional testing and inspecting, at Contractor’s expense, will be performed to determine compliance of replaced or additional work with specified requirements. 3.17 REPAIRS AND PROTECTION Concrete Paving 32 13 13 - 24 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 A. Remove and replace concrete pavement that is broken, damaged, or defective or that does not comply with requirements in this Section. B. Drill test cores, where directed by Engineer, when necessary to determine magnitude of cracks or defective areas. Fill drilled core holes in satisfactory pavement areas with Portland cement concrete bonded to pavement with epoxy adhesive. C. Protect concrete from damage. Exclude traffic from pavement for at least 14 days after placement. When construction traffic is permitted, maintain pavement as clean as possible by removing surface stains and spillage of materials as they occur. D. Maintain concrete pavement free of stains, discoloration, dirt, and other foreign material. Sweep concrete pavement not more than 2 days before date scheduled for Substantial Completion inspections. 3.18 SCHEDULES A. See Table I for silicone sealant requirements: Table 1 - Silicone Sealant Requirements Item Requirement Test Method Flow 0.3” Max. MIL S 8801 ASTM D2202 Extrusion rate 75-350 grams/minute MIL S 8802 Tack free time @ 77 F±1 20-90 minutes MIL S 8802 ASTM C679 Specific Gravity 1.010-1.515 ASTM D792 Durometer Hardness, Shore A. ( 7 days cured @ 77 F±3 and 45-55% relative humidity 10-25 (0 F) ASTM D2240 Tensile stress @ 150% elongation ( 7 day cure @ 77 F ± 3 and 45-55% Relative Humidity) 45 psi maximum ASTM D412 (Die C) Elongation: (7 day cure @ 77 F ± 3 and 45-55% Relative Humidity) 700% minimum ASTM D412 (Die C) Ozone and UV Resistance No chalking, cracking, or bond loss after 5000 hours ASTM D793 Movement Capability and Adhesion +100% and -50%; no adhesive or cohesive failure after 10 cycles at 0 F ASTM C719 Shelf Life 6 months from date of shipment from manufacturer Silicone Sealant material shall meet or exceed Federal Specifications TT-S-001543A (COM- NBS) and TT-S-00230CC (COM-NBS) END OF SECTION High-Security Chain Link Fences and Gates 32 31 13.53 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 32 31 13.53 HIGH-SECURITY CHAIN LINK FENCES AND GATES 1.00 GENERAL 1.01 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.02 SUMMARY A. This Section includes the following: 1. High-security chain-link fences. 2. Gates: Horizontal top trolley cantilever slide and swing. B. Related Sections include the following: 1. Section 03 30 00 “Cast-In-Place Concrete” for concrete post concrete fill and continuous concrete grade beam. 1.03 PERFORMANCE REQUIREMENTS A. Structural Performance: Provide chain-link fences and gates capable of withstanding the effects of gravity loads and the following loads and stresses within limits and under conditions indicated: 1. Line Post Design: Provide line posts of size and in spacing indicated but not less than sizes and spacings required to comply with ASTM F1916, Tables 1 through 5 inclusive in resisting the following wind-load criteria, based on fence height, mesh size, and pattern indicated: a. Design Wind Loads: Determine design wind loads applicable to Project from basic wind speed and exposure category indicated below and according to CLFMI WLG 2445: 1). Wind Speed: 90 mph. 2). Exposure Category: C. b. Fence Height: 6 feet. c. Fence Framework Material Group: IA, ASTM F1043, Schedule 40 steel pipe. 2. Provide framework for fences that comply with ASTM F1043, based on the following criteria: a. Fence Framework Material Group: IA, Schedule 40 round steel pipe. b. Fence Height: 6 feet. c. Line Post Spacing: 10 feet (3 m). 3. Fabric Tension: Provide fences in which fabric deflections do not exceed those indicated in Table X1.1 of ASTM F1916 when tested by applying a 30-lbf (133-N) force at midpoint High-Security Chain Link Fences and Gates 32 31 13.53 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 between rails and horizontally between posts for every eighth lower panel along the fence line. 4. Fence Post Rigidity: Provide fences in which post deflections do not exceed 3/4 inch (19 mm) when tested according to ASTM F1916 by applying a 50-lbf (222-N) force at mid- height of every eighth post along the fence line. B. Lightning Protection System: Maximum grounding-resistance value of 25 ohms under normal dry conditions. 1.04 SUBMITTALS A. Product Data: Include construction details, material descriptions, dimensions of individual components and profiles, and finishes for chain-link fences and gates: 1. Fence and gate posts, rails, and fittings. 2. Chain-link fabric, reinforcements, and attachments. 3. Gates and hardware. 4. Accessories: Barbed tape. B. Shop Drawings: Show locations of fences, gates, posts, rails, tension wires, details of extended posts, extension arms, gate swing, or other operation, hardware, and accessories. Indicate materials, dimensions, sizes, weights, and finishes of components. Include plans, gate elevations, sections, details of post anchorage, attachment, bracing, and other required installation and operational clearances. 1. For installed products indicated to comply with design loads, include structural analysis data signed and sealed by the qualified professional engineer responsible for their preparation. C. Product Certificates: For each type of chain-link fence, and gate, signed by product manufacturer. 1. Strength test results for framing according to ASTM F1043. D. Qualification Data: For Installer. 1.05 QUALITY ASSURANCE A. Installer Qualifications: An experienced installer who has completed chain-link fences and gates similar in material, design, and extent to those indicated for this Project and whose work has resulted in construction with a record of successful in-service performance. 1. Engineering Responsibility: Preparation of data for chain-link fences and gates, including Shop Drawings, based on testing and engineering analysis of manufacturer’s standard units in assemblies similar to those indicated for this Project. 1.06 PROJECT CONDITIONS A. Field Measurements: Verify layout information for chain-link fences and gates shown on Drawings in relation to property survey and existing structures. Verify dimensions by field measurements. High-Security Chain Link Fences and Gates 32 31 13.53 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 B. Interruption of Existing Utility Services: Do not interrupt utility services to 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: 1. Notify Owner no fewer than 2 days in advance of proposed interruption of utility services. 2. Do not proceed with interruption of utility services without Owner’s written permission. 1.07 COORDINATION A. Coordinate, schedule, and obtain Owner’s written approval of interruptions to existing perimeter security fences and systems for installation of new Work. 1.08 WARRANTY A. Special Warranty: Manufacturer’s standard form in which Installer agrees to repair or replace components of high-security chain-link fences and gates that fail in materials or workmanship within specified warranty period. 1. Failures include, but are not limited to, the following: a. Faulty operation of gate operators and controls. b. Deterioration of metals, metal finishes, and other materials beyond normal weathering. c. Deflection of fence fabric beyond design limits. 2. Warranty Period: 5 years from date of Substantial Completion. 2.00 PRODUCTS 2.01 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. Chain-Link Fences and Gates: a. Ameristar Fence b. Southwest wire c. Merchants metal d. General Wire and Supply Co. 2. Barbed Tape: a. Razor Ribbon b. Birmingham Barbed Tape c. Puma Barbed Tape Co. d. Jacksons Security. High-Security Chain Link Fences and Gates 32 31 13.53 - 4 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2.02 CHAIN-LINK FENCE FABRIC A. Chain-Link Fence Fabric: 6 foot. Provide fabric in one-piece heights measured between top and bottom of outer edge of selvage. Comply with ASTM A392, CLFMI CLF 2445, and with requirements indicated below: 1. Steel Wire Fabric: Metallic coated. 2. Fabric 6 feet (1.8 m) high. a. Wire Diameter: 0.148 inch (3.76 mm). b. Mesh Size: 2 inch (51 mm) with 1 inch at Personnel gate. c. Weight of Metallic (Zinc) Coating: ASTM A392, Type II, Class 1, 1.2 oz/sq. ft. (366 g/sq. m) with zinc coating applied before weaving. d. Coat selvage ends of fabric that is metallic coated before the weaving process with manufacturer’s standard clear protective coating. 3. Selvage: Twisted and barbed top and bottom. 2.03 SECURITY FENCE FRAMING A. Posts and Rails: Comply with ASTM F1043 for framing of the following material group and strength requirement for fences of height indicated: 1. Framework Material Group: IA, round steel pipe, Schedule 40. 2. Fence Height: 6 feet (1.8 m). 3. Strength Requirement: Heavy industrial fence. 4. Post Diameter and Thickness: Provide posts of sizes indicated below that comply with ASTM F1043. a. Top Rail: 1.66-inch (42.2-mm) diameter, 0.140-inch (3.6-mm) thickness. b. Line Post: 2.875-inch (73-mm) diameter, 0.203-inch (5.2-mm) thickness]. c. End, Corner, and Pull Post: 4-inch (102-mm) diameter, 0.237-inch (6.02-mm) thickness. d. Swing Gate Post: According to ASTM F900 e. Horizontal-Slide Gate Post: According to ASTM F1184. 1). Openings up to 24 Feet (7.3 m), Overhead Clearance up to 22 Feet (6.7 m): Steel post, 4-inch (102-mm) diameter, and 8.65-ft-lb (12.88-kg/m) weight. 2). Guide Posts for Class 1 horizontal-slide gates, equal gate post height, one size smaller, but weight is not less than 3.11 ft-lb (4.63-kg/m), installed adjacent to gate post to permit gate to slide in space between. 5. Metallic Coatings for Steel Framing: a. Type A, consisting of not less than minimum 2.0-oz./sq. ft. (0.61-kg/sq. m) average zinc coating per ASTM A123/A123M or 4.0-oz./sq. ft. (1.22-kg/sq. m) zinc coating per ASTM A653/A653M. High-Security Chain Link Fences and Gates 32 31 13.53 - 5 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2.04 TENSION WIRE A. General: Provide horizontal tension wire at the following locations: 1. Location: Extended along bottom of fence fabric. 2. Location: Extended along top of barbed wire arms and top of fence fabric for supporting barbed tape. B. Metallic-Coated Steel Wire: 0.177-inch (4.5-mm) diameter, marcelled tension wire complying with ASTM A824 and the following: 1. Metallic Coating: Type [II, zinc coated (galvanized) by hot-dip process, with the following minimum coating weight: a. Class 3: Not less than 2.0 oz./sq. ft. (610 g/sq. m) of uncoated wire surface. 2.05 SWING GATES A. General: Comply with ASTM F900 for double swing gate types. 1. Metal Pipe and Tubing: Galvanized steel. Comply with ASTM F1043 and ASTM F1083 for materials and protective coatings. 2. Metal Pipe and Tubing: Steel. Comply with ASTM B429 and ASTM F1043 for materials and protective coatings. B. Frames and Bracing: Fabricate members from round, galvanized steel tubing with outside dimension and weight according to ASTM F900 and the following: 1. Gate Fabric Height: 2 inches (51 mm) less than adjacent fence height. 2. Leaf Width: As indicated. 3. Frame Members: a. Tubular Steel: 2.875 inches (73 mm) round. C. Frame Corner Construction: 1. Welded and 3/8-inch (9.5-mm) diameter, adjustable truss rods for panels 5 feet (1.52 m) wide or wider. D. Extended Gate Posts and Frame Members: Extend gate posts and frame end members above top of chain-link fabric at both ends of gate frame 12 inches (305 mm)] [as indicated as required to attach barbed wire and tape assemblies. E. Provide separate isolated gate frame according to ASTM F1916 and as indicated. 1. Group: IA, round steel pipe, Schedule 40]. 2. Post: 4 inches (102 mm) and refer to drawings. 3. Separation between Hinge and Latch Post and Fence Termination Post: 2 inches (51 mm) minimum, 2-1/2 inches (63.5 mm) maximum. F. Hardware: 1. Hinges: Offset type, malleable iron, 180-degree swing. High-Security Chain Link Fences and Gates 32 31 13.53 - 6 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2. Latches permitting operation from both sides of gate. Fabricate latches with integral eye openings for padlocking; padlock accessible from both sides of gate. 2.06 HORIZONTAL-SLIDE GATES A. General: Comply with ASTM F1184 for single slide gate types and refer to drawings: 1. Classification: Type II Cantilever Slide, Class 2 with internal roller assemblies. 2. Metal Pipe and Tubing: Galvanized steel. Comply with ASTM F1184 for materials and protective coatings. B. Frames and Bracing: Fabricate members from round, galvanized steel tubing with outside dimension and weight according to ASTM F1184 and the following: 1. Gate Fabric Height: 6 feet (1.8 m). 2. Gate Opening Width: 24 feet (1.2 m). 3. Frame Members: a. Tubular Steel 1.90 inches (48.3 mm) round. 4. Bracing Members: a. Tubular Steel 1.90 inches (48.3 mm) round. C. Frame Corner Construction: 1. Welded frame with panels assembled with bolted or riveted corner fittings and 5/16- inch (7.9-mm) diameter, adjustable truss rods for panels 5 feet (1.52 m) wide or wider. D. Extended Gate Posts and Frame Members: Extend gate posts and frame end members above top of chain-link fabric at both ends of gate frame 12 inches (305 mm) as required to attach barbed tape assemblies. E. Roller Guards: As required per ASTM F1184 for Type II, Class 1 gates. F. Hardware: 1. Latches permitting operation from both sides of gate. Fabricate latches with integral eye openings for padlocking; padlock accessible from both sides of gate. 2. Padlocks and chains. Verify with owner’s keying requirements. 2.07 FITTINGS A. General: Comply with ASTM F626. 1. Line post caps with loop to receive tension wire or top rail. B. Rail and Brace Ends: Attach rails securely to each gate, corner, pull, and end post. C. Rail Fittings: Provide the following: 1. Rail Clamps: Line and corner boulevard clamps for connecting intermediate rails in the fence line to line posts. D. Tension and Brace Bands: Pressed steel, 0.105 inch (2.66 mm) thick, with 1.2-oz/sq. ft. (366- g/sq. m) metallic (zinc) coating. High-Security Chain Link Fences and Gates 32 31 13.53 - 7 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 E. Tension Bars: Steel, length not less than 2 inches (51 mm) shorter than full height of chain- link fabric with 1.2-oz/sq. ft. (366-g/sq. m) metallic (zinc) coating. Provide one bar for each gate and end post, and two for each corner and pull post unless fabric is integrally woven into post. F. Truss Rod Assemblies: Steel, hot-dip galvanized after threading rod and turnbuckle or other means of adjustment. G. Barbed Wire Arms: Pressed steel or cast iron, with clips, slots, or other means for attaching strands of barbed wire , and means for attaching to posts , integral with post cap; for each post, unless otherwise indicated, and as follows: 1. Line posts with arms designed with opening to accommodate top rail or tension wire. 2. Corner arms at fence corner posts, unless extended posts are indicated. 3. Type I, single slanted arm. 4. Bolts or rivets for connection to post. H. Tie Wires, Clips, and Fasteners: According to ASTM F626 and ASTM F1916. 1. High-Security Round Wire Ties: For attaching chain-link fabric to posts, rails, and frames, complying with the following: A. Weight of Metallic (Zinc) Coating: ASTM A641/A 641M, Class B, 2.0 oz./sq. ft. (610 g/sq. m). 2.08 BARBED WIRE A. Zinc-Coated Steel Barbed Wire: Comply with ASTM A121, Chain-Link Fence grade for the following two-strand barbed wire: 1. Standard Size and Construction: 0.099-inch (2.51-mm) diameter line wire with 0.080- inch (2.03-mm) diameter, two-point round barbs spaced not more than 3 inches (76 mm) o.c. 2.09 GROUT AND ANCHORING CEMENT A. Nonshrink, Nonmetallic Grout: Premixed, factory-packaged, nonstaining, noncorrosive, nongaseous grout complying with ASTM C1107. Provide grout, recommended in writing by manufacturer, for exterior applications. B. Erosion-Resistant Anchoring Cement: Factory-packaged, nonshrink, nonstaining, hydraulic- controlled expansion cement formulation for mixing with potable water at Project site to create pourable anchoring, patching, and grouting compound. Provide formulation that is resistant to erosion from water exposure without needing protection by a sealer or waterproof coating and that is recommended in writing by manufacturer for exterior applications. 2.10 FENCE GROUNDING A. Conductors: Bare, solid wire for No. 6 AWG and smaller; stranded wire for No. 4 AWG and larger. 1. Material above Finished Grade: Copper. High-Security Chain Link Fences and Gates 32 31 13.53 - 8 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 2. Material on or below Finished Grade: Copper. 3. Bonding Jumpers: Braided copper tape, 1 inch (25.4 mm) wide, woven of No. 30 AWG bare copper wire, terminated with copper ferrules. B. Connectors and Grounding Rods: Listed in UL 467. 1. Connectors for Below-Grade Use: Exothermic welded type. 2. Grounding Rods: Copper-clad steel. a. Size: 5/8 by 96 inches (16 by 2400 mm). 3.00 EXECUTION 3.01 EXAMINATION A. Examine areas and conditions, with Installer present, for compliance with requirements for a verified survey of property lines and legal boundaries, site clearing, earthwork, pavement work, and other conditions affecting performance. 1. Do not begin installation before final grading is completed, unless otherwise permitted by Architect. 2. Proceed with installation only after unsatisfactory conditions have been corrected. 3.02 PREPARATION A. Stake locations of fence lines, gates, and terminal posts. Do not exceed intervals of 500 feet (152 m) or line of sight between stakes. Indicate locations of utilities, lawn sprinkler system, underground structures, benchmarks, and property monuments. 3.03 INSTALLATION, GENERAL A. Install chain-link fencing to comply with ASTM F567 and more stringent requirements specified. 1. Install fencing on established boundary lines inside property line. 3.04 CHAIN-LINK FENCE INSTALLATION A. Post Excavation: Drill or hand-excavate holes for posts to diameters and spacings indicated, in firm, undisturbed soil. B. Post Setting: Set posts in concrete at indicated spacing into firm, undisturbed soil. 1. Verify that posts are set plumb, aligned, and at correct height and spacing, and hold in position during setting with concrete or mechanical devices. 2. Concrete Fill: Place concrete around posts to dimensions indicated and vibrate or tamp for consolidation. Protect aboveground portion of posts from concrete splatter. a. Exposed Concrete: Extend 2 inches (51 mm) above grade or to same elevation as concrete grade beam; shape and smooth to shed water. C. Terminal Posts: Locate terminal end, corner, and gate posts per ASTM F567 and terminal pull posts at changes in horizontal or vertical alignment of as indicated on Drawings. High-Security Chain Link Fences and Gates 32 31 13.53 - 9 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 D. Line Posts: Space line posts uniformly at 10 feet (3 m) o.c. E. Post Bracing and Intermediate Rails: Install according to ASTM F567, maintaining plumb position and alignment of fencing. Install braces at end and gate posts and at both sides of corner and pull posts. 1. Locate horizontal braces at mid-height of fabric 6 feet (1.8 m) or higher, on fences with top rail and at two-thirds fabric height on fences without top rail. Install so posts are plumb when diagonal rod is under proper tension. F. Barbed Wire Arms: Bolt or rivet to top of post. Angle single arms away from approach side of fence. G. Tension Wire: Install according to ASTM F567 and ASTM F1916, maintaining plumb position and alignment of fencing. Pull wire taut, without sags. Fasten fabric to tension wire with 0.120-inch (3.05-mm) diameter hog rings of same material and finish as fabric wire, spaced a maximum of 24 inches (610 mm) o.c. Install tension wire in locations indicated before stretching fabric. 1. Bottom Tension Wire: Install tension wire within 6 inches (152 mm) of bottom of fabric and tie to each post with not less than same diameter and type of wire. H. Top Rail: Install according to ASTM F567, maintaining plumb position and alignment of fencing. Run rail continuously through line post caps, bending to radius for curved runs and terminating into rail end attached to posts or post caps fabricated to receive rail at terminal posts. Provide expansion couplings as recommended by fencing manufacturer. I. Chain-Link Fabric: Apply fabric to inside of enclosing framework. Pull fabric taut and tie to posts, rails, and tension wires. Anchor to framework so fabric remains under tension after pulling force is released. 1. Leave 1 inch (25.4 mm) between finish grade or surface and bottom selvage, unless otherwise indicated. 2. Overlapping Fabric: At or between post or rail according to ASTM F1916 with wire ties or steel strap method. J. Concrete Grade Beams: Cast-in-place concrete, depth not less than 12 inches (305 mm) below grade and as indicated on Drawings; slope top surface to drain. K. Tension or Stretcher Bars: Thread through fabric and secure to end, corner, pull, and gate posts with tension bands spaced not more than 15 inches (381 mm) o.c. L. Tie Wires: Power-fastened or manually fastened ties configured to wrap a full 360 degrees around rail or post and a minimum of one complete diamond of fabric. Twist ends one and one-half machine twists or three full manual twists, and cut-off protruding ends to preclude untwisting by hand. 1. Maximum Spacing: Tie fabric to line posts at 12 inches (305 mm) o.c. and to braces at 24 inches (610 mm) o.c. 2. Fasten fabric to line posts 12 inches (305 mm) o.c. and to braces 24 inches (610 mm) o.c. M. Fasteners: Install nuts for tension bands and carriage bolts on the side of fence opposite the fabric side. Peen ends of bolts or score threads to prevent removal of nuts. High-Security Chain Link Fences and Gates 32 31 13.53 - 10 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 N. Barbed Wire: Install barbed wire uniformly spaced as indicated on Drawings. Pull wire taut and install securely to extension arms and secure to end post or terminal arms. O. Barbed Tape: Install barbed tape uniformly in configurations indicated and fasten securely to prevent movement or displacement according to ASTM F1911. P. Grounding Barrier Stakes: Stake coils at 10 feet (3 m) o.c., driven to full depth. 3.05 GATE INSTALLATION A. Install gates according to manufacturer’s written instructions, level, plumb, and secure for full opening without interference. Attach fabric as for fencing. Attach hardware using tamper-resistant or concealed means. Install ground-set items in concrete for anchorage. Adjust hardware for smooth operation and lubricate where necessary. 3.06 GROUNDING AND BONDING A. Fence Grounding: Install at maximum intervals of 100 feet (30 m) except as follows: 1. Gates and Other Fence Openings: Ground fence on each side of opening. a. Bond metal gates to gate posts. b. Bond across openings, with and without gates, except openings indicated as intentional fence discontinuities. Use No. 2 AWG wire and bury it at least 18 inches (457 mm) below finished grade. B. Protection at Crossings of Overhead Electrical Power Lines: Ground fence at location of crossing and at a maximum distance of 150 feet (45 m) on each side of crossing. C. Fences Enclosing Electrical Power Distribution Equipment: Ground as required by IEEE C2, unless otherwise indicated. D. Grounding Method: At each grounding location, drive a grounding rod vertically until the top is 6 inches (152 mm) below finished grade. Connect rod to fence with No. 6 AWG conductor. Connect conductor to each fence component at grounding location, including the following: 1. Each Barbed Wire Strand. Make grounding connections to barbed wire with wire-to- wire connectors designed for this purpose. 2. Each Barbed Tape Coil: Make grounding connections to barbed tape with connectors designed for this purpose. E. Bonding Method for Gates: Connect bonding jumper between gate post and gate frame. F. Connections: Make connections so possibility of galvanic action or electrolysis is minimized. Select connectors, connection hardware, conductors, and connection methods so metals in direct contact will be galvanically compatible. 1. Use electroplated or hot-tin-coated materials to ensure high conductivity and to make contact points closer in order of galvanic series. 2. Make connections with clean, bare metal at points of contact. 3. Make aluminum-to-steel connections with stainless-steel separators and mechanical clamps. High-Security Chain Link Fences and Gates 32 31 13.53 - 11 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 4. Make aluminum-to-galvanized-steel connections with tin-plated copper jumpers and mechanical clamps. 5. Coat and seal connections having dissimilar metals with inert material to prevent future penetration of moisture to contact surfaces. 3.07 FIELD QUALITY CONTROL A. Fabric Testing: Test fabric tension according to ASTM F1916. B. Fence Post Rigidity Testing: Test line posts for rigidity according to ASTM F1916. C. Grounding-Resistance Testing: Engage a qualified independent testing and inspecting agency to perform field tests and inspections and prepare test reports. 1. Grounding-Resistance Tests: Subject completed grounding system to a megger test at each grounding location. Measure grounding resistance not less than 2 full days after last trace of precipitation, without soil having been moistened by any means other than natural drainage or seepage and without chemical treatment or other artificial means of reducing natural grounding resistance. Perform tests by two-point method according to IEEE 81. 2. Excessive Grounding Resistance: If resistance to grounding exceeds specified value, notify Architect promptly. Include recommendations for reducing grounding resistance and a proposal to accomplish recommended work. 3. Report: Prepare test reports, certified by testing agency, of grounding resistance at each test location. Include observations of weather and other phenomena that may affect test results. 3.08 ADJUSTING A. Gate: Adjust gate to operate smoothly, easily, and quietly, free of binding, warp, excessive deflection, distortion, nonalignment, misplacement, disruption, or malfunction, throughout entire operational range. Confirm that latches and locks engage accurately and securely without forcing or binding. END OF SECTION Soil Preparation 32 91 13 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 32 91 13 SOIL PREPARATION 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to place topsoil, free from rock and foreign material in areas designated to receive sodding or seeding. 2.00 PRODUCTS 2.01 TOPSOIL A. General: The topsoil shall be fertile loam, easily cultivated and free from objectionable material, and shall have a relatively high erosion resistance and be readily able to support the growth of the planting, seeding, or sodding specified on the plans. B. Sources: 1. The topsoil may be obtained from the right-of-way at sites of proposed excavation, or it may be obtained from sources outside the right-of-way, secured by the Contractor, and meeting the approval of the Engineer. 2. Topsoil required in addition to salvaged topsoil from the project shall be secured from approved off-site borrow sources. Excavated material from construction which is suitable for topsoil shall be salvaged and used before any topsoil is obtained from borrow source. 3.00 EXECUTION 3.01 INSTALLATION A. Stockpile topsoil material at locations approved by the Owner’s Representative. Remove any trash, wood, brush, stumps or other objectionable materials prior to placement. The source and stockpile areas shall be kept drained and in a neat and presentable condition. Place and spread topsoil to a uniform depth to provide 6-inch compacted depth, while maintaining drainage in areas to be seeded or sodded. END OF SECTION Topsoil Placement and Grading 32 91 19.13 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 32 91 19.13 TOPSOIL PLACEMENT AND GRADING 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to place topsoil, free from rock and foreign material in areas designated to receive sodding or seeding. 2.00 PRODUCTS 2.01 TOPSOIL A. General: The topsoil shall be fertile loam, easily cultivated and free from objectionable material, and shall have a relatively high erosion resistance and be readily able to support the growth of the planting, seeding, or sodding specified on the plans. B. Sources: 1. The topsoil may be obtained from the right-of-way at sites of proposed excavation, or it may be obtained from sources outside the right-of-way, secured by the Contractor, and meeting the approval of the Engineer. 2. Topsoil required in addition to salvaged topsoil from the project shall be secured from approved off-site borrow sources. Excavated material from construction which is suitable for topsoil shall be salvaged and used before any topsoil is obtained from borrow source. 3.00 EXECUTION 3.01 INSTALLATION A. Stockpile topsoil material at locations approved by the Owner’s Representative. Remove any trash, wood, brush, stumps or other objectionable materials prior to placement. The source and stockpile areas shall be kept drained and in a neat and presentable condition. Place and spread topsoil to a uniform depth to provide 6-inch compacted depth, while maintaining drainage in areas to be seeded or sodded. END OF SECTION Hydro-Mulching 32 92 13 - 1 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 32 92 13 HYDRO-MULCHING 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, material, equipment and incidentals necessary to prepare the ground, furnish and install fertilizer and hydro-mulching seed or a mixture of seed of the kind specified in areas disturbed by the construction operations. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Texas Testing Seed Label. 2. Specification of fertilizer to be used. 1.03 STANDARDS A. The applicable provision of the following standard shall apply as if written here in its entirety: 1. Texas Seed Law. 1.04 GUARANTEES A. The Contractor shall fertilize and reseed any area which fails to survive for a period of 1 year from the date the project is accepted by the Owner. 2.00 PRODUCTS 2.01 MATERIALS A. General: Seed used must carry a Texas Testing Seed label showing purity and germination, name, type of seed, and that the seed meets all requirements of the Texas Seed Law. Seed furnished shall be of the previous season’s crop and the date of analysis shown on each tag shall be within 9 months of the time of delivery to the project. Each variety of seed shall be furnished and delivered in separate bags or containers. B. Seed: The specified seed shall equal or exceed the following percentages of purity and germination: Common Name Purity Germination Common Bermuda Grass 95% 90% Gulf Coast Annual Rye 95% 90% C. Mulch: The mulch shall be natural cellulose fiber mulch produced from grinding clean, whole wood chips, or fiber produced from ground newsprint with a labeled ash content not to exceed 7 percent. The mulch shall be designed for use in conventional mechanical planting, hydraulic planting of seed or hydraulic mulching of grass seed, either alone or with Hydro-Mulching 32 92 13 - 2 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 fertilizers and other additives. The mulch shall be such that, when applied, the material shall form a strong, moisture-retaining mat without the need of an asphalt binder. D. Fertilizer: Pelleted or granulated type fertilizer of the composition for the season of the year at which applied shall be used: 1. Early season (April 1-June 1) 21-0-0. 2. Normal season (June 1-Sept 1) 10-10-5. 3. Late season (Sept 1-Nov 1) 6-12-12. 3.00 EXECUTION 3.01 PREPARATION A. After the areas disturbed by construction operations have been backfilled and completed to the original pre-construction lines and grades shown on the plans and as provided for in other items of this contract, perform hydro-mulch seeding in accordance with the requirements hereinafter described. 3.02 INSTALLATION A. Cultivation: Cultivate areas to be seeded to a depth of at least 4 inches. Cultivate the seedbed sufficiently to reduce the soil to a state of good tilth when the soil particles on the surface are small enough and lie closely enough together to prevent the seed from being covered too deep for optimum germination. Cultivation of seedbed will not be required in loose sand where depth of sand is 4 inches or more. Maintain the cross-section previously established throughout the process of cultivation and any necessary reshaping shall be done prior to any planting of seed. B. Planting Season and Application Rates: Perform planting between the dates specified for each type except when specifically authorized in writing. The seeds planted per acre shall be of the type specified with the mixture, rate, and planting dates as follows: 1. Common Bermuda Grass - hulled, 20 pounds per acre - February through August or a combination of. 2. Common Bermuda Grass - unhulled, 15 pounds per acre and Gulf Coast Annual Rye - unhulled, 15 pounds per acre - August through February. 3. Apply fertilizer uniformly at the average rate of 400 pounds per acre. C. Hydro-Mulch (Cellulose Fiber) Seeding: Uniformly distribute the fertilizer, seed or seed mixture, in the quantity specified over the areas to be seeded. Mechanical equipment shall be such that all varieties of seed as well as fertilizer may be distributed at the same time, provided that each component is uniformly applied at the specified rate. When seed and fertilizer are to be distributed as a water-slurry, apply the mixture to that area to be seeded within 30 minutes after all components are placed in the equipment. Upon completion of planting the seed, spread cellulose fiber mulch uniformly over the area at the following rates: 1. Sandy soils with 3:1 slope or less: min. 2000 lb./acre. 2. Sandy soils with greater than 3:1 slope: min. 2300 lb./acre. Hydro-Mulching 32 92 13 - 3 Lake Lewisville Water Treatment Plant Phase II Improvements DTN18104 3. Clay soils with 3:1 slope or less: min. 2500 lb./acre. 4. Clay soils with greater than 3:1 slope: min. 3000 lb./acre. 5. The rates are given in dry weight of mulch per acre. A mulching machine, approved by the Owner’s Representative, shall be equipped to eject the thoroughly wet mulch material at a uniform rate to provide the mulch coverage specified. D. Maintenance: Water the planted area at such times as necessary for a period of 1 year after final acceptance of the project by the Owner. Fertilize and reseed any area which fails to survive for a period of 1 year from the date the project is accepted by the Owner. END OF SECTION Ductile Iron Pipe and Fittings 33 05 01.02 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 33 05 01.02 DUCTILE IRON PIPE & FITTINGS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install ductile iron pipe and fittings, including taps, connections, and appurtenances as required for a functional system as indicated herein. Unless otherwise noted, all above grade exposed pipe, fittings, and appurtenances shall be flanged while below grade piping, fittings and appurtenances shall be mechanical joint or push on joints. Trenching, backfilling, and pipe embedment shall be as shown on the Drawings and in accordance with Section 31 23 33.19 “Trenching and Backfill.” 1.02 QUALITY ASSURANCE A. Factory Testing: The manufacturer shall perform all tests as required by AWWA C151. Welded outlets shall be hydrostatically tested at a pressure of 250 psi for a period of 1 hour. No leakage shall be allowed. B. Experience Requirements: Pipe shall be the product of a manufacturer who has a minimum of 10 years’ successful experience manufacturing pipe of the particular type specified and the total pipeline shall be the product of one pipe manufacturer. The manufacturer shall have a minimum of 10 years’ successful experience in the design and manufacturing of pipe joints of similar design, working pressure, pipe diameter and wall thickness as specified. C. Pipe Classification: Pipe manufacturer shall manufacture the pipe to meet the installation conditions, cover depth, and bedding and backfill requirements as shown on the Drawings or specified and furnish the correct class of pipe to meet these conditions. If additional requirements are required, pipe manufacturer shall coordinate their requirements with the Contractor. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Record Data: Catalog data, including dimensions of new pipe and fittings and recommendations for handling and storage; details of lining and coating; thrust restraint provisions; hydrostatic pressure test plan and results; affidavit stating the pipe furnished complies with AWWA C151, AWWA C104, AWWA C110, AWWA C111, and these specifications; mill certificates, including chemical and physical test results for each heat of metal, if requested during pipe manufacturing operations. 2. Certified Test Data: Certified Test Reports from the manufacturer’s testing facility or an Owner approved testing laboratory; results of factory hydrostatic tests; pipe and fitting certification for conformance to ANSI/NSF 61. 1.04 REFERENCE SPECIFICATIONS A. Section 31 23 33.19 “Trenching and Backfill.” Ductile Iron Pipe and Fittings 33 05 01.02 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.05 STANDARDS A. Except as modified herein, the applicable provisions of the following standards shall apply as if written here in their entirety: 1. American Water Works Association (AWWA) Standards: AWWA C104 Standard for Cement Mortar Lining for Ductile Iron Pipe and Fittings AWWA C105 Standard for Polyethylene Encasement for Ductile Iron Piping AWWA C110 Standard for Ductile Iron and Gray Iron Fittings AWWA C111 Standard for Rubber Gasket Joints for Ductile Iron Pipe and Fittings AWWA C150 Standard for Thickness Design of Ductile Iron Pipe AWWA C151 Standard for Ductile Iron Pipe AWWA C153 Standard for Ductile-Iron Compact Fittings for Water Service AWWA C600 Standard for Installation of Ductile Iron Water Mains and Appurtenances AWWA C606 Grooved and Shouldered Joints 2. Steel Structures Painting Council (SSPC) Standard: SSPC SP6, Commercial Blast Cleaning. 3. All ductile iron pipe and fittings for potable water systems shall conform to American National Standards/National Science Foundation (ANSI/NSF) Standard 61 and must be certified by an organization accredited by ANSI. 1.06 DELIVERY AND STORAGE A. Handling and storage of pipe and fittings shall comply with AWWA C600 and the manufacturer’s recommendations. 1.07 GUARANTEES A. The product shall be warranted and guaranteed per the General Conditions of the Specifications. 2.00 PRODUCTS 2.01 MATERIALS A. Ductile Iron Pipe: 1. Ductile iron pipe shall be made of ductile iron in accordance with AWWA C151. All ductile iron pipe shall have a minimum working pressure as indicated on the Drawings. Pipe shall be rated for pressure in accordance with AWWA C151 for pressure class of pipe as indicated. Standard joint length shall be 18 to 20 feet. Flanged ductile iron pipe shall be in accordance with AWWA C115. 2. Pipe manufacturer shall manufacture the pipe to meet the installation conditions, cover depth, and bedding and backfill requirements as shown on the Drawings or specified and furnish the correct class of pipe to meet these conditions. Ductile Iron Pipe and Fittings 33 05 01.02 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Fittings: Fittings shall be ASTM A536 ductile iron or ASTM A48 cast iron in accordance with AWWA C110 or AWWA C153. Fittings shall be rated for a minimum working pressure of 250 psi, unless specified otherwise. Factory welded outlets may be used in lieu of tee fittings for 18-inch and larger tee fittings. Factory welded outlets shall have a minimum pressure rating of 250 psi. Factory welded outlets may not be used near sources of vibration, such as pump stations or roads. C. Joints for Pipe and Fittings: 1. Joints shall be in accordance with AWWA C110, AWWA C111, and AWWA C151. Standard joints for ductile iron pipe and fittings shall be push-on. Where indicated, joints shall be mechanical joint, flanged, or grooved. 2. Flanged joints shall have pressure ratings equal to or greater than adjacent pipe. Flange pattern shall match pattern of valve, fitting, or appurtenance to be attached. Flanges on ductile iron pipe shall be ductile iron. 3. Grooved joints may be used in lieu of flanged. Where used in lieu of flanges, grooved joints shall be of the rigid type, in accordance with AWWA C606. 4. Where indicated, grooved joints in accordance with AWWA C606 shall be used. Grooved joints shall be flexible unless indicated otherwise. All grooved joint couplings and fittings shall be of a single domestic manufacturer. D. Provisions for Thrust: 1. Thrust at bends, tees, plugs, or other fittings shall be resisted by restrained joints. If thrust cannot be accommodated using restrained joints, thrust blocking or concrete anchors to restrain thrust may be used on a case-by-case basis when approved by the Engineer. 2. Restrained joints shall be used for a sufficient distance from each bend, tee, plug, or other fitting to resist thrust which will be developed at the design pressure of the pipe. For the purpose of thrust restraint, design pressure shall be 1.5 times the design working pressure class indicated. 3. The length of pipe with restrained joints to resist thrust forces shall be determined by the pipe manufacturer in accordance with Thrust Restraint Design for Ductile Iron Pipe, Ductile Iron Pipe Research Association using the following parameters: a. Laying condition equal AWWA C600 Type 4 bedding. b. If polyethylene encasement is used, restrained length shall be doubled to account for reduced soil to pipe friction resistance. 4. Where indicated and where required for thrust restraint, joints shall be restrained. Restrained joints shall be mechanically interlocking joints. Restrained joints shall be U.S. Pipe "TR Flex", American Ductile Iron Pipe "Flex Ring", or Clow Corporation "Super- Lock". Restraining fittings using set screws, restraining gaskets, gripper type glands, and field-cuts of restrained joints shall be Mega-Lug, or approved equal. Field welding shall not be allowed. Restrained joints shall be capable of sustaining the design pressure as specified herein. Ductile Iron Pipe and Fittings 33 05 01.02 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements E. Coating: 1. Coat the exterior of the pipe and fittings with a 1 mil bituminous coating in accordance with AWWA C110 and AWWA C151, unless specified otherwise. 2. In addition to the factory applied asphaltic coating, all buried ductile iron pipe and fittings shall have a tube-type polyethylene encasement in accordance with AWWA C105. Polyethylene encasement shall be 8 mils thick. Both ends of the pipe shall be thoroughly sealed with adhesive tape or plastic tie straps at the joint overlap. Place circumferential wraps of tape at 2-foot intervals along the barrel of the pipe to minimize the space between the encasement and the pipe. F. Lining: Ductile iron pipe and fittings shall have a cement mortar lining in accordance with AWWA C104 and bituminous seal coat. Thickness of lining shall be as specified in AWWA C104. Air piping shall not be lined. G. Flexible Joint Couplings: 1. Flexible joint couplings shall be Dresser Style 38, Rockwell Style 411, Victaulic Depend-O- Lok - E x E, Type II or approved equal, unless otherwise shown. 2. Provide restrained flexible joint couplings or restrained flexible joints on all pipes connecting to concrete structures and at other locations shown on the Drawings. Restrained flexible couplings shall be Victaulic Depend-O-Lok F x F Type II or approved equal. Restrained flexible joints shall be U.S. Pipe "TR Flex", American Ductile Iron Pipe "Flex Ring", Clow Corporation "Super-Lock", or approved equal. 3.00 EXECUTION 3.01 INSTALLATION A. General: Install ductile iron pipe, fittings, specials, valves, and hydrants in accordance with AWWA C600 and the Specifications. Trenching and backfilling shall be in accordance with Section 31 23 33.19 “Trenching and Backfill.” Before lowering into the trench, inspect each joint of pipe. Pipe will then be accepted, rejected, or repaired. B. Pipe Laying: Lower pipe, fittings, and special castings into trench by crane or other suitable method. Do not roll in or "dump" into the trench. Handle pipe and fittings with belts, slings, or other equipment designed to prevent damage to the pipe and coating. Remove dirt and trash that may be in the barrel of the pipe, on the spigot or in the bell while the pipe is suspended. Keep the pipe clean during the laying operation and free of sticks, dirt, and trash, and at the close of each operating day seal the open end of the pipe with a gasketed night cap. Do not lay pipe in water. C. Pipe Alignment: Install pipe and fittings to the line and grade indicated. In areas where the line and grade indicated cannot be achieved using standard manufactured bends and fittings, make slight adjustments by deflecting joints. Joint deflections may not exceed the lesser of the maximum deflections stipulated in AWWA C600 or 75 percent of the manufacturer’s maximum recommended deflection. Resolve any conflicts with existing utilities and structures. Ductile Iron Pipe and Fittings 33 05 01.02 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements D. Joint Making: 1. Jointing Mechanical Joint Pipe: a. Joint this type of pipe in accordance with the manufacturer's recommendations, with uniform torque on bolts. b. After carefully cleaning both spigot and bell and after slipping the follower ring and gasket over the spigot end, slip the spigot into the bell. Apply a lubricant to the spigot to assist in assembly. c. Carefully seat the gaskets by hand to be even in the bell at all points. d. After drawing up the follower ring to uniform bearing against the gasket, insert the bolts and tighten by hand in pairs using bolts opposite each other. e. Tighten the nuts to hold the required pressure. Extension wrenches or pipes over wrench handles shall not be permitted. Use 10-inch ratchet wrenches to tighten the nuts to a uniform torque. f. The finished joint shall be watertight. 2. Making Flanged Joints: Erect flanged pipe in accordance with the controlling dimension as specified. Thoroughly clean each piece of flanged pipe to remove dirt, rust, grease, and other foreign matter. Thoroughly wire brush flanged faces to ensure even bearing for gaskets and mating flanges. Place full face gasket, use drift pins to align holes, and tighten flange bolts, each in turn, at a uniform torque around the joint. Finished joints shall be watertight. 3. Making Push-On Joints: a. The jointing of this type of joint shall be as recommended by the manufacturer. The procedure for jointing shall be generally as follows: 1). Thoroughly clean and dry the spigot and bell before starting the assembly of the joint. Wipe the gasket clean with a cloth. 2). Place the gasket into the gasket seat in the bell. 3). Apply a thin film of lubricant to the surface of the gasket that will come in contact with the entering pipe spigot. If necessary, also apply lubricant to the spigot. 4). Make the joint by exerting sufficient force on the entering pipe so that its plain end will move past the gasket to the seat of the bell. 5). If restrained joints are used, orient pipe to permit ease of assembly. Place locking device after installation of spigot into bell. 4. Making Grooved Joints: a. Grooved joints shall be fabricated and installed per AWWA C606. b. Grooved ends shall be clean and free from indentations, projections and roll marks in the area from pipe end to groove. c. Gaskets used with grooved joints shall be verified as suitable for the intended service. Ductile Iron Pipe and Fittings 33 05 01.02 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements d. Install all grooved joint products in accordance with the manufacturer’s latest installation instructions. 5. Making Split-Sleeve Coupling Joints: a. Exterior surfaces of the pipe shall be clean, smooth and free from weld beads, seams, scars, indentations, roll marks, exterior coatings and flat spots. b. Install split-sleeve couplings in accordance with the manufacturer’s latest installation instructions. E. Polyethylene Encasement: Wrap bituminous coated ductile iron pipe in polyethylene encasement in accordance with AWWA C105. Repair or replace encasements which have tears, rips, or punctures in the polyethylene wrap. F. Painting: Paint piping which is submerged or exposed to the atmosphere in accordance with Section 09 96 00.01 “High-Performance Coatings.” 3.02 FIELD QUALITY CONTROL A. Perform a hydrostatic test as specified in Section 01 40 00 “Quality Requirements.” B. Disinfect the piping system as specified in Section 33 10 13 “Disinfecting of Water Utility Distribution.” END OF SECTION Polyvinyl Chloride (PVC) Pressure Pipe and Fittings 33 05 01.09 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 33 05 01.09 POLYVINYL CHLORIDE (PVC) PRESSURE PIPE AND FITTINGS 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install polyvinyl chloride (PVC) pressure pipe, appurtenances, and fittings to the diameters indicated for water supply and wastewater pressure piping. Trenching, backfilling, and pipe embedment shall be in accordance with Section 31 23 33.19 “Trenching and Backfill.” B. Other PVC Pipe: Gravity sewer pipe shall be as specified in Section 33 05 01.12 “Sanitary Sewer Pipe (PVC)” (ASTM D2241). 1.02 QUALITY ASSURANCE A. Certification: Domestic water piping shall be approved by the Underwriters Laboratory and shall be accepted by the State Fire Insurance Commission for use in water distribution systems. PVC water pipe shall bear the seal of approval (or “NSF” mark) of the National Sanitation Foundation Testing Laboratory for potable water pipe. B. Design Criteria: The maximum allowable load for PVC pipe installations shall produce a maximum deflection of 4 percent. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Certified Test Reports from the Manufacturer’s testing facility or an approved testing laboratory. 2. Manufacturer’s data on piping and jointing methods as Record Data. 3. Thrust restraint lengths and lay schedule as Shop Drawing. 1.04 REFERENCE SPECIFICATIONS A. Section 01 33 00 “Submittal Procedures.” B. Section 01 40 00 “Quality Requirements.” C. Section 33 10 13 “Disinfecting of Water Utility Distribution.” D. Section 31 23 33.19 “Trenching and Backfill.” 1.05 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety. PVC piping and fittings shall be in full compliance with the applicable standards and specifications for each type of plastic pipe involved. Pipe may be rejected for failure to comply with any requirement of this Section. Polyvinyl Chloride (PVC) Pressure Pipe and Fittings 33 05 01.09 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1. American Society for Testing and Materials (ASTM) Standards: ASTM D1785 Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120 ASTM D2464 Standard Specification for Threaded Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80 ASTM D2466 Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings Schedule 40 ASTM D2467 Standard Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80 ASTM D2855 Standard Practice for Making Solvent-Cemented Joints with Poly (Vinyl Chloride) (PVC) Pipe and Fittings ASTM D3139 Standard Specification for Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals ASTM F1674 Standard Test Method for Joint Restraint Products for Use with PVC Pipe 2. American Water Works Association (AWWA) Standards: AWWA C104 Cement-Mortar Lining for Ductile Iron Pipe and Fittings for Water AWWA C105 Polyethylene Encasement for Ductile-Iron Pipe Systems AWWA C110 Ductile-Iron and Gray-Iron Fittings AWWA C153 Ductile-Iron Compact Fittings AWWA C605 Underground Installation of Polyvinyl Chloride (PVC) Pressure Pipe and Fittings for Water AWWA C900 Poly Vinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4 through 12 Inches for Water Transmission and Distribution AWWA C905 Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 14 through 48 Inches for Water Transmission and Distribution 1.06 DELIVERY AND STORAGE A. Store PVC material so that there is no exposure to sunlight. 2.00 PRODUCTS 2.01 MATERIALS A. Pipe: 1. Four to 12 inches: Class 165 (DR25) C900 with cast iron outside dimensions PVC pressure drain lines, plant effluent lines, 165 psi pressure rating Class 235 (DR18) C900 with cast iron outside dimensions Potable water lines, non-potable plant and reverse osmosis reuse lines, 235 psi rating Class 305 (DR14) C900 with cast iron outside dimensions Fire water lines, 305 psi rating Polyvinyl Chloride (PVC) Pressure Pipe and Fittings 33 05 01.09 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Fourteen to 42 inches: 14” to 42” PR 165 (DR-25) C905 with cast Iron Outside dimensions Large diameter transmission mains B. PVC Pressure Piping: 1. Smaller than 4 inches in size shall be Type 1, Grade 1, Polyvinyl Chloride, Schedule 80 pipe conforming to ASTM D1785. 2. For pipe 2 inches in diameter and smaller, joints shall be glued. 3. For pipe larger than 2 inches in diameter, joints shall be bell and spigot push-on type as specified in ASTM D3139. C. Fittings: 3- through 12-inch cast iron and conforming to AWWA C110, American National Standard Specification for Gray Iron and Ductile Iron Fittings. Fittings smaller than 12 inches in diameter shall be of the short body design, ASA Class 250. Fittings for piping smaller than 3 inches shall be in accordance with ASTM D2466. D. Thrust Restraint: Thrust restraint devices shall be Mega-lug or approved equal and shall be factory tested and pressure rated in accordance with ASTM F1674. 1. Joint restraint devices shall be designed specifically for use with PVC pipe of the joint type and pressure rating specified. 2. Restrained joints shall be used for a sufficient distance from each bend, tee, plug, valve or other fitting to resist thrust which will be developed at the design pressure of the pipe. For the purposes of thrust restraint, working pressure shall be 1.5 times the design working pressure of 150 psi or the pipe pressure class indicated. 3. The length of pipe with restrained joints to resist thrust forces shall be the sole responsibility of and determined by the Pipe Manufacturer using the following parameters: a. Laying condition equal to AWWA C605 Type 3 bedding. b. No thrust restraint contribution shall be allowed for pipe in casing. c. Soil density = 100 pcf. 2.02 MARKINGS A. The Pipe Manufacturer shall mark the piping with the size and appropriate AWWA/ASTM Standard designations as applicable. 2.03 MATERIALS A. Schedule 40 or 80 PVC Pipe: ASTM D1785, Type 1, Grade 1, rigid, unplasticized PVC, normal impact, bearing NSF seal. Fitting shall be in accordance with ASTM D2464, D 2465, or D 2467, or AWWA C110 or C153. Schedule 40 pipe shall not be threaded. B. C 900 Pipe: Pipe shall meet the requirements of AWWA C900 with outside diameter equivalent to cast iron pipe, in accordance with AWWA C900, Table 2. Fittings shall be in accordance with AWWA C110 or C153. C. SDR 26 Pipe: Pipe and fittings shall be in accordance with ASTM D2241. Polyvinyl Chloride (PVC) Pressure Pipe and Fittings 33 05 01.09 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.00 EXECUTION 3.01 INSTALLATION A. Install pipe, fittings, and specials to the lines and grades indicated. Install hangers, brackets, supports, etc., at spacings as recommended by pipe manufacturer. Flexible connections shall be required at locations where pipe passes through concrete walls. Begin installation at the main supply line valve and make connections where indicated. B. Excavate trenches to alignment and depth specified or as required for proper installation of pipe. Carefully lower pipe, fittings, and specials into the trench to avoid damage to the pipe and/or fittings. Take necessary precautions to protect pipe during backfilling operations. Replace any damaged pipe before it is buried. Keep the pipe clean during laying operations, and seal the pipe against the entrance of objects at the close of each operating day. C. Place thrust restraint fittings at bends, tees, crosses, valves, and plugs in the pipe line in accordance with approved Shop Drawing lay schedule and Paragraph 2.01.D. D. Buried ductile iron fittings shall be double wrapped in 8mm high density polyethylene encasement in accordance with AWWA C105, repair or replace encasements which have tears, rips or punctures in the polyethylene wrap. E. The minimum cover for 1- to 4-inch PVC piping shall be 36 inches. For 6-inch PVC piping and larger, the minimum cover shall be 48 inches. F. The following minimum horizontal clearances shall be maintained between crossing lines: Water line/new sanitary or reuse sewer line separation. When new sanitary sewers or reuse waterlines are installed, install lines no closer to potable waterlines than 9 feet in all directions. Wastewater lines that parallel potable waterlines must be installed in separate trenches. Where the 9-foot separation distance cannot be achieved, the following guidelines shall apply: G. Where a sanitary sewer parallels a potable waterline, construct the sewer of PVC meeting ASTM specifications with a pressure rating for both the pipe and joints of 150 psi. The vertical separation shall be a minimum of 2 feet between outside diameters and the horizontal separation shall be a minimum of 4 feet between outside diameters. The wastewater line shall be located below the waterline. H. Where a sanitary sewer line crosses a waterline, construct the sewer of PVC with a minimum pressure rating of 150 psi, an absolute minimum distance of 6 inches between outside diameters shall be maintained. In addition, the sewer shall be located below the waterline where possible and one length of the wastewater pipe shall be centered on the waterline. I. Where a sewer crosses over a waterline construct all portions of the sewer within 9 feet of the waterline of PVC pipe with a pressure rating of at least 150 psi using appropriate adapters. J. For threaded joints not more than three threads at each pipe connection shall remain exposed after installation. Ream ends of pipe after threading and before assembly, to remove burrs. Threaded joints shall be made up with a suitable joint compound. Apply joint compound to male threads only. Polyvinyl Chloride (PVC) Pressure Pipe and Fittings 33 05 01.09 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements K. Solvent weld joints shall be in accordance with ASTM D2855, and shall be made generally as follows: cut square and smooth the ends of the plastic pipe and wipe clean. Apply primer and solvent cement to the outside of the pipe and the inside of the fitting socket with a small brush. Immediately push the coated surfaces snugly together and rotate the pipe approximately one-half turn to insure uniform distribution of the cement. Remove the excess cement by wiping. Cement shall be of type which welds plastic surfaces together. Cement shall be as recommended by the Pipe Manufacturer and shall be compatible with the chemical conveyed. L. Push-on joints shall be in accordance with the manufacturer’s instructions. M. Joint lubricant shall be as recommended by the pipe manufacturer. 3.02 FREEZE PROTECTION SYSTEM A. Heat tracing: Provide heat trace as directed on the Drawings and areas vulnerable to freezing. Heat trace shall be installed under the insulation. B. Heat tracing shall be automatic self-regulating, UL listed, with tinned copper braid, able to crossover itself without overheating, parallel circuit design, able to be cut to length at job site, flat and flexible for easy installation, corrosion and chemical resistant, complete with power connection kits, splice kits, end seal kits and necessary accessories for a complete operating installation 120 VAC, 60 HZ, 5W/ft. C. Cable shall be Raychem 5BTV1-CT or equal by Chromalox. D. Thermostat Control: NEMA 4X enclosure. UL listed ambient-sensors thermostat with adjustable set point. Acceptable manufacturers and models: Tyco Digitrace AMC-1A-120V E. Contractor to provide necessary J-Boxes. J Boxes shall be Raychem JBM-100 for multiple connections and Raychem JBS-100 for single connection. F. Contractor to provide a minimum of end seal with LED per assembly, end seal shall be Raychem E100-L1A. LED shall be used to verify the system is on. G. All other end seal shall be Raychem E150. H. Tape shall be Raychem GT66. I. Pipe strap shall be Raychem PS-10. J. Labels shall be Raychem ETL. K. Insulation shall be a minimum of 1.5” thick mineral wool. L. Heat Trace to be installed by Raychem Trace Construction or manufacturer-approved installer. M. Contractor to provide and install necessary conduits and circuit per Division 26. 3.03 FIELD CONTROL HYDROSTATIC TESTING A. Test PVC pressure piping for leakage by a hydrostatic pressure test in accordance with Section 01 40 00 “Quality Requirements.” Polyvinyl Chloride (PVC) Pressure Pipe and Fittings 33 05 01.09 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.04 PURGING OF WATER LINES A. Purge, sterilize, and test the constructed water lines in accordance with Section 33 10 13 “Disinfecting of Water Utility Distribution.” 1. During construction operations, maintain the installed surfaces of the system, which come in contact with the City’s water supply, in a sanitary condition. 2. Every effort must be made to keep the inside of the pipe, fittings, and valves free of loose foreign matter. 3. Should the Contractor’s carrier be required to transport potable water to the job site for main testing, sterilize tankage and piping, including pumps used to transport or transfer potable water into the main. B. When the entire pipeline or selected sections have been completed and are ready for use, disinfect the line or section according to the following procedures: 1. Flush piping sections. 2. Flush back flow water from the system that has inadvertently entered the pipe. 3. After purging and flushing, sterilize the system in accordance with procedures in Section 33 10 13 “Disinfecting of Water Utility Distribution.” 3.05 SERVICE CONNECTIONS A. Make service connections in accordance with AWWA Manual M23 “PVC Pipe - Design and Installation” and the instructions from the Manufacturer. Use a service clamp or saddle to connect 2-inch and smaller services to PVC pipe sizes 4 to 12 inches. Use a ductile iron tapped tee to connect 3-inch service connections. 3.06 FIELD QUALITY CONTROL A. Do not enclose or cover any Work until inspected. 3.07 SCHEDULES Service Diameter (in.) Type Min. Design Pressure Joint Type Buried Exposed Water, Wastewater, or Sludge 0-2 Sched.80 300 psi SW or THD 2-1/2, 3 Sched.80 300 psi PO SW or THD 4-12 C900 150 psi PO N/A Chemicals 0-6 Sched.80 250 psi SW SW SW - Solvent Weld, THD – Threaded, PO - Push-On END OF SECTION PVC Sanitary Sewer Pipe 33 05 01.13 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 33 05 01.13 PVC SANITARY SEWER PIPE 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment, and incidental necessary to install 4- through 48-inch gravity flow PVC pipe. Trenching, backfilling, and pipe embedment shall be in accordance with Section 31 23 33.19 “Trenching and Backfill.” 1.02 QUALITY ASSURANCE A. Certification: The sewer pipe manufacturer shall provide certification that the pipe supplied conforms to these specifications and shall include laboratory tests results that support such certification. If the manufacturer is unable to provide the certification, an independent testing facility shall be utilized and retained at no cost to the Owner. The pipe supplied shall be permanently marked with the manufacturer’s name, the date of manufacture, and identification with the tests performed to warrant its certification as being in conformance with this standard. B. Testing: 1. At a minimum, actual test results shall be required as follows: a. Load bearing tests. b. Material tests. c. Hydrostatic tests. 2. Tests on PVC pipe 4 through 48 inches shall be made in accordance with appropriate ASTM standard testing procedures and shall be performed on a minimum of 1 percent of the pipe purchased. C. Inspection: An inspection of the pipe after delivery to the Project shall be made by a representative of the Owner. Pipe with visible defects which are indicative of poor structural condition or poor workmanship shall be rejected and replaced without cost to the Owner. Visible defects shall include cracks of any type, honeycombs, or any other defects of poor workmanship. Any pipe rejected shall not be returned under any condition to the Project. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Manufacturer’s data on all piping and joint methods. 1.04 REFERENCE SPECIFICATIONS A. Section 01 33 00 “Submittal Procedures.” B. Section 01 40 00 “Quality Requirements.” C. Section 31 23 33.19 “Trenching and Backfill.” PVC Sanitary Sewer Pipe 33 05 01.13 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.05 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American Society of Testing and Materials (ASTM) Standards: ASTM D3034 Standard Specification for Type PSM Poly(Vinyl Chloride) (PVC) Sewer Pipe and Fittings ASTM D2241 Standard Specification for Poly (Vinyl Chloride) PVC Pressure Rated Pipe (SDR Series) ASTM D3212 “Standard Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals” ASTM F477 Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe ASTM F679 & Annex Standard Specification for Poly(Vinyl Chloride) (PVC) Large Diameter Plastic Gravity Sewer Pipe and Fittings ASTM F794 Standard Specification for Poly(Vinyl Chloride) (PVC) Profile Wall Gravity Sewer Pipe and Fittings Based on Controlled Inside Diameter ASTM F1803 Standard Specification for Poly(Vinyl Chloride) (PVC) Closed Profile Wall Gravity Sewer Pipe and Fittings Based on Controlled Inside Diameter 2. American Water Works Association (AWWA) Standards: AWWA C900 Standard for Polyvinyl Chloride (PVC) Pressure Pipe, 4 through 12 Inches AWWA C905 Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 14 through 48 Inches 2.00 PRODUCTS 2.01 MATERIALS A. Gravity Pipe: ASTM D3034 4- to 15-inch SDR 35 (26) or ASTM F679 18- to 48-inch PS46 (115) Polyvinyl chloride pipe with bell and spigot compression joints. Pipe shall have a home mark on the spigot to indicate proper penetration when the joint is made. B. Pressure Pipe: Pressure rated pipe as called for on the Drawings shall be ASTM D2241 SDR 26, PR 160 or AWWA C900 DR 25 PR165 (4 to 12 inches). C. Gaskets: Conform to ASTM F477. D. Joints: Tested in accordance with ASTM D3212. E. Services: Where pressure rated piping is called for on the Drawings, PVC service laterals shall be pressure rated. 3.00 EXECUTION 3.01 INSTALLATION PVC Sanitary Sewer Pipe 33 05 01.13 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements A. Install pipe to the lines and grades indicated. Begin installation at the downstream discharge connection point and make connections where indicated. B. Carefully lower sanitary sewage pipe into the trench to avoid damage to the pipe. Remove dirt and trash from the pipe while suspended. Keep pipe clean during laying operations, and seal the pipe against entrance of objects at the close of each operating day. C. Where a gravity flow PVC wastewater line is within 9 feet of, and parallels a waterline, construct the sewer of PVC meeting ASTM or AWWA specifications with a minimum pressure rating for both the pipe and joints of 150 psi. The vertical separation shall be a minimum of 2 feet between outside diameters and the horizontal separation shall be a minimum of 4 feet between outside diameters. The gravity flow line shall be located below the waterline. D. Where a gravity flow PVC wastewater line crosses a waterline, construct the wastewater line of PVC with a minimum pressure rating of 150 psi, and maintain an absolute minimum distance of 6 inches between outside diameters. In addition, the wastewater line shall be located below the waterline where possible and one length of the wastewater pipe must be centered on the waterline. E. Where a gravity flow PVC wastewater line crosses over a waterline, construct all portions of the wastewater line within 9 feet of the waterline of PVC pipe with a pressure rating of at least 150 psi with one joint of pipe centered on the waterline, using appropriate adapters. 3.02 FIELD QUALITY CONTROL A. Testing shall be as specified in Section 01 40 00 “Quality Requirements.” B. Do not enclose or cover any Work until inspected. END OF SECTION Disinfecting of Water Utility Distribution 33 10 13 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 33 10 13 DISINFECTING OF WATER UTILITY DISTRIBUTION 1.00 GENERAL 1.01 WORK INCLUDED A. Disinfect the facilities for pumping, storing, or conveying potable water to comply with the standards for potable water of the regulatory agency of jurisdiction. Potable water is defined as any water that has been filtered, disinfected or otherwise treated to meet regulatory standards (in the water treatment plant this includes the inside surfaces of the filters). B. Disinfect piping systems that are used to convey water, solutions, or chemicals to the potable water facilities. C. Test water from the disinfected system per regulatory standards to verify that water is acceptable. Repeat procedure if tests do not meet standards. D. For critical operations identified in Section 01 35 00 “Special Procedures” the Contractor shall plan and perform the repairs/work in a manner to allow the Bac-T samples to be taken by noon. In accordance with Texas Commission on Environmental Quality (TCEQ) Chapter 290 regulations, disinfection must be performed when repairs are made to existing facilities and before new facilities are placed into service. When it is necessary to return the facility back to service as rapidly as possible, it is acceptable to increase the doses to 500 mg/l and the contact time reduced to 30 minutes. This Project may require the critical operations to be disinfected by 500 mg/l for 30 minutes followed by flushing prior to the sample being taken. The Owner will take the sample and have it tested. Contractor may also take a sample to be tested. Cost for failed tests and all associated re-disinfection, flushing shall be borne by the Contractor. Prior to the 30 minute test time, all new valves shall be fully closed and opened. 2.00 PRODUCTS 2.01 MATERIALS A. Liquid Chlorine: Meeting the requirements of AWWA B301. B. Calcium Hypochlorite: Meeting the requirements of AWWA B300. 3.00 EXECUTION 3.01 NEW FACILITIES A. New facilities shall be thoroughly disinfected in accordance with AWWA Standard C651 - Water Mains, C652 - Storage Facilities, C653 – Water Treatment Plants, and then flushed and sampled before being placed in service. Samples shall be collected and tested in accordance with the TCEQ Rules and Regulations, Chapter 290. B. During construction keep basins, pipe, fittings, equipment, and appurtenances free from dirt and debris. 1. Clean basins thoroughly before disinfection. Disinfecting of Water Utility Distribution 33 10 13 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Seal the open ends of pipe with water-tight plugs when pipe is not being laid. 3. Pump water from trenches before removing the plug when water accumulates in the trench. C. Complete hydrostatic test of the line prior to disinfection. D. Wash the surfaces to be disinfected. 1. Flush pipelines. The minimum quantity of water used for flushing must exceed the capacity of the line to ensure that clean water has traversed the entire length of pipe. 2. Power wash the surfaces of basins and reservoirs using high pressure wash systems. E. Disinfect facilities per the following procedures of AWWA: 1. Water Mains: C651 - latest revision. 2. Water Storage Facilities: C652 - latest revision. 3. Water Treatment Plants: C653 - latest revision. F. Fill the system with potable water. Test the water to see that it meets the requirements of the regulatory agency of jurisdiction for potable water. Monitor the system for 2 days. If water test fails to meet the prescribed standards, repeat the disinfection process until water meets quality standards for disinfection. 3.02 REPAIRS OR CONNECTIONS TO EXISTING LINES A. Clean and sterilize the interior surfaces of new piping, fittings, equipment, and appurtenances to be installed in an existing potable water system or connected to an existing system. B. Clean and sterilize the existing pipe or facilities for a minimum distance of 3 pipe diameters back from the ends of the pipe. Plug the ends of the line when work is not being performed on the pipe. C. Perform sterilization by swabbing each item with a concentrated chlorine solution. 1. Each piece is to be disinfected prior to being assembled for installation in the existing pipe. 2. Disinfect each piece just prior to assembly to help prevent re contamination. 3. Plug the ends of the assembly until a new item is to be added to the assembly. 4. Store disinfected materials on blocks to prevent contact with the ground. 3.03 DISPOSAL OF FLUSHING AND DISINFECTION WATER A. Chlorinated water used in flushing and disinfecting pipelines, storage tanks, or vessels prior to connection to the distribution system shall be disposed of by the Contractor in an acceptable manner. Chlorinated water must be “de-chlorinated” prior to disposal to eliminate adverse impacts to the surrounding environment. Water released to the environment shall meet all AWWA, EPA, and TCEQ regulatory requirements. Disinfecting of Water Utility Distribution 33 10 13 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 1. The Contractor is responsible for complying with all of the applicable requirements of the TPDES General Permit TXG670000, issued by the TCEQ, regarding the discharge of hydrostatic test water. 2. Residual chlorine concentrations may be reduced using sulfur dioxide, sodium bisulfite, sodium sulfite, sodium thiosulfate, or ascorbic acid. 3. The discharge must be to a splash pad or paved area, and may not be located within 300 feet of the intake for a domestic drinking water supply or 500 feet of any public or private water well. 4. An effluent water sample must be taken during the first hour of discharge at a location immediately near the point of discharge, and collected prior to commingling with storm water, wastewater, or other flows. 5. For discharges that extend beyond an hour in duration, a second sample must be taken of the last 10 percent of the effluent. 6. Sampling protocol, sample containers, holding times, preservation methods, and analytical methods must follow the requirements set forth in the general permit. 7. The effluent grab sample(s) must be analyzed for total residual chlorine by an accredited and certified laboratory. 8. Any noncompliance that endangers human health or safety, or the environment must be reported to the TCEQ in accordance with the general permit. 9. Any effluent violation which deviates from the permitted effluent limitation by more than 40 percent must be reported to the TCEQ in accordance with the general permit. 10. The Contractor must record all hydrostatic test water sample results on an approved DMR (EPA Form 3320-1). These monitoring records shall be retained for a period of 3 years from the date of the record and be readily available for review by the TCEQ upon request. See attached form B. With the written permission of the Owner of the system, chlorinated water may be disposed of in a sanitary sewer system if one is available. In the case of larger pipelines and the larger volumes of water involved, the Contractor will not be permitted to use the sanitary sewer system for disposal even if one is available. END OF SECTION Disinfecting of Water Utility Distribution 33 10 13 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements Sanitary Utility Sewage Manholes, Frames and Covers 33 39 13 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 33 39 13 SANITARY UTILITY SEWAGE MANHOLES, FRAMES AND COVERS 1.00 GENERAL 1.01 WORK INCLUDED A. Provide labor, materials, equipment and incidentals necessary to construct standard and special manholes and cleanouts complete with covers, fittings, and other appurtenances, in accordance with the details and/or called out on the Drawings. At a minimum, provide 48- inch inside diameter manholes for pipe diameters 18 inches and smaller, 60-inch inside diameter manholes for pipe diameters 24 to 27 inches, and 72-inch inside diameter manholes for pipe diameters 30 inches and larger. B. For precast manholes, the tops of the manholes be set to proper elevation by using a predetermined length of the bottom section of the manhole riser and using standard lengths for the other sections of the riser pipe. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Drawings and data covering precast concrete sections. These shall be submitted as Record Data. 2. Concrete batch mix for cast-in-place sections shall be submitted as a Shop Drawing. 3. Manhole cover and ring shall be submitted as Record Data. 4. Design and fabrication details for fiberglass manholes and components shall be submitted as Record Data. 1.03 REFERENCE SPECIFICATIONS A. Section 01 33 00 “Submittal Procedures.” B. Section 01 40 00 “Quality Requirements.” C. Section 03 30 00 “Cast-in-Place Concrete.” 1.04 STANDARDS A. Applicable provisions of the following standards shall apply as if written here in their entirety: 1. American Society for Testing and Materials (ASTM) Standards: ASTM A48 Specification for Gray Iron Castings ASTM C478 Specification for Precast Reinforced Concrete Manhole Sections ASTM D2240 Test Method for Rubber Property - Durometer Hardness ASTM C76 Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe ASTM C33 Concrete Aggregates Sanitary Utility Sewage Manholes, Frames and Covers 33 39 13 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements ASTM C923 Resilient Connectors Between Reinforced Concrete Manhole Structures, Pipes, and Laterals ASTM D3753 Glass-Fiber Reinforced Polyester Manholes and Wet wells 2. American National Standards Institute (ANSI) Standards: ANSI A21.10 American National Standard for Gray Iron and Ductile Iron Fittings, 3 through 48 Inches for Water and Other Liquids B. With the following additions for Precast Reinforced Concrete Manhole Sections: 1. All ASTM C478 pipe shall be machine made by a process that shall provide for uniform placement of zero slump concrete in the form and compaction by mechanical devices which shall assure a dense concrete in the finished product, except that reducer cones may be wet-cast. 2. Aggregates for the concrete shall comply with the requirements of ASTM C33, with the additional requirement that the aggregate shall have a minimum of 50 percent of calcium carbonate equivalent. 3. Minimum wall thicknesses for the manhole risers shall be as listed under Wall “B” in the ASTM C76 “Class Tables.” 4. Manhole steps shall not be furnished for sanitary sewer manholes. 5. Resilient connectors shall provide an airtight seal that eliminates infiltration and exfiltration. 1.05 DELIVERY AND STORAGE A. Do not deliver precast concrete section to the Site until representative concrete control cylinders have attained a strength of at least 80 percent of the specified minimum. B. Inspect precast concrete sections upon delivery, and reject any cracked or otherwise visibly defective units. 2.00 PRODUCTS 2.01 MATERIALS A. Concrete: Concrete for all cast-in-place bases shall be as specified in Section 03 30 00 “Cast- In-Place Concrete” and at a minimum shall be 3000-psi concrete. Mortar shall be as specified in Section 03 30 00 “Cast-In Place Concrete.” B. Precast Concrete Manholes: Above the manhole base, manholes shall be constructed with precast concrete rubber gasket sections in accordance with ASTM C478 pipe as detailed on the Drawings using the following materials. 1. Non-Shrinking Grout: Material shall be a non-shrink cement-base grout. “Five Star Grout” as manufactured by U.S. Grout Corporation or “Supreme” grout as manufactured by Hanson Pipe and Products or approved equal. 2. Rubber Gaskets: Neoprene or other synthetic, 40 plus or minus 5 hardness when measured by ASTM D2240, Type A durometer. Sanitary Utility Sewage Manholes, Frames and Covers 33 39 13 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. Precast Cone: Precast cone shall be concentric. 4. Grade Adjustment Risers shall be pre-cast, reinforced concrete in conformance to ASTM C478. C. Manhole Rings and Covers: 1. Manhole rings and covers shall be made of gray iron castings, ASTM A48, and shall conform to Class No. 30. 2. A minimum of four stainless steel anchor bolts for the ring are required for the connection to manholes. A minimum of five stud bolts for anchoring of the waterproof lid shall be of 316 stainless steel. 3. Castings shall be clean, sound, and free of blow or sand holes or other defects. D. Cleanout Fittings: 1. Pipe fittings shall be ductile iron and shall conform to ANSI A21.10 with a minimum pressure rating of 250 psi. 2. The cleanout casting shall conform to ASTM A48, Class 30. 3. Ductile Iron fittings shall be lined with factory installed Protecto 401 Ceramic Epoxy Lining by Enduron or American Polybond Plus (fusion bonded epoxy and fusion bonded polyethylene) or an approved equal, Lining primers, applications and thicknesses shall be in accordance with manufacturer’s recommendations for sanitary sewer applications. 2.02 MANUFACTURED PRODUCTS A. Precast Concrete Sections: Sections shall be as manufactured by Hanson Pipe and Products or CSR Hydroconduit or approved equal. Joints shall be sealed with “O” ring rubber gaskets. B. Manhole Rings and Covers: Manhole rings and covers shall be made of gray iron castings in accordance with ASTM A48 and shall conform to Class No. 30. Lids shall have pick slots. Minimum manhole ring and cover inside diameter shall be 30 inches. Ring depth shall be minimum 6 inches. Lid and ring shall be designed for traffic loading. Water tight lids shall be bolted using stainless steel bolts to ring and neoprene gaskets. 1. For a manhole installed on a slope less than 4.1 percent use LADTECH Adjusting Ring Wedge or approved equivalent. If slope is greater than 4.1 percent either re-grade area around manhole to an acceptable grade or present alternative solution to Engineer and city for approval. C. Corrosion Protection Manhole Liner: 1. Resurfacing Material: a. Provide resurfacing material to fill cavities and resurface exposed aggregate where it is impossible to achieve a pinhole-free membrane at the specified total topcoat film thickness. b. Resurfacing material shall be the following: AquataPoxy A-7 manufactured by Raven Lining Systems, 1024 North Lansing, Tulsa, OK 74106, or Arc 791 by A.W. Chesterton Co., Stoneham, MA, 02180, or Spectrashield Lining System by CCI Spectrum, Inc., 9716 Florida Mining Blvd. W., Jacksonville, FL, 32257. Sanitary Utility Sewage Manholes, Frames and Covers 33 39 13 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Topcoat: a. Provide a high build epoxy coating that is 100 percent solids epoxy formulated with a wide range of chemical resistance, including resistance to hydrogen sulfide and sulfuric acid, and a high physical strength. Coating must be designed for temperatures up to 200 F. Coating shall be Raven 405 manufactured by Raven Lining Systems, 1024 North Lansing, Tulsa, OK 74106, or Arc S1HB by A.W. Chesterton Co., Stoneham, MA, 02180, (781) 438-7000, or Spectrashield Lining System by CCI Spectrum, Inc., 9716 Florida Mining Blvd. W., Jacksonville, FL, 32257 or approved equal. b. The material must be suitable for overhead, vertical and horizontal surfaces, and capable of being spray applied, brushed or rolled at a specified thickness as recommended by the manufacturer. c. The material must provide a permanent impermeable, high strength, monolithic lining for concrete structures that is sulfuric acid corrosion, abrasion and impact resistant. Performance Testing Flexural Strength ASTM D790 Compressive Strength, Yield ASTM D695 Tensile Strength ASTM D638 Tensile Ultimate Elongation ASTM D638 Hardness, Shore D ASTM D2240 Impact, IZOD ASTM D256 Water Vapor Transmission ASTM D1653, Method B Taber Abrasion, CS17 Wheel ASTM D4060 Adhesion ASTM D4541 Temperature Resistance 200 F 3.00 EXECUTION 3.01 INSTALLATION A. Manhole Base: 1. Cast-in-place Manhole Base: The applicable details as indicated in the Drawings shall apply. Form and place the manhole base at an elevation that allows the invert to match the pipe flowline. a. The cast-in-place manhole base shall form a water tight seal with the bottom of the manhole. This may be accomplished by placing a continuous 1-inch ring of epoxy grout or using a rubber gasket at the joint of the manhole and manhole base or other pre-approved methods. 2. Give the concrete portion of all inverts within the manholes a smooth steel trowel finish. Sanitary Utility Sewage Manholes, Frames and Covers 33 39 13 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements 3. The first section of pipe extending out a minimum of 24 inches from each side of the manhole base shall be supported by lean concrete as part of the manhole base. No additional payment shall be made for this concrete cradle; the sum shall be included in the bid price for the manhole. B. Inverts: Construct invert channels to provide a smooth waterway with no disruption of flow at the connection between the pipe and manhole. C. Manhole Rings and Covers: Securely anchor the base of the manhole ring into a 6-inch minimum thickness precast concrete ring as indicated, and set on top of concentric manhole cone as a unit. D. Cleanouts: Provide a cleanout at the ends of all sewer lines unless a manhole is provided at that point. Construct cleanouts in accordance with the details shown on the Drawings. E. Drop Manholes: Install a drop manhole piping assembly in all cases where the distance between the incoming pipe and the floor of the manhole is 2 feet or more. External drop assemblies shall be encased in concrete as indicated in the Drawings. 3.02 GROUTING A. Use the mortar for grouting within 40 minutes after mixing. Discard mortar which has begun to take an initial set. Do not mix mortar with additional cement or new mortar. 3.03 CORROSION PROTECTION A. Surface must be clean and structurally sound. Repair and resurface any defective areas prior to surface preparation. Apply resurfacing material in accordance with the manufacturer’s recommendation. B. Clean and dry the concrete by dry abrasive brush blast removing laitance, form release agents, curing membranes and contaminants to provide a sound, firm surface with no loose matter. Wet abrasive blasting is allowed provided that the water produced does not hinder application. Water blasting alone will not be allowed except for decontamination. Abrasive blasting must produce an anchor pattern on the surface, similar to sandpaper, suitable for coating. Avoid opening excessive cavities during abrasive blast. Round off any sharp edges by chipping, wire brushing or any other method. C. Alternate methods of surface preparation, i.e. acid etch or high pressure water wash, may be used with prior written approval of the liner manufacturer. D. Repair all hydrostatic leaks in the structure prior to applying the liner system. Use a cement base, quick-setting, hydraulic leak repair compound which instantly stops water or seepage and expands as it sets. 3.04 FIELD QUALITY CONTROL A. Manholes shall be tested by hydrostatic exfiltration or vacuum testing in accordance with Section 01 40 00 “Quality Requirements.” Manholes shall be tested after installation with all connections (existing and /or proposed) in place. Drop connections and gas sealing connections shall be installed prior to testing. END OF SECTION Stainless Steel Process Pipe for Liquid Service 40 05 23.23 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 40 05 23.23 STAINLESS STEEL PROCESS PIPE FOR LIQUID SERVICE 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment, and incidentals as shown, specified, and required to furnish and install stainless steel pipe and fittings for liquid service. B. Coordination: 1. Review installation procedures under this and other Sections and coordinate installation of items that must be installed with or before stainless steel piping Work. 1.02 REFERENCES A. Standards referenced in this Section include: 1. ANSI B2.1, Pipe Threads. 2. ANSI B16.1, Cast-Iron Pipe Flanges and Flanged Fittings. 3. ANSI B16.11 Forged Fittings, Socket Welding and Threaded. 4. ANSI B36.19, Stainless Steel Pipe (ASME B36.19M). 5. ASTM A182/A182M, Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service. 6. ASTM A193/A193M, Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service. 7. ASTM A240/A240M, Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications. 8. ASTM A276, Specification for Stainless Steel Bars and Shapes. 9. ASTM A312/A 312M, Specification for Seamless and Welded Austenitic Stainless Steel Pipes. 10. ASTM A320/A320M, Specification for Alloy-Steel and Stainless Steel Bolting Materials for Low-Temperature Service. 11. ASTM A403/A403M, Specification for Wrought Austenitic Stainless Steel Piping Fittings. 12. ASTM A409/A409M, Specification for Welded Large Diameter Austenitic Steel Pipe for Corrosive or High-Temperature Service. 13. ASTM A480/A480M, Specification for General Requirements for Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet and Strip. 14. ASTM A774/A774M, Specification for As-Welded Wrought Austenitic Stainless Steel Fittings for General Corrosive Service at Low and Moderate Temperatures. 15. ASTM A778, Specification for Welded, Unannealed Austenitic Stainless Steel Tubular Products. Stainless Steel Process Pipe for Liquid Service 40 05 23.23 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 16. ASTM F593, Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs 17. AWS D1.6/D1.6M, Structural Welding Code – Stainless Steel. 1.03 QUALITY ASSURANCE A. Qualifications: 1. Manufacturer’s Qualifications: Manufacturer shall have a minimum of five years’ experience producing stainless steel pipe and fittings for liquid service substantively similar to the materials specified, and shall be able to provide documentation of satisfactory service in at least five completed installations. 2. Welders shall be qualified in accordance with AWS D1.6. B. Component Supply and Compatibility: 1. Obtain all materials included in this Section, regardless of component Supplier, from a single stainless steel pipe manufacturer. 2. Stainless steel pipe manufacturer shall review and approve to prepare all Shop Drawings and other submittals for all materials furnished under this Section. 3. Materials shall be suitable for specified service conditions and shall be integrated into overall assembly by stainless steel pipe Supplier. C. Regulatory Requirements: Comply with applicable provisions of the following. 1. ASME Boiler and Pressure Vessel Code. 2. National Fire Protection Association 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Shop Drawings: a. Piping layout Shop Drawings in accordance with Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation. 2. Product Data: a. Product data on pipe, fittings, gaskets, hardware, and appurtenances sufficient to demonstrate compliance with the Contract Documents. B. Informational Submittals: Submit the following: 1. Certificates: a. Certificate of compliance standards referenced in this Section. 2. Qualifications Statements: a. Manufacturer’s qualifications when requested by ENGINEER. 2.00 PRODUCTS 2.01 MANUFACTURERS Stainless Steel Process Pipe for Liquid Service 40 05 23.23 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements A. Manufacturers: Provide products of one of the following: 1. Alaskan Copper & Brass Company. 2. Felker Brothers Corporation. 3. Douglas Brothers Division, Robert Mitchell Co., Inc. 4. Or equal. 2.02 MATERIALS A. Fabricated Stainless Steel Pipe: 1. Pipe: a. Type: Pipe and fittings less than three-inch diameter shall be seamless. Pipe three- inch diameter and larger may be electrically welded or seamless. Spiral welded pipe is not acceptable. b. Material: ASTM A240/A240M, Type 316 stainless steel. c. Diameter: Pipe diameters as shown and specified shall mean nominal outside diameter of pipe, except for pipes specified with schedule numbers for wall thickness. Pipes specified with schedule numbers for wall thickness shall conform to ANSI B36.19. d. Wall Design Criteria: 1). Provide a piping that meets fabrication, installation, and service conditions as shown and specified. 2). Based on internal design pressure indicated for test pressure in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation. 3). Minimum Wall Thickness: Stainless steel piping shall be Schedule 40. e. Fabrication of stainless steel pipe shall be in accordance with ASTM A312 and ASTM A778, where applicable. Large-diameter pipe in corrosive or high-temperature applications shall conform with ASTM A409. 1). Longitudinal Seams: Maximum of two per section of pipe. 2). Girth Seams: Not less than six feet apart, except at fittings and specials. 3). Pipe Ends: Perpendicular to longitudinal axis. 4). Roundness: Tolerance of 1/16-inch. 5). Straightness: Tolerance of 1/8-inch in ten feet. 6). Edges: Joint-edges shall be true so as to not leave shoulder on inside of pipe. f. Welding: 1). Longitudinal Welds: Tungsten Inert Gas or Metal Inert Gas. 2). Circumferential Welds: Heliarc or metallic air process. 3). Grinding: Interior welds shall be ground smooth to provide internal bead of 1/16-inch or less. Stainless Steel Process Pipe for Liquid Service 40 05 23.23 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements g. Factory Finish: 1). Pipe and fittings shall be pickled after manufacture by immersing in acid bath until weld discoloration and iron pickup is removed. 2). Passivate piping welds after fabrication. 3). Thoroughly wash pipe and fittings with clear water after pickling. 2. Joints: a. General: 1). Comply with Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation. 2). Provide flanged joints at connections to valves, equipment, instruments, and at such joints where pipe dismantling may be required to facilitate equipment removal and maintenance. 3). Provide flanged joints for field assembly of exposed and submerged piping. 4). Joints shall be shop welded, unless otherwise shown or specified. 5). Stainless steel pipe fabricated into spool pieces shall have shop-welded circumferential butt-welded joints or flanges. b. Flanged Joints: 1). Two-part flange: a). Slip-on rolled angle face rings of 1/8-inch stainless steel for pipe less than 16-inch diameter, and 3/16-inch thick for pipe 16-inch diameter and larger. Angle face ring thickness shall be equal to or greater than wall of pipe or fitting to which angle face ring is welded, and continuously weld angle face ring to pipe or fitting on both sides. Angle leg shall not interfere with flange bolt holes. b). Backing Flange: Hot-dipped galvanized ductile-iron drilled to ANSI B16.1 Class 125 standards. For submerged joints, backing flanges shall be stainless steel plate flanges. Minimum flange thickness shall be: Diameter Flange Thickness 10 to 12 inches 11/16-inch 14 to 18 inches 3/4inch 20 to 30 inches One-inch 36 to 54 inches 1-3/8-inch Stainless Steel Process Pipe for Liquid Service 40 05 23.23 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2). Gaskets: a). Comply with stainless steel pipe manufacturer’s recommendations for service conditions shown and as specified. 3). Bolts and Nuts: a). Provide stainless steel bolts complete with washers complying with ASTM F593, AISI Type 316 and with nitrided stainless nuts. b). For low-temperature service, comply with ASTM A320/A320M. For high- temperature service, comply with ASTM A193/A193M. 3. Fittings: a. Type: Welded or flanged as shown, all stainless steel. b. Construction: 1). Stainless steel fittings, 2.5-inch diameter and smaller, shall be ASTM A403/A403M, of same material and pressure rating as associate pipe, threaded, long-radius with dimensions conforming to ANSI B16.11. 2). Unless otherwise specified, stainless steel fittings three-inch diameter and larger shall be of same material and same thicknesses as associated pipe. Long-radius elbows up to 24-inch diameter shall be smooth flow. Short-radius, special- radius, and reducing bends, and long-radius bends greater than 24-inch diameter, shall be mitered construction. Reducers shall be tapered, cone type. Tees, crosses, laterals, and wyes shall be shop-fabricated pipe. 3). For general corrosive service at low and moderate temperatures, comply with ASTM A774/A774M. c. Wall Thickness: Conform to wall thickness specified in Section 40 05 05, Exposed Piping Installation, but in no case less than pipe wall thickness. d. Base Fitting: Provide Type 316 stainless steel. 4. Threaded Connections: Threaded pipe, gage, or instrument connections shall be made using stainless steel, 150-pound, threaded half-couplings conforming to ASTM A182/A182M or ASTM A276, shop welded to pipe at locations specified or shown. B. Specials: 1. Taps: a. Provide taps as shown or required for small pipe and instrument connections. b. Connections shall be welded, forged threaded Type 316L stainless steel boss. c. Products and Manufacturers: Provide the following: 1). Thredolet by Grinnell Company. 2). Or equal. 2. Pipe Adapters: Where necessary to join pipe of different type, provide necessary adapters. Ends shall conform to the Specifications for appropriate type joint. C. Welding of Pipe: Stainless Steel Process Pipe for Liquid Service 40 05 23.23 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1. Welding performed under this Section shall be completed in shop. Field welding is not allowed. Welding shall conform to AWS D1.6. 2. Stainless steel joining welds shall be made using fully automatic, inert gas process. Before welding longitudinal butt seal, starting and run off tabs shall be heliarc spot welded to each end of pipe. Ends shall be checked for trueness to axis. Rigid jigs and fixtures shall be used for holding parts in proper alignment during welding. 3. During welding, joint shall be backed up from opposite side with chill bar. Chill bar shall have series of holes running its entire length through which gas is introduced to assure shielding to interior of joint. Welding of joint shall be by automatic arc, inert gas method. Gas shield shall be utilized top and bottom to assure that weld is made in completely inert atmosphere. 4. Filler wire shall be added to all gauges of material to provide cross section of weld metal equal to or greater than parent metal. Filler wire shall be at least one grade higher than parent metal and always of extra low carbon grade. Filler wire shall be automatically fed to weld with rate of travel of automatic welding machine. Use non-consumable tungsten electrode, with shielding gas being either argon or helium. 5. Welds shall be fully penetrated, sound, and of uniform bead. Circumferential welds shall be made using tungsten shielded arc process. Welds shall have full penetration to interior surface of pipe. Provide gas shielding to interior of joint as well as to exterior, to assure that weld is made in completely inert atmosphere. 6. Welds shall have surface finish equal to smoothness of 2D sheet finish. Interior weld beads shall be smooth, evenly distributed, with interior projection not exceeding 1/16- inch beyond inside diameter of pipe or fitting. Ripples or unevenness shall be finely ground to meet above requirements. Major grinding of interior seams to remove excess projection of welds or severe unevenness is not allowed. 7. Outside weld area shall be wire brushed. Brushes shall be of stainless steel and used only on stainless steel material. Exterior discoloration and deposits left by welding shall be removed mechanically with wire brushes or non-metallic abrasives. 2.03 FINAL CLEANING A. After fabrication, mechanically clean accessible weld surfaces with wire brushes or non- metallic abrasives. B. Pipe, fittings, and flanges shall be free of iron particulates and other foreign material. 2.04 IDENTIFICATION A. Pipe and fitting materials shall be stamped, marked, or identified with the following: 1. Name of manufacturer. 2. Date of manufacture. 3. Operating design pressure at operating design temperature. 4. Type of service. 5. Manufacturer’s part number. Stainless Steel Process Pipe for Liquid Service 40 05 23.23 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 3.00 EXECUTION 3.01 INSPECTION A. Inspect pipe materials for defects in material and workmanship. Verify compatibility of pipe and fittings. 3.02 INSTALLATION A. For buried piping installation and testing, refer to Section 33 05 05, Buried Piping Installation. END OF SECTION Miscellaneous Valves 40 05 43 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 40 05 43 MISCELLANEOUS VALVES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment, and incidentals necessary to install miscellaneous valves. Valves and accessories specified in this Section are to be installed only in the absence of product specifications in other Sections and must be approved by the Engineer. Review other Sections for specific requirements. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Shop Drawings. 2. Operation and Maintenance Manuals. 1.03 GUARANTEE AND WARRANTY A. Manufacturer shall warrant the equipment and materials furnished under this Section against defects in materials and workmanship and operational failure for a period of 1 year from the date of Owner acceptance. B. In the event of failure of any part or parts of the equipment during the first year of service, provided that the equipment has been operated and maintained in accordance with good practice, the Manufacturer shall furnish and deliver a replacement for the defective part or parts at the Manufacturer’s own expense. Manufacturer is also responsible for equipment freight. 2.00 PRODUCTS 2.01 PVC BALL VALVES A. PVC Ball Valves shall be furnished for chlorine vacuum and solution lines, alum tanks, polymer tanks, alum pumps, and polymer pumps and as otherwise indicated. B. Valves shall be true union, of Type 1 PVC, with PTFE seats,Viton “O” rings and with socket end connections. C. Valves shall be: 1. ASAHI-America Type 21/21A 2. GF Plastic Systems, Inc. Type 546, 3. Hayward TB Series, or 4. Approved equal. 2.02 CORPORATION STOPS A. Corporation stops shall be bronze with tapered plug and flat key operator. Miscellaneous Valves 40 05 43 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Unless otherwise indicated, stops shall have iron pipe thread on inlet and outlet, of the size indicated. C. Corporation stops shall be: 1. Mueller H-10046 or 2. Approved equal. 2.03 YARD HYDRANT A. Yard Hydrant shall be automatically draining, backflow protected with standard garden hose thread outlet and lever handle. B. Yard Hydrants shall be: 1. Woodford Model Y2, 2. Jay R. Smith Figure Number 5909, 3. Zurn Z1395, or 4. Approved equal. 2.04 GLOBE VALVES A. Globe Valves, where indicated shall be Crane Figure 351 or approved equal with American Standard Class 125 flanges. B. Globe valves for screwed piping shall be equal to Crane No. 1. 2.05 CHLORINE VALVES (NOT USED) 2.06 PRESSURE AND VACUUM RELIEF VALVES (NOT USED) 2.07 DRAIN (MUD) VALVES A. Drain valves shall be non-rising stem mud valves, with cast iron body; bronze stem, stem nut, disc ring, and seat ring; and stainless steel bolts and nuts. Valves shall be furnished with handwheels. B. Drain valves shall be by: 1. Trumbull Industries, Inc. or 2. Approved equal. 2.08 SHEAR GATES A. Shear gates shall be double wedge type, with iron body and bronze wedges. Wedges shall be bolted to the shear gate frame. Gates shall be furnished with a pull rod, lifting handle, and catch. B. Shear Gates shall be: 1. M&H style 44-02 or 2. Approved equal. Miscellaneous Valves 40 05 43 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.09 DIAPHRAGM VALVES A. Diaphragm valves shall be furnished for filling suction and drain lines for caustic tanks and caustic pumps. B. Valves shall be furnished with flanged cast iron body and straight through flow path. Lining shall be ASTM Grade polypropylene. Bonnet shall be cast iron with lubrication fitting, bronze brushing and adjustable travel stop. Diaphragm shall be EPDM elastomer with sealing beads. Valves shall be handwheel operated. C. Diaphragm valves shall be: 1. ITT Dia-Flow Figure #2538-M-903, 2. Saunders Valve, Inc. Type K model, or 3. Approved equal. 2.10 CHECK VALVES FOR CHEMICAL SOLUTION A. General Applications: 1. Check valves in chlorine, sulfur dioxide, alum and polymer solution lines and other locations indicated. Material of construction shall be Type 1 PVC with Viton seats and ends shall be Class 125 flanges, or sockets as indicated or required. 2. Check valves shall be: a. Nibco-Chemtrol Ball Check (BC) Series or b. Approved equal. B. Caustic Soda Applications: 1. Check valves in caustic soda solution line shall consist of a carbon steel body, flanged ends and of the sizes as indicated. a. Crane Swing Check Valve Class 600 or b. Approved equal 2.11 FLAP VALVES (NOT USED) 2.12 PRESSURE REDUCING VALVES A. The Contractor shall furnish and install insert size-inch pressure reducing valve between the high service pump discharge line and the plant service water lines as shown on the Drawings and specified herein. The pressure reducing valve shall be a hydraulically operated, single pilot, globe pattern valve. The valve body shall be cast iron. The pilot valve, piston, liner, seat, and crown shall be bronze. The valve shall receive a 12 mil epoxy coating for corrosion protection. B. The pressure reducing valve shall be suitable for insert psi working pressure, insert psi surge pressure, and shall be capable of reducing a maximum insert psi inlet pressure to a discharge pressure of insert range psi. The diaphragm operated pilot valve shall be easily adjustable providing a minimum discharge pressure range of insert psi. Miscellaneous Valves 40 05 43 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements C. Valve shall come complete with two glycerin filled pressure gauges with snubber fittings, one to monitor upstream pressure in psi, and one to monitor downstream pressure in psi. D. Pressure reducing valves shall be GA Industries Model 4500-D or approved equal. 2.13 TELESCOPIC VALVES (NOT USED) 2.14 BACKFLOW PREVENTERS A. Reduced pressure backflow preventers shall be designed to provide cross-connection protection of potable water supply. B. Provide reduced pressure principle backflow preventers meeting requirements of ANSI/ASSE 1013, compliant with AWWA Standard C511, and approved by the Foundation for Cross- Connection Control and Hydraulic Research at the University of Southern California. C. Units 2-1/2 inches and larger shall consist of two independently acting check valves together with an automatically operating pressure relief valve, two gate valves, and four test cocks, bronze or iron body with bronze internal parts. Acceptable manufacturers and models are: 1. Watts, LF909, 2. Wilkins, 375, and 3. Febco, LF860. D. Units 2 inches and smaller shall consist of two independently acting check valves together with an automatically operating pressure relief valve, two ball valves, strainer, and four test cocks, bronze or iron body with bronze internal parts. Acceptable manufacturers and models are: 1. Watts, LF009, 2. Wilkins, 975XL2, and 3. Febco, 825Y LF825Y. E. Provide test kit consisting of gauge test valves, hoses, adaptors, securing strap, instruction guide and lightweight case. Acceptable manufacturers and models are: 1. Watts, TK-9A, 2. Wilkins, TG-5, and 3. Febco, TK-1. 2.15 DUCKBILL CHECK VALVES (NOT USED) 2.16 SOLENOID VALVES A. Solenoid valve shall be a two-position valve. Solenoid enclosure shall be water tight. The construction of the valve shall be brass with FPM seals. The valve shall be normally open, energize closed. Control voltage shall be coordinated with the control manufacturer. Valve shall be ASCO or approved equal. Miscellaneous Valves 40 05 43 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.17 CHEMICAL INJECTION AND SAMPLE CONNECTIONS A. Materials of construction for chemical injection connections shall be compatible with the chemical solution and shall be capable of withstanding maximum pump discharge line pressure, water main pressure and flow rate. The water main connection shall be a Stainless Steel Ball Valve. Thread connections shall be NPT or AWWA inlet and capable of withstanding maximum water main pressure. Corp. stop must include an acceptable safety device to prevent accidental withdrawal of solution tube while under maximum pressure and/or surge conditions. A ball check valve shall be included to prevent backpressure from the main from entering the chemical feed system. A stainless steel safety chain shall be included to prevent withdrawal of solution tube past Corp. stop. Safety chain length shall be preset by manufacturer for closure of the Corp. stop before withdrawal of solution tube. Operator shall be able to safely withdraw or insert solution tube into center of main while under pressure and without having to shut down the main. Chemical injector assembly shall be Saf-T-Flo, Severn Trent or approved equal. 2.18 SURGE RELIEF/ANTICIPATOR VALVE A. The pressure relief/surge anticipator valve shall control high pressures and power failure surges by bypassing system pressure that exceeds the high-pressure control setting and also by opening a preset amount when sensed pressure decreases below a preset minimum in anticipation of a surge. B. In the event of loss of power, the surge anticipator control valve shall continue to function and relieve the surge while the check valves on the downstream side of each of the raw water pumps close. C. Materials of Construction 1. The materials of construction shall be as specified below. Component Material of Construction Body & Cover Ductile Iron (ASTM A536) Valve Body Configuration Angle Main Valve Trim Stainless Steel Disk Retainer Cast Iron Diaphragm Washer Cast Iron Seat Stainless Steel Stem, Nut, and Spring Stainless Steel (non-magnetic 303) Seal Disk Buna-N Rubber Diaphragm Nylon Reinforced Buna-N Rubber Internal Trim Components Stainless Steel End Connection/Sized/Pressure Rating Flange/12”/Class 150 Other Wetted Metallic Components Stainless Steel Coasting Fusion Bonded Epoxy Coating (Interior and Exterior) – ANSI/NSF 61 Approved D. Main Valve 1. The main valve shall be hydraulically operated, single diaphragm actuated, globe or angle pattern, as specified above. The valve shall consist of three major components: Miscellaneous Valves 40 05 43 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements the body with seat installed; the cover with bearing installed; and the diaphragm assembly. E. Main Valve Body 1. The valve shall contain a resilient, synthetic rubber disc, with a rectangular cross-section contained on three and one half sides by a disc retainer and forming a tight seal against a single removable seat insert. No O-ring type disks 9circulr, square or quad type) shall be permitted as the seating surface. 2. The disc guide shall be of the contoured type to permit smooth transition of flow and shall hold the disk in place. It must have a straight edge sides and a radius at the top edge to prevent excessive diaphragm wear as the diaphragm flexes across this surface. 3. The diaphragm assembly shall include a non-magnetic 303 stainless steel shaft of sufficient diameter to withstand high hydraulic pressure. The shaft shall be fully guided at both ends by a bearing in the main valve cover and an integral bearing in the valve seat. 4. The flexible, non-wicking, FDA approved diaphragm shall consist of nylon fabric bonded with synthetic rubber compatible with the operating fluid. The diaphragm’s center hole for the main valve stem must be sealed by the vulcanized process or a rubber grommet sealing the center stem hole from the operating pressure. 5. The diaphragm shall not be used as the seating surface. The diaphragm shall be fully supported in the valve body and cover by machined surfaces which support no less than one-half of the total surface area of the diaphragm in either the fully opened or fully closed position. 6. The main valve seat and stem bearing in the valve cover shall be removable. F. Pilot Control System 1. The high-pressure surge relief pilot shall be a direct-acting, adjustable, spring-loaded, diaphragm valve designed to permit flow when controlling pressure exceeds the adjustable spring setting. The pressure relief pilot control is normally held closed by the force of the compression in the spring above the diaphragm and it opens when the pressure acting on the underside of the diaphragm exceeds the spring setting. Pressure relief pilot control sending shall be upstream of the pilot system strainer so accurate control may be maintained if the strainer is partially blinded. Pilot shall comply with NSF/ANSI 61. 2. The low-pressure pilot shall be a direct-acting, adjustment, spring-loaded, normally open, diaphragm valve designed to open when the sensed pressure falls below the control setting and close when pressures are normal. The pilot control is held open by the force of the compression on the spring above the diaphragm and it closed when the delivery pressure acting on the underside of the diaphragm exceeds the spring setting. The pilot control system shall include a fixed orifice. The pilot control shall have a second downstream sensing port that can be utilized to install a pressure gauge. Pilot shall comply with NSF/ANSI 61. 3. The pilot system shall include an adjustable flow limited to limit main valve travel during low pressure opening without affecting high-pressure relief valve travel. This hydraulically operated flow limiter has two calibrated orifices, each positioned Miscellaneous Valves 40 05 43 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements proportional to valve position, to vary main valve cover control chamber operating pressure. Mechanical flow meters shall not be permitted. 4. The pilot controls shall be hard piped or bracket mounted to the main valve. 5. The pilot control system shall include a strainer, an adjustable closing speed, and all required control accessories, equipment, control tubing and fittings. The pilot system shall include isolation ball valves on sizes as standard equipment. Pilots shall be manufactured by control valve manufacturer. 6. The surge anticipating control valve shall include a visual position indicator assembly. 7. The materials of construction for the pilot control system shall be as specified below. Component Material of Construction Flow Limiter Body Adjustment Tube O-Rings Stem Brass Brass Buna-N Stainless Steel Pilots (High and Low) Body & Cover Pilot trim Pilots Rubber Pilots Connections Pressure Rating Stainless Steel Stainless Steel 303 Buna-N FNPT 400 psi (maximum) Control Tubing and Fittings Stainless Steel 8. Each control valve shall be factory assembled and tested. Factory testing shall include a valve body and cover leakage test, seat leakage test, and a stroke test. Control valves and pilot valves, in the partially open position, with both ends closed off with blind flanges for valves and pipe plugs for pilots, shall be subject to an air test. The applied air pressure shall be 90 psi (minimum) and shall be applied for a minimum of 15 minutes, with no visible leakage permitted through the valve seat, the pressure boundary walls of the valve body, body cover, pilot body, pilot cover, or body-cover joint. G. Surge anticipator valve shall be by: 1. Cla-Val Series 52.03 or 2. Approved Equivalent by Bermad Series 735. 3.00 EXECUTION 3.01 INSTALLATION A. Carefully handle and install valves in a manner that prevents damage to any part of the valves. Install valves in accordance with the Manufacturer’s instructions. END OF SECTION Identification for Process Piping and Equipment 40 05 53 - 1 DTN18194 – Lake Lewisville WTP Improvements Phase II 40 05 53 IDENTIFICATION FOR PROCESS PIPING AND EQUIPMENT 1.00 GENERAL 1.01 WORK INCLUDED A. Provide identifying devices for the following: 1. Piping. 2. Equipment. 3. Electrical Equipment. 4. Valves. 5. HVAC equipment. 6. Fire sprinkler and piping. 7. Control devices. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Product data sheets for identifying devices. 2. A list of where devices are to be installed, and the data to be included on each identifying device. 1.03 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American National Standards Institute (ANSI) Standards: ANSI A13.1 Pipe Marking Specifications 1.04 DELIVERY AND STORAGE A. Store products inside storage sheds until installed. 1.05 GUARANTEES A. Guarantee Identifying devices installed in wet locations or areas subject to moisture to be weather resistant for a period of 3 years after installation. 2.00 PRODUCTS 2.01 MATERIALS A. Piping Identification: Pressure sensitive, adhesive-backed vinyl plastic label having the lettering indicated on background color as scheduled. Provide labels manufactured by the Identification for Process Piping and Equipment 40 05 53 - 2 DTN18194 – Lake Lewisville WTP Improvements Phase II Seton Name Plate Corp. or Brady “Perma Code”. Provide labels having an arrow to indicate the direction of flow. Provide 1-1/4-inch high letters. B. Outdoor Pipe Markers: Seton “Weather Code” Fade resistant, vinyl markers, 2-1/4 by 9 inches. C. Valve Identification: Provide Seton Style 2961, 1-1/2-inch round, plastic tag with proper identification stamped on tag. Tag shall have the proper prefix followed by a code number that is unique and identifies the valve from all others in the project. Provide hole in top of tag for mounting chain. Provide brass jack chain, copper metal meter seals, or brass “S” hooks as appropriate. D. Equipment Nameplate: Seton Style 2060 “Seton-ply” engraved plastic plaque, approximately 3/4 by 2-1/2 inches in size. Plaque shall be 1/16 inch thick having beveled edges and drilled with two mounting holes when attached by screws. Mounting screws shall be stainless steel. Lettering shall be approximately 3/16 inch high. Text to include equipment mark and equipment description (Example: EXHAUST FAN EF-5). Identification label on nameplate shall correspond to a typewritten legend included in the O & M Manual which includes the following: 1. Equipment identifier. 2. Location inside building (or on project site). 3. Manufacturer’s model number. 4. Brief description of function. 5. Reference to shop drawings, parts lists, or other data included in the O & M Manual. E. Fire Sprinkler System Signs: Signs for fire protection system shall conform to NFPA-13 and shall be equal to Seton Style SFB, furnished in porcelain with “white on red” color. 3.00 EXECUTION 3.01 PREPARATION A. Install piping complete with insulation and valves in place prior to installing identification devices. Mount electrical components, including electrical control devices. Piping shall be dry and free of oil, grease, or other contaminants. Insulation shall be completely dry. 3.02 INSTALLATION A. Install pipe labels on piping exposed to view, in any location inside buildings or structures, or in underground vaults, pump stations, basements, or other exposed locations. B. Install a minimum of one label in each area or room and additional labels at spacings not to exceed 5 feet. Position labels so that lettering is visible from the front of piping at floor level. Provide labels of a size that is legible from floor level. Install labels in rows with uniform spacings where several pipes run parallel to each other. C. Name the fluid flowing inside the pipe on color coded labels with text per the schedule below. Labels shall also include an arrow indicating the direction of flow. Identification for Process Piping and Equipment 40 05 53 - 3 DTN18194 – Lake Lewisville WTP Improvements Phase II 3.03 VALVE IDENTIFICATION A. Install a valve tag on all valves 6-inches and larger. Attach the tag to hand wheel of valve stem so that it does not interfere with operation of valve tag brass link chains or copper meter seals furnished by the Tag Manufacturer. B. Number valves to correspond to a typewritten list included in the Operational and Maintenance Manual and include the following information: 1. Valve Number. 2. Description of piping fluid or purpose. 3. Normal position of valve (Open or Closed). 4. Manufacturer’s catalog number. 5. Brief description of valve specification. 6. Brief description of valve’s function in the system. C. Valve identification shall be based on the following example: Valve Number Function Location Normal Position Mfg’s Cat No. Valve Type Description P-1 Domestic Water Rm. 103 Open Crane Fig. 315C Gate rising stem Shut off to heater 3.04 EQUIPMENT IDENTIFICATION A. Provide an equipment identifier on each separate piece of equipment, including process equipment, HVAC equipment, plumbing equipment (other than plumbing fixtures), and electrical equipment. Provide a nameplate for each separate piece of electrical equipment, including but not limited to panelboards, switchgear, starters, disconnects, control devices and control panels. Provide name tags for each separate switch, starter, contactor, or other compartment on electrical switchgear. B. Engrave lettering on nameplates corresponding to the identification marks. Install nameplates prominently on equipment not occurring in occupied spaces. Install nameplates on the inside covers of lighting panelboards. Install nameplates on all other equipment centered and at top of equipment. Nameplates shall not be installed in a location that interferes with the equipment’s ability to operate. C. Attach nameplates to exterior equipment with two 3/8-inch stainless steel screws. Interior plaque may be attached by screws, or by the adhesion method when approved by the Engineer. 3.05 ELECTRICAL OUTLET A. Provide a nameplate for electrical outlet listed below. The nameplate shall be white letters on red background, and shall specify the outlet’s voltage and ampere rating. The nameplate on special outlets shall have an appropriate warning. Lettering shall be 1/8 inch high. Overall plate size shall be approximately 3/4 by 2-1/2 inches. B. Provide nameplates on the following: Identification for Process Piping and Equipment 40 05 53 - 4 DTN18194 – Lake Lewisville WTP Improvements Phase II 1. 208/240 outlet: voltage and ampere rating. 2. Special outlet: voltage, ampere rating and intended function (Example: Welder Outlet 240 V – 40 A). 3.06 POTABLE AND NON-POTABLE WATER A. Provide name tags at every water hydrant or outlet. Fabricate name tags of 3/4-by-1-1/2- by-1/8-inch aluminum with a medium, duranodic finish and plexiglas face panel. The face panel shall have 1-inch high, white, helvetica medium lettering on blue background stating “Potable Water”, or white lettering on green background stating “Non-Potable Water”. Place signs on walls above the hydrant locations and attach to backplates. Yard hydrants shall have concrete piers which are 6 inches in diameter by 36 inches with signs attached to the face of the concrete directly in front of the hydrants. Extend the piers 4 inches minimum above finish grade. Signs shall be manufactured by Vomer Products, Inc., equal to Vocator Exterior sign series E9/12. 3.07 SCHEDULES A. Prepare a typed schedule showing piping label requirements, valve tag identification, and equipment tags. Include each valve or piping type and the appropriate identification on the schedule. Submit the schedule to the Engineer for approval. B. Mark valve tags and pipe labels to conform with the following legend, or with requirements of standards noted. Include the full name, as appearing under the column heading “Description”, and the abbreviation under the column heading “Abbrev. Legend.” Description Valve Prefix Abbrev. Legend Label Color (Letter on Background) Plumbing Sewer, Sanitary W SW Black on Green Sewer, Storm SS SS Black on Green Waste, Drain W DP Black on Green Water, Domestic, Cold P CW Black on Green Water, Domestic, Hot P HW Black on Yellow Water, Domestic, Ret. P HWR Black on Yellow Water, Non-potable N NPW Black on Green Fire Protection Fire Protection, Mains F FM White on Red Fire Protection, Sprinkler F FS White on Red Gas Piping Natural Gas G NG Black on Yellow Fuel Gas G NG Black on Yellow Oxygen G OX Black on Yellow Identification for Process Piping and Equipment 40 05 53 - 5 DTN18194 – Lake Lewisville WTP Improvements Phase II Description Valve Prefix Abbrev. Legend Label Color (Letter on Background) Compressed Air G CA White on Blue Instrument Air G IA White on Blue HVAC Refrigerant, Suction H RS Black on Green Refrigerant, Liquid H RL Black on Green Chilled Water H CW Black on Green Chilled Water Ret. H CWR Black on Green Hot Water H HW Black on Yellow Hot Water, Ret. H HWR Black on Yellow Condensate H CD Black on Green Process Piping Chlorine PP CH Black on Yellow Ammonia PP AM Black on Yellow Primary Effluent PP PE White on Green Sludge PP PS White on Green Electrical Panelboards LP-1 White on Black Starters for Exhaust Fan S/EF-1 White on Black Control Panels for Exhaust Fan CP/EF-1 White on Black Disconnects for Exhaust Fan DS/EF-1 White on Black Junction Boxes JB/101 White on Black Controllers for Exhaust Fan CI/EF-1 White on Black C. Piping Color Schedule: Description Pipe Color Potable Water Dark Blue Compressed Air Dark Green Instrument Air Light Green with Dark Green Bands Chlorine (solution) Yellow Liquid Alum Orange Alum (solution) Yellow with Green Bands Ammonia White Polymers Orange with Green Bands Identification for Process Piping and Equipment 40 05 53 - 6 DTN18194 – Lake Lewisville WTP Improvements Phase II Description Pipe Color Caustic (solution) White with Orange Bands Fluoride Light Blue with Red Bands Ozone Yellow with Orange Bands Settled Water Aqua Filter Effluent Light Blue Backwash Supply Light Blue Drain Dark Grey Raw Water Tan END OF SECTION Gate Valves 40 05 61 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 40 05 61 GATE VALVES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install gate valves and appurtenances, including valve boxes, operators, bolts, nuts and gaskets. 1.02 QUALITY ASSURANCE A. Acceptable Manufacturers: 1. Crispin Ludlow-Rensselaer. 2. American-Flow Control. 3. M&H. 4. Mueller. 5. Clow. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Operation and Maintenance Manuals. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American National Standards Institute (ANSI) Standards: ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings 2. American Society for Testing and Materials (ASTM) Standards: ASTM A126 Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings ASTM A536 Standard Specification for Ductile Iron Castings 3. American Water Works Association (AWWA) Standards: AWWA C111 Rubber-Gasket Joints AWWA C500 Gate Valves for Water and Sewage Systems AWWA C509 Resilient Seated Gate Valves for Water and Sewage Systems Gate Valves 40 05 61 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.00 PRODUCTS 2.01 GATE VALVES A. General: 1. Unless otherwise specified, gate valves greater than 24 inches in size shall be in strict accordance with AWWA C500. Gate valves shall be double disc, parallel seat internal wedging type with non-rising stem. Unless otherwise specified, gate valves 3 through 24 inches in size shall be in accordance with AWWA C509, Resilient Wedge. [Manual operated valves 16 inches and larger shall be provided with gearing to reduce the maximum required opening and closing torque to 80 ft-lb. 2. Gate valves 2-1/2 inches and smaller shall be bronze, non-rising stem with wedge disc and screwed ends for 300-psi W.O.G. working pressure. Bronze gate valves shall be Crane No. 437, Mueller No. H 10914, or approved equal. 3. Gate valves 30 inches and larger shall be equipped with non-rising stem bypass valve and with spur-gears in enclosed oil or grease lubricated gear cases. Gear boxes shall be factory lubricated. Flanges shall conform to ANSI, Class 125. B. Gate: Gate for double disc valves shall be cast iron with bronze mounted wedges and seats. Gate for resilient seated valves shall be cast iron with rubber-seat compound bonded to the valve gate. C. Slime Line Valves: Where called out on the drawings, the use of slim line double gate valve shall be utilized. The requirements specified for double-disk gate valves shall apply; however, the laying length and weight will be less than a typical gate valve. Slime line valves shall be provided with flushing/clean-out ports for each of maintenance in typical low flw and low pressure applications. D. Stem and Seal: The non-rising stem shall be bronze with inside screw. Shaft seal shall employ O-rings or V-type packing. E. Bell Ends: Where designated, valves shall be mechanical joint or rubber gasketed push on joints in accordance with the applicable requirements of AWWA C111. 2.02 VALVE OPERATORS A. Manual operators shall turn counterclockwise to open the valve. Exposed valves shall have handwheel operators unless otherwise designated. A directional arrow and the word “open” shall be cast on the handwheel. Valves for buried service shall have a 2-inch square nut operator and shall be installed with extension stems where required to extend operating nut to within 12 inches of the finished grade. Provide a cast iron valve box to enclose the operating stem. Valve box shall be three-piece extension type equal to Mueller No. 10380 or Clow F2450. 2.03 ELECTRIC MOTOR OPERATORS A. General: 1. The valve operators shall be of the reversible motor type. The rate torque capacity of each operator shall be sufficient to seat, unseat, and rigidly hold in any position the valve disc that is controlled under the operating conditions. Gate Valves 40 05 61 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Operators shall be self-contained units comprising housing, motor reversing contactor, limit switches, torque switches, relays, control transformer, gear train and auxiliary handwheel. Approved valve operator manufacturers are AUMA, EIM, Limitorque, and Rotork. 3. Operator shall move the valve from fully open to fully closed position, or from fully closed to fully open, in approximately 60 seconds. Time of travel shall be based on a geared reducer, not jogging the motor. B. Construction: 1. Operators shall be equipped with an auxiliary handwheel to provide for actuation of the valve in the event of a power failure. The handwheel shall have a clutch so that it will not turn during normal operation of the valve. The clutch shall lockout the motor so that it will not engage when the wheel is turning. 2. Each operator shall have an integral three-phase, full voltage, reversing contactor with electrical and mechanical interlocks and three over-load sensing relays. The contactor shall operate on 120 VAC and shall have a control transformer 460/230 VAC to 120 VAC. The control transformer shall be sized with sufficient capacity to operate the contactor and the motor switch compartment heaters. 3. Limit switches shall be furnished for the end of stroke disconnect, other control functions, and remote and local Open and Closed indications. Limit switches shall be independently adjustable at the open and close limits. Auxiliary limit switches for remote Open and Closed indication shall have isolated Form C contacts rated at 120 VAC. 4. The operator enclosure shall be NEMA 4X. Space heaters with thermostat shall be provided in the enclosure of wattage suitable for keeping the compartment dry at all times. There shall be installed also a suitable breather and drain. A laminated schematic wiring diagram shall be attached and protected from the environment for maintenance use. A terminal strip shall be provided in the switch compartment. Controls and switch compartments shall be shop wired to terminal strip complete and ready for field installation. All wires to terminal strip shall be identified. 5. Motor shall be for 460/230-VAC, 3-phase, 60-Hertz service, and control voltage shall be 120 VAC provide by an internal transformer. Motor shall be designed for continuous use. 6. Valves shall have Local-Remote selector switch, Open/Stop/Close Pushbuttons and Open and Closed indicator lights mounted on the operator. Selector switches and pushbuttons shall be provided with water-tight boots. 7. Non-modulating valves shall receive an open signal and a closed signal from remote, and shall provide contacts for REMOTE STATUS, OPENED, CLOSED, HIGH TORQUE. 3.00 EXECUTION 3.01 INSTALLATION A. Carefully handle and lower buried valves into position to prevent damage to any part of the valves. Place the valve in the proper position with stem truly vertical and securely hold until Gate Valves 40 05 61 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements connections have been made. Furnish bolts, nuts, and gaskets. The Contractor shall be responsible for adjusting the valve boxes to the proper length to conform with the ground surface. 3.02 BLOCKING UNDER GATE VALVE A. Gate valves 18 inches and larger which are buried shall rest on a concrete pad. Pad shall extend for the full width of the trench and from back of hub to back of hub (or flange). Care shall be taken to not interfere with the jointing. Concrete shall be minimum 1500-psi compressive strength. 3.03 FIELD QUALITY CONTROL A. Upon completion of installation of the equipment, an acceptance test to verify the satisfactory operation of each unit shall be conducted. The test shall be conducted in a manner approved by and in the presence of the Engineer. The unit shall be checked for general operation and leakage. The unit must perform in a manner acceptable to the Engineer before final acceptance will be made by the Owner. 3.04 SCHEDULE A. The required valves, 6 inches and larger, and certain pertinent data are given below. No. Req’d Description Size Ends Max. Diff (psi) Type Service 1 Lk. Lewisville RWPS Lower Intake Isolation (Slim Line Style with Electric Motor Operator) 36” FLG 20 Raw Water – Open/Close 1 Lk. Lewisville RWPS Upper Intake Isolation (Slim Line Style with Electric Motor Operator) 36” FLG 10 Raw Water – Open/Close 2 HSP No. 1 & 4 Discharge Isolation 20” FLG 150 Finished Water – Open/Close 1 HSPS Header Room Alt. Backwash Isolation 16” FLG 150 Finished Water – Open/Close 1 Offsite Distribution 30” Field Determ. 150 Finished Water – Open/Close 1 Offsite Distribution 36” Field Determ. 150 Finished Water – Open/Close END OF SECTION Eccentric Plug Valves 40 05 62 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 40 05 62 ECCENTRIC PLUG VALVES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install eccentric plug valves. 1.02 QUALITY ASSURANCE A. Acceptable Manufacturers: 1. Crispin. 2. DeZurik. 3. Pratt. 4. Val-Matic. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Shop drawings. 2. Operation and Maintenance Manuals. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American Water Works Association (AAWA) Standards: AWWA C111 Standard for Rubber Gasket Joints for Ductile Iron Pipe and Fittings AWWA C504 Standard for Rubber-Sealed Butterfly Valves 2.00 PRODUCTS 2.01 MATERIALS A. Valve Bodies: Constructed of cast iron, ASTM A126, Class B, in accordance with AWWA C504. B. Flanges: Class 125 conforming to ANSI standard for cast-iron flanges. C. Mechanical Joint Ends: For buried service shall be to AWWA Standard C111. D. Nuts, Bolts, Springs, Washers, etc.: Type 316 Stainless Steel. E. Resilient Plug Facings: Neoprene, nitrile rubber, BUNA-N, or approved equal. F. Mating Surface: Overlaid with thick, welded and machined nickel alloy. Eccentric Plug Valves 40 05 62 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements G. Valve Boxes: Three piece cast iron extension type, Mueller No. 10380 or Clow F2450, with No. 6 round base. The three pieces shall consist of the top section, center section, and base plus the cover. 2.02 ECCENTRIC PLUG VALVES A. Eccentric valves shall be non-lubricated quarter-turn type with resilient faced plugs. Unless otherwise indicated, buried valves shall be furnished with mechanical joint ends and exposed valves shall be furnished with flanged ends. Valves shall have a minimum nominal port area of 80 percent of the pipe for valve sizes up to 20 inches. Port area for valves 24 inches and larger shall be at least 70 percent of full pipe area. B. Valves 6 inches and smaller shall be wrench operated unless otherwise shown or scheduled. Supply a wrench operator for each wrench operated valve. Larger valves shall be supplied with a handwheel. Valves shall have seals on shafts and gaskets on the valve operator covers to prevent the entry of water. C. Valves larger than 6 inches shall be side-mounted and come complete with a totally enclosed worm gear operator. Valves shall have seals on all shafts and gasketed valve operator covers to prevent the entry of water. D. Valves for buried service shall be supplied with cast iron valve boxes. The valve box shall be firmly supported, maintained, centered, and plumb over the wrench nut of the plug valve, with box cover flush with the surface of the ground. E. Where noted on the Plans or scheduled herein, buried valves shall be supplied with above- ground handwheel or electric motor operators. The Manufacturer shall supply valve box, floor stand and extension stem and necessary appurtenances for complete installation. The floor stand shall come complete with a dial valve position indicator. 2.03 ELECTRIC MOTOR OPERATORS A. General: 1. The valve operators shall be of the reversible motor type. The rate torque capacity of each operator shall be sufficient to seat, unseat, and rigidly hold in any position the valve disc that is controlled under the operating conditions. 2. Operators shall be self-contained units comprising housing, motor reversing contactor, limit switches, torque switches, relays, control transformer, gear train and auxiliary handwheel. Approved valve operator manufacturers are AUMA, EIM, Limitorque, Rotork. 3. Operator shall move the valve from fully open to fully closed position, or from fully closed to fully open, in approximately 60 seconds. Time of travel shall be based on a geared reducer, not jogging the motor. B. Construction: 1. Operators shall be equipped with an auxiliary handwheel to provide for actuation of the valve in the event of a power failure. The handwheel shall have a clutch so that it will not turn during normal operation of the valve. The clutch shall lockout the motor so that it will not engage when the wheel is turning. Eccentric Plug Valves 40 05 62 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Each operator shall have an integral three-phase, full voltage, reversing contactor with electrical and mechanical interlocks and three over-load sensing relays. The contactor shall operate on 120 VAC and shall have a control transformer 460/230 VAC to 120 VAC. The control transformer shall be sized with sufficient capacity to operate the contactor and the motor switch compartment heaters. 3. Limit switches shall be furnished for the end of stroke disconnect, other control functions, and remote and local Open and Closed indications. Limit switches shall be independently adjustable at the open and close limits. Auxiliary limit switches for remote Open and Closed indication shall have isolated Form C contacts rated at 120 VAC. 4. The operator enclosure shall be NEMA 4X. Space heaters with thermostat shall be provided in the enclosure of wattage suitable for keeping the compartment dry at all times. There shall be installed also a suitable breather and drain. A laminated schematic wiring diagram shall be attached and protected from the environment for maintenance use. A terminal strip shall be provided in the switch compartment. Controls and switch compartments shall be shop wired to terminal strip complete and ready for field installation. All wires to terminal strip shall be identified. 5. Motor shall be for 460/230-VAC, 3-phase, 60-Hertz service, and control voltage shall be 120 VAC provide by an internal transformer. Motor shall be designed for continuous use. 6. Valves shall have Local-Remote selector switch, Open/Stop/Close Pushbuttons and Open and Closed indicator lights mounted on the operator. Selector switches and pushbuttons shall be provided with water-tight boots. 7. Non-modulating valves shall receive an open signal and a closed signal from remote, and shall provide contacts for Remote Status, Opened, Closed, High Torque. 3.00 EXECUTION 3.01 INSTALLATION A. Carefully handle and lower valves into position in such a manner as to prevent damage to any part of the valves. Place the valve in the proper position with stem truly vertical or horizontal as the case may be. Furnish bolts and gaskets for flange connections. Adjust the valve boxes to the proper length to conform with the ground surface. 3.02 PAINTING A. Valves to be exposed shall be cleaned to a bright metal and given a shop coat of rust inhibitive primer. Primer shall be coordinated with field painting to ensure compatibility. Final painting shall be in accordance with Section 09 96 00.01 “High-Performance Coatings.” Eccentric Plug Valves 40 05 62 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 3.03 SCHEDULES A. The required valves, 6 inches and larger, and certain pertinent data are given below. No. Req’d Description Size Ends Max. Diff (psi) Type Service 16 Filter Effluent Isolation (Valve and Electrical Motor Actuator) 12” FLG 10 Filtered Water – Open/Close 16 Filter Drain (Electric Motor Actuator Only) 16” N/A 10 Backwash Waste – Open/Close END OF SECTION Butterfly Valves 40 05 64 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 40 05 64 BUTTERFLY VALVES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install butterfly valves. 1.02 QUALITY ASSURANCE A. Acceptable Manufacturers: 1. DeZurik. 2. M&H. 3. CMB/K-Flo. 4. Pratt. B. Experience Requirements: The Manufacturer shall have had successful experience in manufacturing tight-closing, rubber-seated butterfly valves for this type service in the sizes indicated. The Manufacturer shall have at least 10 years’ experience in the manufacture of valves. C. Manufacturer’s Representative for Startup and Testing: The Valve Vendor or Manufacturer shall provide the services of a competent manufacturer’s representative for an indefinite period of time as required to insure proper adjustment, installation, and operation of the valve. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Shop Drawings (needed if electric actuators are used). 2. Operation and Maintenance Manuals. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American National Standards Institute (ANSI) Standards: ANSI B16.1 Cast Iron Pipe Flanges and Fittings 2. American Society for Testing and Materials (ASTM) Standards: ASTM A48 Standard Specification for Gray Iron Castings ASTM A126 Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings ASTM A276 Standard Specifications for Stainless Steel Bars ASTM A536 Standard Specification for Ductile Iron Castings Butterfly Valves 40 05 64 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements ASTM B148 Standard Specifications for Aluminum Bronze Coatings 3. American Water Works Association (AWWA) Standards: AWWA C504 Standard for Rubber-seated Butterfly Valves AWWA C550 Standard for Protective Interior Coatings for Valves and Hydrants 2.00 PRODUCTS 2.01 VALVE CONSTRUCTION A. General: Butterfly valves supplied under this Contract shall be of the tight-closing, rubber seated type with rubber seats that are securely attached to the valve disc or body. Valves shall be bubble tight at rated pressures with flow in either direction and shall be satisfactory for applications involving valve operation after long periods of inactivity. Butterfly valves shall conform to the applicable requirements of AWWA C504 and AWWA C550. All valves for potable water service shall comply with NSF61 standards. B. Valve Bodies: Valve bodies shall be constructed of cast iron ASTM A126, Class B or ASTM A48, Class 40 or ductile iron in accordance with ASTM A536, Grade 65/45/12. Valve class shall be suitable for the pressure class of the adjacent pipe in which it is installed or as shown in the valve list herein. C. Valve Discs: Valve discs shall be cast iron conforming to ASTM A126, Class B, aluminum bronze conforming to ASTM B148, or ductile iron conforming to ASTM A536, Grade 65/45/12. D. Valve Shafts: Valve shafts shall be turned, ground and polished, constructed of stainless steel conforming to ASTM A276. Valve shafts may consist of a one-piece unit extending completely through the valve disc, or may be of the “stub shaft” type, which comprises two separate shafts inserted into the valve disc hubs. If of the “stub shaft” construction, each stub shaft shall be inserted into the valve disc hubs for a distance of at least 1-1/2 shaft diameters. The shaft shall be tightly connected to the disc using tapered or wedged keying devices. E. Valve Seats: Valves shall have EPDM or EPDM-P resilient seats to provide tight shut off at the pressure specified. The mating seat surface shall be ASTM A276, 18-8 stainless steel or a 95 percent pure nickel overlay. All valves shall have replaceable, adjustable seats. Valves 30 inches and larger shall have in-line replaceable seats. F. Valve Bearings: Valve shall be fitted with sleeve type bearings. Bearings shall be of corrosion-resistant and “self-lubricated” materials that will not deteriorate natural or synthetic rubber. G. Valve Shaft Seals: Where shafts project through the valve bodies for operator connection, a split-V or O-ring type shaft seal shall be provided. 2.02 VALVE OPERATORS: A. General: The valve operator shall be designed and manufactured in accordance with the applicable requirements of AWWA C504 and AWWA C540, and shall be arranged for horizontal or vertical valve shaft installation. Butterfly Valves 40 05 64 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements B. Manual Operators: 1. Manual operators shall have all gearing totally enclosed and shall be pre-lubricated or grease packed. Operators shall be of the worm gear or travelling nut and link type with field adjustable stops to prevent over travel in the open or closed positions. The direction of the manual rotation shall be clockwise to close. 2. Operators for exposed valves shall be provided with a valve position indicator and a handwheel or chain and sprocket device. Provide chain and sprocket for valves greater than 6 feet above walking surface. 3. Operators for buried valves shall have an extended stem with a 2-inch square operating nut within 12 inches of the finished grade. Provide a cast iron valve box to enclose the operating stem. Valve box shall be three-piece extension type equal to Mueller No. 10380 or Clow F2450. For valves which are installed with the shaft vertical, provide a level gear for vertical operation of the operating nut. 2.03 ELECTRIC MOTOR OPERATORS A. General: 1. The valve operators shall be of the reversible motor type. The rated torque capacity of each operator shall be sufficient to seat, unseat, and rigidly hold in any position the valve disc that is controlled under the operating conditions. 2. Operators shall be self-contained units comprising housing, motor reversing contactor, limit switches, torque switches, relays, control transformer, gear train and auxiliary handwheel. Approved valve operator manufacturers are AUMA and Rotork. 3. Operator shall move the valve from fully open to fully closed position, or from fully closed to fully open, in approximately 60 seconds. Time of travel shall be based on a geared reducer, not jogging the motor. B. Construction: 1. Operators shall be equipped with an auxiliary handwheel to provide for actuation of the valve in the event of a power failure. The handwheel shall have a clutch so that it will not turn during normal operation of the valve. The clutch shall lockout the motor so that it will not engage when the wheel is turning. 2. Each operator shall have an integral three-phase, full voltage, reversing contactor with electrical and mechanical interlocks and three over-load sensing relays. The contactor shall operate on 120 VAC and shall have a control transformer 460/230 VAC to 120 VAC. The control transformer shall be sized with sufficient capacity to operate the contactor and the motor switch compartment heaters. 3. Limit switches shall be furnished for the end of stroke disconnect, other control functions, and remote and local Open and Closed indications. Limit switches shall be independently adjustable at the open and close limits. Auxiliary limit switches for remote Open and Closed indication shall have isolated Form C contacts rated at 120 VAC. 4. The operator enclosure shall be NEMA 4X. Space heaters with thermostat shall be provided in the enclosure of wattage suitable for keeping the compartment dry at all Butterfly Valves 40 05 64 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements times. There shall be installed also a suitable breather and drain. A laminated schematic wiring diagram shall be attached and protected from the environment for maintenance use. A terminal strip shall be provided in the switch compartment. Controls and switch compartments shall be shop wired to terminal strip complete and ready for field installation. All wires to terminal strip shall be identified. 5. Motor shall be for 460/230-VAC, 3-phase, 60-Hertz service and control voltage shall be 120 VAC provide by an internal transformer. Motor shall be designed for continuous use and modulating actuators rated for jogging duty. 6. Valves shall have Local-Remote selector switch, Open/Stop/Close Pushbuttons and Open and Closed indicator lights mounted on the operator. Selector switches and pushbuttons shall be provided with water-tight boots. 7. Modulating valves shall receive a 4-20 mA positioning signal and position based on 4 being full closed and 20 being full open. Outputs from the valve shall include a 4-20 mA signal indicating valve position, and contacts for REMOTE STATUS, OPENED, CLOSED, HIGH TORQUE. 3.00 EXECUTION 3.01 INSTALLATION A. Installation shall be in accordance with the Manufacturer’s instructions. Valve shaft shall be truly vertical or horizontal as indicated. 3.02 FIELD QUALITY CONTROL A. Upon completion of installation of the butterfly valves an acceptance test shall be conducted to verify the satisfactory operation of the valves. The valves must perform in a manner acceptable to the Engineer before final acceptance will be made by the Owner. 3.03 SCHEDULES; VALVES A. The required valves and certain pertinent data is given below. This list is given to facilitate description of the various valves and as an aid to plan take off and is not guaranteed to be complete. Location/ Description Service No. Req’d Size AWWA Class Max. Diff. (psi) Type Operator Filtered Water Line West of Filter Building Filtered Water 1 30” 25 psi 25 Manual, Buried (Geared) HSPs 1 & 4 Discharge Line Finished Water (Throttling) 2 18” 250 psi 50 Positioning Electric Motor Operator HSPs 5 & 6 Suction Connections Finished Water (Isolation) 2 36” 25 psi 25 Manual, Geared Butterfly Valves 40 05 64 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements Common Disch. Header West of HSPS Finished Water (Isolation) 3 36” 250 psi 150 Manual, Buried (Geared) END OF SECTION Swing Check Valves 40 05 65.23 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 40 05 65.23 SWING CHECK VALVES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install swing check valves (external weight and lever) at the locations and size as indicated. Valves shall be designed, manufactured and tested in accordance with American Water Works Association Standards ANSI/AWWA C508. B. Furnish labor, materials, equipment and incidentals necessary to install an oil controlled, side-mount, cushioned swing check valves at the locations and sizes as indicated. Valves shall be designed, manufactured and tested in accordance with American Water Works Association Standards ANSI/AWWA C508. C. Furnish labor, materials, equipment and incidentals necessary to install an air controlled, side-mount, cushioned swing check valves at the locations and sizes as indicated. Valves shall be designed, manufactured and tested in accordance with American Water Works Association Standards ANSI/AWWA C508. D. Furnish labor, materials, equipment and incidentals necessary to install a rubber flapper swing check valves at the locations and sizes as indicated. Valves shall be designed, manufactured and tested in accordance with American Water Works Association Standards ANSI/AWWA C508. 1.02 QUALITY ASSURANCE A. Acceptable Manufacturers: 1. APCO Valve & Primer Corporation. 2. Crispin Valve Company. 3. Golden Anderson Equal Model. 4. Val-Matic. B. Experience Requirements: The Manufacturer shall have had successful experience in manufacturing valves for this type service in the sizes indicated. The Manufacturer shall have at least 10 years’ experience in the manufacture of the valves. C. Manufacturer’s Representative for Startup and Training: The Manufacturer shall provide the services of a competent manufacturer’s representative for an indefinite period of time as required to insure proper adjustment, installation and operation of the valve. D. All valves shall be hydrostatically tested and seat tested to demonstrate zero leakage. When requested, the Manufacturer shall provide test certification and required documentation. The valve coating system shall be NSF61 approved. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: Swing Check Valves 40 05 65.23 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 1. Shop Drawings. 2. Operation and Maintenance Manuals. 1.04 STANDARDS A. The following standards shall apply as if they are included in these documents: 1. American Society for Testing and Materials (ASTM) Standards: ASTM A126 Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings ASTM A536 Standard Specification for Ductile Iron Castings ASTM A276 Standard Specifications for Stainless Steel Bars ASTM A582 T303 Standard Specification for Free-Machining Stainless Steel Bars 2. American Water Works Association (AWWA) Standards: AWWA C508 Swing-Check Valves for Waterworks Service, 2- through 24-inch NPS 2.00 PRODUCTS 2.01 SWING CHECK VALVES A. The check valves used shall be swing check valves unless otherwise specified and shall be constructed with a ductile iron body and stainless steel body seat ring, single continuous stainless steel shaft for attachment of weight and lever, and complete aluminum alloy air cylinder. The air cushion cylinder shall be totally enclosed, and externally attached to the side of the valve body with the cylinder piston rod connected to the external lever arm in a manner to lift the piston upwards when flow starts and downwards when flow stops to compress the trapped air in the cylinder for cushion closing. The air cushion cylinder shall be fitted with an adjustable valve to increase or decrease air compression in the cylinder. Swing check valves shall be APCO Series 6000 CLW, Golden-Anderson (Equal Model), or approved equal. B. The valve disc shall absolutely prevent the return of water back through the valve when the inlet pressure decreases below the delivery pressure, on pump shutoff or power failure. The valve shall be tight-seating. The seat ring shall be renewable and shall be securely held in place by stainless steel screws. The valve disc shall be of ductile iron and shall be suspended from a stainless steel (non-corrosive) shaft which passes through bushings and shall be connected to the weight and lever on the outside of the valve. The shaft shall be keyed into the disc and lever arm. Set screws shall not be acceptable. C. Swing check valves shall be furnished with ANSI 125/150 pound flat faced flanges. Valve exterior and interior to be painted with Fusion Epoxy Paint per AWWA C550. Swing check valves shall be APCO Series 250, or pre-approved equal. D. The closing and opening rate of the valve shall be field adjustable. E. In lieu of the Swing Check Valve with Air Cushion Cylinder, Oil Control Bottom Buffer Cushioned Swing Check Valves may be provided. The valve body and cover shall be ASTM Swing Check Valves 40 05 65.23 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements A126 Grade B Cast Iron or ASTM A536 Ductile Iron as required to handle design pressure, and shall be provided with a flush and drain hole. The body seat shall be locked in place with stainless steel lock screws. The single continuous pivot shaft shall be high strength T303 stainless steel and attached to the external weight and lever. The disc shall be ductile iron utilizing a double clevis hinge, and be connected to a ductile iron disc arm assembly which shall be suspended from the shaft. The valve must be equipped with a bottom hydraulic buffer to permit free open, but positive non-slam control closure of the disc. The hydraulic buffer and oil system shall be removable without need to remove the entire valve, and the oil system shall be totally independent from the main line to prevent corrosion or contamination to the main line media. Oil Control Bottom Buffer Swing Check Valve to be Apco 6000B or pre-approved equal. 3.00 EXECUTION 3.01 INSTALLATION A. Carefully handle and lower the valves into position so to prevent damage to any part of the valves. 3.02 CLEAN AND ADJUST A. Adjust weight position and air cushion operation in accordance with manufacturer recommendations. 3.03 SCHEDULE A. The required valves, 6 inches and larger, and certain pertinent data are given below. No. Req’d Description Size Ends Type Service 1 Check Valve 16” FLG Raw Water 2 Check Valve 14” FLG Raw Water 1 Check Valve 10” FLG Raw Water END OF SECTION Air Release and Air and Vacuum Valves 40 05 78 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 40 05 78 AIR RELEASE AND AIR AND VACUUM VALVES 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install air release and air and vacuum valves of the sizes and types indicated. Furnish the necessary isolating valves and piping. 1.02 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Shop Drawings. 2.00 PRODUCTS 2.01 MANUFACTURED PRODUCTS A. General: 1. Each air valve shall have a cast iron body, bronze or stainless steel trim, and stainless steel float. Float shall be baffled to prevent air from blowing valve closed until air is exhausted. 2. Valve body, float, etc., shall be designed for a working pressure and shall seat at a minimum pressure shown in the valve schedule, Paragraph[3.02. 3. Air valves shall be manufactured by the Valve and Primer Corporation (APCO), Val-Matic Manufacturing Corp., or Multiplex Manufacturing Company (Crispin). 4. Top of valve assembly shall be fitted to attach discharge pipe as indicated. Valve inlet shall be N.P.T. for 2-inch and smaller valves. Valve inlet shall be ANSI flange for 3-inch and larger valves. Flange rating shall equal or exceed the maximum working pressure. B. Air Release Valves (AR): Air release valves shall be designed to automatically release accumulated air pockets within the pipeline while in operation and under pressure. Air release valves shall be APCO Model 200, Val-Matic Model 38, or Crispin Model P. C. Air and Vacuum Valves (AV): Air and vacuum valves shall be designed to allow large volumes of air to escape through the valve orifice when filling a pipeline and to close water tight once the air has been expelled. Air and vacuum valves shall also permit large volumes of air to enter through the valve orifice when the pipeline is being drained to break the vacuum. Air and vacuum valves shall be APCO Model 140, Val-Matic Model 100, or Crispin Model AL. D. Combination Air Valves (CAV): 1. Combination air valves shall be heavy duty air and vacuum valves with air release. 2. Combination air valves shall be designed to release accumulations of air at high points within a pipeline by exhausting large volumes of air as the pipeline is being filled and by releasing accumulated pockets of air while the pipeline is in operation and under Air Release and Air and Vacuum Valves 40 05 78 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements pressure. Combination air valves shall also be designed to permit large volumes of air to enter the pipeline during pipeline drainage. 3. Combination air valves shall be APCO Model 140C, Val-Matic Model 200, or Crispin Model C. E. Air and Vacuum Valves for Vertical Turbine Pumps (PAV): 1. Air and vacuum valves for vertical turbine pumps shall be designed to allow large volumes of air to escape out the valve orifice when the pump is started and close water tight when the liquid enters the valve. The air valve shall also permit large volumes of air to re-enter through the valve orifice when the pump is stopped to prevent a vacuum in the pump column. 2. The baffle shall be designed to protect the float from direct contact of the rushing air and water to reduce premature float closures in the valve. 3. The entire float and baffle assembly must be shrouded with a perforated water diffuser to reduce slamming of the float. 4. The discharge orifice shall be fitted with an adjustable throttling device to regulate the flow of air escaping to establish a pressure loading on the rising column of water to minimize shock to the pump and check valve. 5. Air and vacuum valves for vertical turbine pumps shall be APCO Series 140 WDT, Val- Matic Model 100 DWS-T, or Crispin Model DL. 3.00 EXECUTION 3.01 INSTALLATION A. Carefully handle and install valves vertically in such a manner as to prevent damage to any part of the valves. Installation shall be in accordance with the Manufacturer’s instructions. Provide nuts, bolts, and gaskets where applicable. 3.02 SCHEDULES Pressure Location Size Type WP./Min.P. No. Required Pump Discharge 2” PAV 200# / 100# 4 END OF SECTION Commissioning of Process Systems 40 80 00 - 1 DTN18104 – Lake Lewisville WTP Improvements Phase II 40 80 00 COMMISSIONING OF PROCESS SYSTEMS 1.00 GENERAL 1.01 SCOPE A. Inspection, operational testing, adjustment, and calibration of each device, subsystem, and system, and placement of each device and system into service. The system supplier shall submit certified calibration reports for all instruments and loops for this project. The calibration shall comply with manufacturer’s and ISA recommended practices. All calibrations shall be performed in the presence of Owner’s authorized representative. Calibrations of all instruments shall be performed by the instrument manufacturer’s factory technicians only. 1.02 SUBMITTALS A. Test Plan: 1. At least 60 days before commissioning starts, submit a description of the tests to be conducted. The test procedure shall be detailed. Step-by-step on a loop-by-loop basis. 2. Include list of test equipment, test procedures, check-lists, and test report formats. 3. At the completion of each commissioning phase, deliver all test reports for phase to Owner with statement that phase test requirements have been satisfied. 4. Shop drawings. 5. All other applicable requirements of Division 01 - General Provisions. B. Responsibility: Review for acceptance by the Owner’s representative of any plan, report, or other commissioning activity will not relieve the Contractor of his responsibility to meet the Contract requirements. 2.00 PRODUCTS 2.01 MATERIALS A. Devices and systems are specified in other sections of this Specification. Reference to “devices” means all devices included in the Contract. B. Any device which fails to meet contract requirements or published performance specifications of the manufacturer must be repaired or replaced as directed by the Owner at no cost to the Owner. C. Demonstrate that test equipment is fully operational and properly calibrated. D. The Owner reserves the right to disapprove test equipment that is improper or functioning improperly. 3.00 EXECUTION 3.01 OBSERVATION Commissioning of Process Systems 40 80 00 - 2 DTN18104 – Lake Lewisville WTP Improvements Phase II A. The Owner and/or Engineer reserves the right to witness any test, inspection, calibration, or start-up activity. B. Notify the Engineer in writing at least 2 working days in advance of any test. All tests executed without notifying the Engineer are invalid and must be repeated. C. Perform commissioning of each device, subsystem and system under direct supervision of the individual manufacturer’s factory-trained representative. 3.02 REPORTS A. Prepare report showing test procedures, conditions, and results of each test. In the test report, give applicable contract requirements, manufacturer’s performance specifications, permissible tolerances at each test point, actual values of test signals, and test results. B. Check off List: 1. Maintain a check-off list by loop number indicating tasks remaining to be done to make loop operational. 2. Submit check-off list form at least 60 days before commissioning starts. 3. Submit check-off lists when requested by Owner. 4. Lists will be requested no more frequently than once a week. 3.03 SCHEDULING GUIDELINES FOR COMMISSIONING PHASES A. Perform all commissioning in accordance with the instructions on the Contract Drawings, these Specifications, manufacturer’s instruction manuals, and the direction of the Owner’s representative. B. Commission field devices after installation of field instruments and prior to commissioning the instrument or the control panel. C. After installation of the instrument or control panel, and prior to loop commissioning, commission panel-mounted devices and systems. D. After commissioning field devices and panel-mounted devices, commission loops. 3.04 REQUIREMENTS A. Transmitters and Receivers: 1. Remove shipping stops before starting with these procedures. 2. Have manufacturer’s instruction manuals available. 3. Install miscellaneous components such as charts, illumination, etc., which have been supplied separately but are integral parts of equipment. 4. Test and exercise each instrument to demonstrate correct operation, first individually, then collectively, as a functional network. 5. Check calibration of and recalibrate, where necessary, instruments at a minimum of three points over full operational range and prove instruments to be within specified accuracy. Commissioning of Process Systems 40 80 00 - 3 DTN18104 – Lake Lewisville WTP Improvements Phase II 6. Calibrate instruments individually and, where applicable, as loop (i.e., transmitter, controller, and valve). 7. Specified accuracy for loop is defined as root-mean-square summation (RMS) of individual device specified accuracies. 8. Individual device specified accuracy requirements shall be as specified by contract requirements, or by published manufacturer accuracy specifications whenever contract accuracy requirements are not specified. 9. Test each loop by applying simulated analog and/or discrete inputs to first elements of loop (i.e., applying simulated analog and/or discrete sensor signals) and measuring outputs from final elements of loop (i.e., controllers, alarms, indicators, etc.). 10. Apply continuously variable analog inputs to verify proper operation and setting of discrete devices (i.e., alarms, etc.). 11. Make provisional settings on controllers, alarms, etc., during loop installation tests. 12. Prepare calibration report on each instrument and loop. B. Integrators, Ratio Relay, Etc. 1. Check devices in conformance with manufacturer’s recommendations. 2. Receiver integrators may be calibrated for proper operation and multiplication factor by feeding maximum input signal for a specified period of time using a stopwatch. 3. Ratio signals may be simulated to check proper ratio settings and output. C. Flow Meters, Level Transmitters, and Pressure Transmitters: 1. Perform volumetric drawdown test for all flow meters and level transmitters. 2. Prepare test report for each meter and level transmitter. 3. If test results conflict with calibration report, recalibrate in accordance with Paragraph 3.04.A above and repeat volumetric drawdown test. 4. Continue until drawdown test results prove calibration to be correct. D. Software Level Switches: Perform drawdown test for each level switch. Set switch in accordance with Specifications or, in absence of switch setting in Specifications, set in accordance with instructions from Owner’s representative. E. PLC PID Controllers: 1. Check control action of each controller. 2. Check calibration of gain, integral and rate adjustments where specified, including all codes of operation. 3. For each setting, check output for at least three inputs evenly spaced through input range. 4. Check at least three settings for each adjustment evenly spaced throughout the adjustment range. 5. Run all diagnostic procedures. Commissioning of Process Systems 40 80 00 - 4 DTN18104 – Lake Lewisville WTP Improvements Phase II F. Interlocks: Ring and check interlocking circuits for conformance to Plans and Specifications. G. Start Up of Instruments: 1. Test each control loop under start up and steady-state operating conditions to verify that proper and stable control is achieved using instruments in each instrument panel and control panel. a. Test control of final control elements using specified modes of manual and automatic control. b. Demonstrate bumpless transition between control station modes. c. Use signals from transducers, sensors, and transmitters. d. Simulated input data signals are not permitted. Simulated input date signals may be used subject to prior written approval on a case-by-case basis by the Owner’s or Engineer’s representative. 2. Set proportional band, reset rate and derivative settings for each control as recommended by manufacturer. 3. Verify transient stability of each control loop by applying control signal disturbances, monitoring amplitude and decay rate of control parameter oscillations, and making necessary controller adjustments to eliminate excessive oscillatory amplitudes and decay rates while retaining control sensitivity. Verify proper suppression of “reset wind- up.” 4. Contractor shall be responsible for calibration and ringing out all devices which are to be interfaced with the distributed control system. This shall include devices purchased and installed under other contracts, or are already existing. END OF SECTION Instrumentation and Control for Process Systems 40 90 00-1 DTN18104 – Lake Lewisville WTP Improvements Phase II 40 90 00 INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS 1.00 GENERAL 1.01 SCOPE A. General Requirements for Instrumentation and Control. 1. There are two areas of work in the Instrumentation Work in this project as described below: a. The Instrumentation System Integrator Contractor shall provide all hardware, software, and configuration and integration associated with the PLC based Instrumentation and Process Control system. Provide a complete and operational system in accordance with these Contract Documents: 1) Provide instrumentation, hardware, conductors and raceway required for a complete and operable system that is above that specified in the Contract Documents. Provide all labor and materials specified in the Contract Documents. 2) Provide a PLC with a UPS at the High Service Electrical Building. RTU shall communicate with the City’s SCADA plant network via a fiber optic cable. 3) Provide all required labor, materials and PLC programming and system configuration and integration to interconnect the PLC to the water treatment plant’s existing SCADA system. Coordinate all requirements with the City of Denton and its subcontractors for fiber and communications. 4) Provide an Ethernet switch to interconnect to the feeder protection relays for the 4160V swtichgear relays, pump starter motor protection relays, and 4160V switchgear and 480V switchboard power meters. Refer to plans for more information. 5) Provide all required software and programming in the PLC for a complete and operational system in accordance with these Contract Documents. 6) Coordinate and fully cooperate with WHECO Controls, to provide all required hardware and PLC hardware and PLC programming necessary to interface with the existing City’s SCADA System. 7) Provide personnel to check out, test and commission the system. 8) Provide personnel to train the Owner's staff as specified b. Prime Controls shall provide all required labor, materials and PLC programming and system configuration and integration in the PLC and I/O as required per the project requirements to the Modicon M340 PLC at the High Service Electrical Building. 1) Contractor shall provide an RTU cabinet with a PLC at the High Service Electrical Building. The Contractor shall provide all programming and wiring for the RTU and PLC. Instrumentation and Control for Process Systems 40 90 00-2 DTN18104 – Lake Lewisville WTP Improvements Phase II 2) Provide all required software and programming in the PLC and existing computer system at the City of Denton’s HMI for a complete and operational system in accordance with these Contract Documents. 3) Coordinate and fully cooperate with the OWNER to provide all required hardware and PLC hardware and PLC programming necessary to interface with the existing system. 4) Provide all required software and programming in the PLC at the High Service Electrical Building for a complete and operational system in accordance with these Contract Documents 5) Provide personnel to check out, test and commission the system. 6) Provide factory trained personnel to train the OWNER's staff as specified. 7) Provide software programming to create new screens on the computer system as specified. Provide a copy of all screens to the Owner as an official submittal when screens are developed. 8) Provide PLC programming, interconnection, wiring, etc as required by the Process and Instrumentation Sheets and the Loop Descriptions. 1.02 QUALITY ASSURANCE A. GENERAL: Should there be a conflict between various standards, codes, specifications, and contract drawings, bring the matter immediately to the attention of the OWNER's Representative. B. REFERENCE STANDARDS: 1. American Society of Testing Materials: A269 Seamless and Welded Austenitic Stainless Steel Tubing for General Service B 68 Seamless Copper Tube D 1047 Polyvinyl Chloride Jacket for Wire and Cable A 36 Specification for Structural Steel Zinc Coating (Hot-Dip) on Iron and Steel Hardware 2. Research Council on Riveted and Bolted Structural Joints (RCRBSJ). 3. American Institute of Steel Construction (AISC). 4. Steel Structures Painting Council (SSPC): Painting Specifications for weather exposure. 5. American Welding Society (AWS): Welding Code D 1.1-75. 6. Federal Specifications: Primer, Paint Zinc, Chromate, Alkyd Type, Fed. Spec. TT-P-645a. 7. National Electrical Manufacturers Association (NEMA). 8. National Fire Protection Association (NFPA): National Electrical Code (NEC), 1990 edition. 9. Instrument Society of America (ISA): Instrumentation and Control for Process Systems 40 90 00-3 DTN18104 – Lake Lewisville WTP Improvements Phase II RP 3.1-1960 Flow Meter Installations, Seal and Condensate Chambers S5.1-1973 Instrumentation Symbols and Identification RP7.1-1956 Pneumatic Control Circuit Pressure Test S7.3-1975 Quality Standard for Instrument Air RP18.1-1965 Specifications and Guides for the Use of General Purpose Annunciators S5.4-1976 Instrument Loop Diagrams S8.1-1968 Instrument Enclosures for Industrial Environments RP12.1-1960 Electrical Instruments in Hazardous Atmospheres RP20.1, 20.2 Specification Forms for Instruments S39.1-1972 Control Valve Sizing Equations S39.2-1972 Control Valve Capacity Test Procedures S51.1 Process Instrumentation Terminology 10. American Petroleum Institute (API): API RP 550 Manual on Installation of Refinery Instruments and Control Systems API RP 520 Recommended Practice for the Design and Installation of Pressure-Relieving Systems in Refineries 11. Scientific Apparatus Makers Association (SAMA): PM 20.1-1973 Process Measurement and Control Terminology RC5-10-1963 Resistance Thermometers 12. Underwriters' Laboratory (UL): Subject 13, Subject 1227. 13. Factory Mutual (FM). 14. American National Standard Institute (ANSI): 15. Supplement to C37.90-1971, Relays and Relay Systems Associated with Electric Power Apparatus (IEEE Std. 313-1971), C37.90a-1974. 16. National Bureau of Standards (NBS). 17. Institute of Electrical and Electronics Engineers (IEEE): Tray Fire Tests, IEEE 383. 1.03 GUARANTEE A. GUARANTEE PERIOD: The CONTRACTOR shall provide guarantees as defined hereunder for a period of two years after final acceptance by the OWNER. B. GUARANTEE REQUIREMENTS FOR ANALOG DEVICES: Each device shall perform its intended function within the specified operating accuracy and repeatability without more than 12 adjustments for any consecutive period of 12 months. The availability of each device shall be not less than 98.0 percent for any consecutive period of six months. Downtime of analog devices affecting more than 8 loops shall be considered a system failure. Instrumentation and Control for Process Systems 40 90 00-4 DTN18104 – Lake Lewisville WTP Improvements Phase II 1.04 CONTRACTOR'S QUALIFICATIONS A. The Instrumentation System Integrator Contractor's personnel shall have a minimum of ten years of prior experience in furnishing, installation, testing, programming, debugging, start- up, and training for systems at least as large and similar to the one in this Contract. The system installer shall have employees who are qualified technicians for the duration of the contract located in the project area. The CONTRACTOR shall submit for evaluation within one week of Notice to Proceed, his instrumentation systems installer's company resumes complete with company history, project lists, locations, OWNER, costs, type of system installed, and references with phone numbers. Installers not meeting these qualifications shall not be accepted. As a part of this contract, the instrumentation system installers shall assume complete system responsibility, including coordination and interfacing with all subsystems and equipment suppliers and manufacturers. The CONTRACTOR shall actively be involved in control system integration industry for the last five years. The CONTRACTOR shall not act as a broker for the project; he shall provide and be responsible for all hardware, interfacing software, training, testing, and extended warranties. B. The following PLC programming and system configuration and integration are pre-qualified with the City of Denton for PLC and HMI programming: 1. Prime Controls. 2. No others shall be accepted. C. The following Instrumentation System Integrator Contractors are pre-qualified with the City of Denton for Hardware. 1. Prime Controls. 2. No others shall be accepted. 1.05 DEFINITIONS A. The terms used in this specification conform to definitions in ISA S51.1, SAMA PMC 20.1- 1973 and RC 5-10-1963, except as modified below. 1. Device: An electronic or mechanical apparatus designed to perform a specific measurement or control function. 2. Equipment: The machinery used in a process, e.g., pumps, fans, etc. 3. Interchangeability error: The algebraic difference between the indication and true value of the measured variable as a result of exchanging a device with a replacement. 4. Loop: Any combination of interconnected transmitters, receivers, switches, alarms, indicators, controllers, computers, or final control elements. 5. Operating accuracy: Conformity of indicated value to accepted standard value or true value throughout specified operating conditions with a confidence level of 95 percent includes, but is not limited to, hysteresis, linearity, and operating influence of temperature, pressure, supply voltage, and transmitter power supply. Operating accuracy for loop is defined as root-mean-square (RMS) of individual device operation accuracies. Instrumentation and Control for Process Systems 40 90 00-5 DTN18104 – Lake Lewisville WTP Improvements Phase II 6. Process: A progressively continuing operation that consists of a series of controlled actions systemically directed toward a particular result, e.g., a process to mix, filter, heat, and/or cool air to a particular condition. 7. Response: The results of the act, or process of measuring the time difference between the time of a change in an input signal or a measured variable, and the time when the output, display, and final control element in the loop has changed to at least 60 percent of the change which should result from the input change. 8. Subsystem: A discrete subdivision of a system and an assemblage of parts, devices, or software modules designed to perform one or more of the specific tasks required for the system to accomplish its functions. 9. System: An assemblage of sometimes diverse parts, devices, or software modules serving a common set of measurement or control functions. 10. Time resolution: The result of the act or process of rendering distinguishable events occurring at nearly the same time. Expressed as a measurement of time in seconds. 11. Unit: Any combination of equipment items interconnected in a predetermined manner, performing one or more controlled actions toward a particular result. A discrete subdivision of a process. 12. Concealed - Accessible: Out of general sight, but can be easily reached by removing panels or access doors. 13. Concealed - Inaccessible: Out of general sight and cannot be easily reached except by removing a permanent part of the building or using special tools. 14. Exposed: Open to general view without removing panels, access doors, or a permanent part of the building. 15. Field termination point: Termination of a run of raceway from an instrument panel to the vicinity of a field instrument. Field termination point is usually within five horizontal feet from the field instrument. 16. Analog device: Any sensor, transmitter, indicator, recorder, controller, computing relay, or control valve which transmits or receives an analog signal. Excludes the analog portion of a digital system or I/O subsystems. 1.06 SUBMITTALS A. SHOP DRAWINGS AND PRODUCT DATA: 1. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures”. 2. Detail: Give sufficient detail to permit system configuration, installation, and wiring without reference to design drawings. Refer to Division 1 - General Requirements. 3. As a minimum, shop drawings shall include a bill of materials with original manufacturer's name and catalog number (re-labeled component information is not acceptable), original manufacturer's catalog cut sheets, front views, assembly drawings, nameplate schedules, electrical schematics, and electrical connections diagrams. Instrumentation and Control for Process Systems 40 90 00-6 DTN18104 – Lake Lewisville WTP Improvements Phase II 4. Electrical and interconnection diagrams shall show all terminations of equipment, complete with conduit, cable, and equipment designations, and shall include terminal identification information. 5. Include size of all conduits, pipe, cables, and conductors. 6. Physical arrangement drawings shall include operating and servicing clearance requirements, cooling requirements, electrical power requirements, and cabling information. 7. Logic drawer drawings shall show used space and expansion space. 8. Show appropriate tag numbers on all product data. 9. Software specifications for all software provided in addition to existing standard software. a. Include fully annotated source listings, input-output requirements, memory requirements, timing and sequencing requirements, flow chart showing functions performed, operating sequences and decision points, required system configuration, list of known or anticipated limitations of software modules, list of malfunction procedures to be followed for recovering from operator error or other malfunction, and description of how each module interfaces with calling and called programs. b. Provide proposed screen layouts showing modifications to existing screens, and new screens: Show all displays, inputs, outputs, recorders, alarms and indications along with the associated signal tag number. OWNER shall review and approve screen layouts. B. TECHNICAL MANUALS: 1. Supply six (6) sets of technical manuals with software specifications to OWNER's Representative no later than the equipment shipment date. Each set shall be bound in a standard size, three-ring, loose-leaf, vinyl plastic, hard-cover binder suitable for bookshelf storage. Binder ring size shall not exceed 2.5 inches. 2. Each set of technical manuals shall include a general and detailed description, a theory of operation description, detailed schematic drawings, specifications, and installation, connection, calibration, operating, troubleshooting, preventive maintenance, and overhaul instructions in complete detail with a clear and specific description of the steps the operators must take to perform each of the tasks and modes of operating specified. These manuals shall provide the OWNER with comprehensive information on all systems and components to enable operation, service, maintenance and repair. Exploded or other detailed views of all instruments, assemblies, and accessory components shall be included together with complete parts lists and ordering instructions. These manuals are in addition to all applicable requirements of Division 01 - General Requirements. C. SPARE PARTS LIST: Instrumentation and Control for Process Systems 40 90 00-7 DTN18104 – Lake Lewisville WTP Improvements Phase II 1. Contractor shall prepare and submit for Owner's review a master spare parts list of all Instrumentation items. All instrumentation spare parts shall be turned over to the Owner at one time and stored in lockable cabinets provided by the Contractor. 2.00 PRODUCTS 2.01 INFORMATION ON DRAWINGS A. The following information is indicated on the drawings: 1. Loop diagram on flow sheet for each control loop. Diagrams are schematic in nature and intended only as a guide to work to be performed. 2. Approximate location of primary elements, instrument panels, and final control elements. 3. Location of electrical distribution panel boards for instrument electrical power. 4. Location of equipment having alarms and equipment status contacts. 5. Location of equipment being controlled by system. B. The following information is not shown on drawings, but shall be the responsibility of the CONTRACTOR to determine, furnish, and coordinate with other divisions based upon systems specified. Show this information on project record drawings. 1. Instrument loop drawings per ISA S5.4 minimum, desired and optional items. 2. Location of electrical distribution panel boards supplying power to any device supplied under this Contract. 3. Detailed enclosure and instrument panel layouts, RTU enclosure layouts, fabrication details, and wiring diagrams. 4. Detailed system configuration. 5. Raceway and cable routing for instrumentation wiring. 2.02 OPERATING CONDITIONS A. AMBIENT CONDITIONS: Provide equipment suitable for ambient conditions specified. Provide system elements to operate properly in the presence of radio frequency fields produced by portable RF transmitters with output of five watts operated at 24 inches from instruments in the presence of plant telephone lines, power lines, and electrical equipment, and in the presence of digital data transmission systems. B. FIELD LOCATIONS: Field equipment may be subjected to ambient temperatures from -5 to 50°C with direct radiation and relative humidity from 45 to 95 percent with condensation. C. POWER SUPPLY: Power supply will be 120 volts a-c, single-phase, 60-hertz commercial power. Voltage variation tolerance will be plus or minus 8 percent. Certain loops shall have integral power supply as specified in the Contract Documents. Power supplies shall be provided in the panels as specified in the Contract Documents or required for a complete system, plus one spare. Instrumentation and Control for Process Systems 40 90 00-8 DTN18104 – Lake Lewisville WTP Improvements Phase II 2.03 MATERIALS AND EQUIPMENT A. Provide equipment of solid-state construction utilizing second source semiconductors, unless otherwise specified. Derate components to assure dependability and long-term stability. Provide printed or etched circuit boards of glass epoxy, hand or wave soldered, of sufficient thickness to prevent warping. Coat printed circuit boards in field-mounted equipment with two mils of solderable conformal coating complying with MIL-I-46058B. Alignment and adjustments shall be noncritical, stable with temperature changes or aging, and accomplished with premium grade potentiometers. Do not insert components of specially selected values into standard electronic assemblies to meet performance requirements. Use parts indicated in instruction manuals, replaceable with standard commercial components of the same description without degrading performance of completed assembly. B. Use test equipment and instruments to simulate inputs and read outputs suitable for purpose intended and rated to an accuracy of at least five times greater than the required accuracy of device being calibrated. Such test equipment shall have accuracies traceable to the National Bureau of Standards as applicable. 2.04 SPECIAL PROJECT REQUIREMENTS A. As a part of this Contract, the instrumentation systems CONTRACTOR shall coordinate with the City of Denton, and with all the sub-systems suppliers and manufacturers, during bidding, construction, testing, installation and start-up phases of the project. The coordination is to assure that the instruments and sub-systems are in compliance with the Contract Documents and that the necessary tie-ins and interface signals with the existing system are provided as specified or required. B. The instrumentation system CONTRACTOR shall provide the OWNER's staff with all required training and operating procedures, at no extra cost to the OWNER, in addition to the SCADA training specified in Section 40 90 02, SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM. The training schedule shall be coordinated with the OWNER's Representative. Training shall include operating, testing, calibration and programming of the system, and simple troubleshooting of the system. The training shall include manuals which are specifically written for the system provided as described in Division 1 - General Requirements of these Specifications. C. The calibration, testing, and start-up of all instruments shall be done by the manufacturer's field technician/ENGINEER in the presence of the OWNER. The CONTRACTOR shall provide a list of all manufacturers whose technicians will perform this work. The CONTRACTOR shall also provide a certified calibration report stating that each instrument shown or specified in the Contract Documents has been installed, tested and calibrated per manufacturer's recommendations and per these Contract Documents. Instrumentation and Control for Process Systems 40 90 00-9 DTN18104 – Lake Lewisville WTP Improvements Phase II D. Follow-up Services: After the acceptance of the system, the CONTRACTOR shall make four (4) trips to the project site for calibration and adjustment of all the instruments and devices, including the SCADA system. The first trip shall be three months after acceptance of the complete system, and thereafter every three months for a total of four trips. These trips are in addition to all warranty items, and shall be at no extra cost to the OWNER. The CONTRACTOR shall provide the services of a trained technician for each trip with appropriate calibration and testing instruments. All defects shall be immediately remedied. The trips shall be coordinated with the OWNER. E. All control software developed for this contract shall be delivered to the OWNER stored on electronic media in a format suitable for installing on the existing equipment and new equipment installed under this contract. This includes all source code, complied code, link libraries, run-time libraries or other modules necessary to recreate an operational system in the event of a catastrophic failure or cessation of business by any of the Contractors. In addition, copies of all data bases and necessary associated files as configured after the final test shall be supplied on the same medium. END OF SECTION Instrumentation 40 90 01 - 1 DTN18104 – Lake Lewisville WTP Phase II Improvements 40 90 01 INSTRUMENTATION 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install all equipment for complete instrumentation and controls. CONTRACTOR's work shall include but not be limited to the following: 1. Installation of equipment furnished under this contract. 2. Interconnections between equipment furnished under this contract. 3. Interconnection between equipment furnished under this contract and the existing instrumentation and control equipment or that furnished and installed under other contracts. B. The CONTRACTOR's attention is directed to the fact that instrumentation is an integrated system and as such shall be furnished by one vendor or system integrator who shall provide all the equipment and appurtenances, regardless of manufacture, and be responsible to the CONTRACTOR for satisfactory operation of the entire system. C. Supervision, labor, tools, and materials necessary for installation of the instrumentation equipment and material furnished herein and their interconnection shall be provided by the CONTRACTOR. Installation work shall conform to applicable city, state, and national building and electrical codes. D. Coordinate the work of the system manufacturer's service personnel during construction, testing, calibration and acceptance of the instruments. E. Provide equipment as shown in the specifications and on the drawings. 1.02 QUALITY 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. OPERATING VOLTAGE: Electrical components of the system shall operate on 120 volt, single-phase, 60 Hertz, except as otherwise noted in the specifications. C. 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. D. PROTECTION 1. The instrumentation system supplier shall be responsible for input-output isolation of all incoming and outgoing signals. Instrumentation 40 90 01 - 2 DTN18104 – Lake Lewisville WTP Phase II Improvements 2. Each 4-20 mA DC process measurement current loop installed on this contract shall be protected by insertion of a 1/16 amp fuse, Buss Type MKB. Fuses shall be installed in standard fuse blocks. 3. The necessary fuses or switches required by the Instrumentation Manufacturer for his equipment shall be provided with the equipment. The instruments requiring an internal power supply shall have an internal ON-OFF switch. E. INPUT/OUTPUT 1. In general and unless specifically stated otherwise, inputs and outputs involving instrumentation systems shown shall be 4-20 mA DC process measurement signals. Current loop isolators, current repeaters, or other signal isolators shall be furnished and installed as required to meet instrument specifications and to make instrumentation system fully operational. 2. Pair shielded cable, as specified in Section 26 05 19 LOW VOLTAGE ELECTRICAL POWER AND CONDUCTORS AND CABLES shall be used for all 4-20 mA DC loops. F. HARDWARE CHECKOUT 1. CONTRACTOR shall be responsible for checkout and calibration of all field instrumentation up to and including the PLC cabinets. CONTRACTOR shall provide a checkout of all I/O points under the supervision of the OWNER'S REPRESENTATIVE. Checkout shall be scheduled two weeks in advance of the date with the OWNER'S REPRESENTATIVE. CONTRACTOR shall provide a schedule of checkout and procedures to be used to the OWNER'S REPRESENTATIVE two weeks in advance of the test date for the OWNER'S REPRESENTATIVE's approval. 2. I/O points and sequence of operations shall be judged Pass/Fail by the OWNER'S REPRESENTATIVE. If a point fails, the CONTRACTOR shall move on to the next point and resubmit a new test schedule to the OWNER'S REPRESENTATIVE. The CONTRACTOR shall run a rehearsal of the test procedure to be witnessed by the OWNER'S REPRESENTATIVE prior to the test date as field modifications of equipment during the testing for a failed point shall not be allowed. Testing shall simulate actual field conditions and reflect the sequence of operations expected when in use. G. EQUIPMENT WARRANTY 1. All equipment shall be warrantied for a period of two (2) years after final acceptance. 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Shop Drawings: a. Shop drawings shall be submitted to the ENGINEER for approval before fabrication or shipment to the job. Equipment shall not be fabricated or shipped to the job before receipt of approved shop drawings from the ENGINEER. Submittals for approval shall include (1) component manufacturing data sheet indicating pertinent data and identifying each component by item number and nomenclature, (2) component drawing showing dimensions, mounting, and external connection Instrumentation 40 90 01 - 3 DTN18104 – Lake Lewisville WTP Phase II Improvements details, (3) a system piping schematic and wiring schematic each on a single drawing with full description of operation, (4) complete schematic diagram of each piece of electrical and electronic equipment including electrical valves and tolerances for each component. Component identification on the schematic shall be as described above. b. Following approval, the manufacturer shall be responsible for preparation of the required sets of these drawings for distribution as indicated in Division 0 and Division 1 specifications. c. Shop drawings submitted for all equipment furnished under this section of the specifications, shall be submitted at the same time in the same package. Partial submittals will not be reviewed. B. Sales bulletins and other general publications are not acceptable as submittals for approval. C. Equipment installation Report. CONTRACTOR shall provide an Equipment Installation Report for each instrument (flow meter, level transmitter, etc.) to the ENGINEER/OWNER for approval. The equipment installation report shall include documentation stating that the instrument was installed and properly calibrated per the manufacturer’s recommendations by an Authorized representative of the instrument manufacturer. All parameters required for programming of the instrument shall be provided in a hard copy format as part of the equipment installation report. Documentation stating that the person performing the calibration and start-up is an authorized representative shall be provided as well. D. Operation and Maintenance Manuals 1. Operating instructions shall incorporate a functional description of the entire system including the system schematics which reflect "as-built" modifications. Wiring diagrams shall be furnished as a part of the Operation and Maintenance Manuals which clearly show terminal numbers and wire numbers as they actually are in the instrumentation system. Instrument panel wiring shall be such that each wire installed has its own number designation at each end and such that no number is repeated. Instrument panel wire tagging instructions as specified in Section 26 05 19 LOW VOLTAGE ELECTRICAL CONDUCTORS & CABLES shall be followed. 2. Special maintenance requirements particular to the system shall be clearly defined along with special calibration and test procedures. 3. CONTRACTOR shall provide point to point interconnection diagrams for all control/instrumentation connections between the RTU cabinet and field devices including instruments, motor starters, and switchgear. Point-to-point diagrams shall be provided for all control/instrumentation wiring between field devices and panels, i.e. motor starters, switchgear, etc. CONTRACTOR shall provide AutoCad files of interconnection diagrams to the OWNER. Interconnection diagrams shall include cable no., terminal block no., instrument no., panel no., etc. Hard copies of the Interconnection drawings shall be submitted to the ENGINEER for approval as an official submittal prior to the final AutoCAD files being submitted. Instrumentation 40 90 01 - 4 DTN18104 – Lake Lewisville WTP Phase II Improvements 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: ASTM A-126 Specification for Gray Iron Castings for Valves, Flanges and Pipe Fittings ASTM B-61 Specification for Steam and Valve Bronze Castings 1.05 JOB CONDITIONS A. SPECIAL TOOLS: Furnish a kit which contains special size wrenches and other types of tools, not normally available, which are necessary for assembling, disassembling, aligning, and calibrating each piece of equipment. In addition, any piece of equipment (meter, test set, etc.) required by the Manufacturer to align, adjust, or otherwise calibrate any item under this section of the specification shall be furnished, including software. 2.00 PRODUCTS 2.01 REMOTE EQUIPMENT A. Controls for remote electrically operated or motor driven equipment shall be complete, including the necessary auxiliary relays so as to require only wiring and connections to the equipment control circuit. Contacts for control of remote motor operated or electrically operated equipment shall be rated not less than 10 amperes at 120 volts unless otherwise specified herein. B. Remote motor operated or electrically operated equipment shall have a separate 120 volt control circuit which operates through the dry contacts provided by the instrumentation system. 2.02 ENCLOSURES/PANELS A. Enclosures and panels as indicated on the plans and in this specification shall be furnished, installed, and wired. Enclosures for equipment in the electrical room shall be NEMA 1, 14 gauge steel for interior air conditioned rooms, NEMA 12 for interior areas with ventilation and NEMA 4X, 316 Stainless Steel for all other locations. All enclosures shall have a quick release luggage type stainless steel clasp. 2.03 TUBING A. Instrument tubing shall be 316 stainless steel conforming to ASTM A269 for seamless tubing for use with compression type fittings. Hydraulic connections to instruments shall be made with compression type fittings. B. Tubing shall be 3/8" trade size (OD= .375", ID= .315", wall thickness =.030"), and shall be rated for 810 psi working pressure at 150°F and shall be manufactured by Halstead or approved equal. Tube fittings shall be compression type as manufactured by Parker or approved equal. Instrumentation 40 90 01 - 5 DTN18104 – Lake Lewisville WTP Phase II Improvements 2.04 VENTURI FLOW METER A. Products - The flow meter shall be a short form Venturi design utilizing pure static pressure sensing taps in the inlet and throat sections and shall produce a differential pressure, which shall be measured and transmitted by the specified differential pressure flow transmitter. B. Performance - The Venturi flow meter shall have an accuracy of +/-0.25% of actual flow above a pipe Reynolds number of 75,000 with a discharge coefficient of 0.9900 and a permanent pressure loss not exceeding 10% of the differential. C. Venturi Tube Design - The Venturi meter shall have a cylindrical inlet section of the same I. D. as the inlet piping and shall contain two high pressure taps and a single vent and drain tap. The cylindrical throat section shall contain two low-pressure taps. The length of the cylindrical throat section shall be equal to one-half its diameter. The converging section shall be comprised of a single angle of 30 degrees. Converging sections using a radius or multiple inlet angles will not be acceptable. The recovery section shall be comprised of a single angle of 10 degrees and shall be truncated at approximately 90% of the downstream pipe I.D. The Venturi shall be provided with ANSI flanges with ANSI Class 300 ends to meet the specifications of the adjacent pipe class. Manufacturer shall verify and determine that the flow tube is compatible with the pipe as indicated on the plans and specifications. Meter element shall not have debris collecting cavities or annular chambers. Vent ports and drains shall be included on a 90 degree plane to the metering taps. Meter shall have a 3” diameter inspection port. D. Materials - The Venturi meter body shall be cast iron per ASTM A-126, Gr. B. and the foundry shall be located in North America. The throat section and high-pressure tap bushing shall be 304 stainless steel. The interior and exterior of the Class 400 ductile iron surfaces shall be coated with NSF-61 coating suitable for potable water contact per Section 09 96 00.01 HIGH-PERFORMANCE COATINGS and recommended by Venturi manufacturer. E. Tubing and Valves – Pressure tap tubing shall be seamless annealed 316 S.S. tubing in accordance with ASTM 269 with a HRB80 maximum hardness. Cut tube ends shall be deburred. Tubing shall be bent using a Swagelok or approved equal tubing bender sized to match the tubing diameter. Tubing fittings shall be SWAGELOK 316 S.S. tube fittings; no substitutions will be accepted. Provide NPT to tube fittings adapters for connection to Venturi pressure taps. Use a gap inspection gage to verify proper tightening and pull up. All tubing and fittings shall be leakage tested in accordance with Section 01400 prior to insulating. Pressure taps shall be installed per meter and transmitter manufacturer’s recommendations. All exposed tubing shall be insulated and heat traced. F. Needle valves shall be Swagelok integral bonnet needle valves Model SS-18RS8, no substitutions will be accepted. G. Appurtenances - Provide all vent riser tubes, vents, blow down lines, valves, flow transmitters and all appurtenances for a complete and working system. Instrumentation 40 90 01 - 6 DTN18104 – Lake Lewisville WTP Phase II Improvements H. One Venturi meter shall be flow calibrated by an independent flow lab and provided with certified copies of the test results to substantiate the flow meter’s accuracy, discharge coefficient, coefficient values of tolerance, effects of upstream configurations, head loss as a function of the velocity head expended and permanent pressure loss. The Venturi meter shall be flow calibrated to the largest flow for the project. I. Quality Assurance - The venturi meter supplier shall provide written certification that the cast iron portion of the meter is of North American origin in order to insure that it meets applicable ASTM code requirements. In addition, in order to insure a high level of quality control in the design and manufacturing of the venturi meter, the venturi meter manufacturer must be ISO 9001 certified. A copy of the current certification shall be included in the submittal for approval documentation. J. Warranty: The manufacturer shall provide a 25-year warranty against defects in workmanship and materials. K. Supplier – The Venturi meter shall be a Model 20” A-HVT-CI with a throat diameter of 12.600” as manufactured by Primary Flow Signal, Inc., Cranston, RI USA. No substitutions shall be allowed. Tag Service Range Flow Meter Flow Meter Flow Meter Flow Meter 2.05 LEVEL SWITCH A. Level detecting device shall be a 5 ½” diameter type 316 stainless steel float switch with a mercury free switch inside and flexibly supported by a PVC jacketed, heavy-duty cable. The float shall be cable suspension mounted with a stainless steel weight where applicable. B. Float switch shall have a 1 amp rating at 150 VAC. The float shall be Type SO with four #16 AWG fine-stranded copper conductors. Float shall be mounted using stainless steel suspension cable with a stainless steel weight. Float switch shall be Contegra Model FS 90 or approved equal. C. Float switch shall be installed in accordance with the manufacturer’s recommendations. Instrumentation 40 90 01 - 7 DTN18104 – Lake Lewisville WTP Phase II Improvements Tag Service Set Point Meter Vault High Level Alarm 3” Above Finished Floor Meter Vault High Level Alarm 3” Above Finished Floor Meter Vault High Level Alarm 3” Above Finished Floor Meter Vault High Level Alarm 3” Above Finished Floor Lake Lewisville Chemical Building High Level Alarm 3” Above Finished Floor Ray Roberts Chemical Building High Level Alarm 3” Above Finished Floor D. Coordinate elevations with the Owner prior to submittals. 2.06 DIFFERENTIAL PRESSURE FLOW TRANSMITTER 1. Flow transmitters shall be of the thin film strain gage, solid state electronic type having a 4-20 mA DC output signal proportional to the calibrated differential pressure range. The transmitter shall have wetted parts of 316 stainless steel and a Hastelloy C diaphragm. The transmitters shall have a hermetically sealed enclosure with externally adjustable span and zero, and an accuracy of ±0.25% of span. Transmitter mounting bracket shall be furnished. 2. Transmitters shall be ROSEMOUNT MODEL 3051 Series or Endress and Houser PMD75. No substitutions shall be allowed. Each transmitter shall include an integrally mounted transient protector. Provide manufacturer approved lightning protection, to protect the instrument against lightning-produced voltage spikes and other transient surges. Each transmitter shall be furnished with a 316 stainless steel service block and zeroing manifold with NORMAL, ZERO, BLOCKED, CALIBRATED AND BLOWDOWN functions, D/A Manufacturing Model SBZ-43AT. Tag Service Flow Range (MGD) Low Optimum High XXXX-DPT Venturi Flow Meter XXXX-DPT Venturi Flow Meter XXXX-DPT Venturi Flow Meter HEAT DETECTOR B. Hermetically sealed and factory set stainless steel sensing element. Cold rolled steel mounting facility. Normally closed contacts that operate at a set temperature of 225F. Instrumentation 40 90 01 - 8 DTN18104 – Lake Lewisville WTP Phase II Improvements Designed with rate compensation. UL listed, surface mounted in horizontal or vertical position, Fenwal Detect-A-Fire. Tag Service XXXX-1001 High Service Electrical Building Heat Detector XXXX-1001 High Service Electrical Building Heat Detector 2.07 INTRUSION ALARM A. Hermetically sealed brushed anodized aluminum housing, Rhodium plated switch contacts, industrial wide gap magnetic contacts, UL listed, surface mount, 3’ stainless steel armored cable, Sentrol 2500 series. Provide with one normally open and one normally closed set of contacts. Tag Service XE-XXX Electrical Room North Door Intrusion Alarm XE-XXX Electrical Room South Door Intrusion Alarm XE-NDR Ray Roberts Chemical Building North Door Intrusion Alarm XE-SDR Ray Roberts Chemical Building South Door Intrusion Alarm XE-NDR Lake Lewisville Chemical Building North Door Intrusion Alarm XE-SDR Lake Lewisville Chemical Building South Door Intrusion Alarm XE-ELECDR Lake Lewisville Chemical Building Electrical Room Door Intrusion Alarm 2.08 PRESSURE TRANSMITTER A. Pressure indicating transmitter shall be of the two wire capacitance sensing solid state electronic type having a 4-20 mA DC output signal proportional to the calibrated pressure range. The transmitter shall have 316 stainless steel wetted parts and Hastelloy C diaphragm. The transmitter shall have 1/4 NPT on flange process connection. The transmitters shall have an externally adjustable span and zero, an integral junction box and an accuracy of +/-0.25% of span, +/-0.25% stability of upper range limit. Pressure transmitter shall be provided with pressure indication. B. Range limits of transmitter shall be 0-50 to 0-200 psig. Each transmitter shall include an integrally or externally mounted transient protector to protect the instrument against lightning produced voltage spikes and other transient surges. Transient protector shall be Rosemount Model 470. Each transmitter shall be furnished with a 3-valve manifold with NORMAL, ZERO, BLOCK, CALIBRATE and BLOWDOWN functions and shall be D/A PTM6 or approved equal. Transmitter shall have local indication of pressure. Transmitter shall be Rosemount 3051, Endress & Hauser with Hart protocol. No substitutions shall be allowed. Instrumentation 40 90 01 - 9 DTN18104 – Lake Lewisville WTP Phase II Improvements Tag Service Range PIT-XXX HSP No.1 Pump Discharge Pressure 0-200 psig PIT-XXX HSP No.2 Pump Discharge Pressure 0-200 psig PIT-XXX HSP No.3 Pump Discharge Pressure 0-200 psig PIT-XXX HSP No.4 Pump Discharge Pressure 0-200 psig PIT-XXX HSP No.5 Pump Discharge Pressure 0-200 psig PIT-XXX HSP No.6 Pump Discharge Pressure 0-200 psig 2.09 SMOKE DETECTOR A. Photoelectric smoke detector with self-diagnostic capability, field replaceable optical chambers, automatic drift compensation, auxiliary alarm relay, rated at 12/24VDC. Smoke detector to meet NFPA 72 field sensitivity. GE TS7 series. Tag Service XA1-XXX Electrical Room Smoke Detector XA2-XXX Electrical Room Smoke Detector 2.10 PRESSURE (LEVEL) TRANSMITTER A. Pressure indicating transmitter shall be of the two wire capacitance sensing solid state electronic type having a 4-20 mA DC output signal proportional to the calibrated pressure range. Pressure transmitter shall be used to measure the level in the clearwells. The transmitter shall have 316 stainless steel wetted parts and Hastelloy C diaphragm. The transmitter shall have 1/4 NPT on flange process connection. The transmitters shall have an externally adjustable span and zero, an integral junction box and an accuracy of +/-0.25% of span, +/-0.25% stability of upper range limit. Pressure transmitter shall be provided with pressure indication. B. Range limits of transmitter shall be 0-50 to 0-200 psig. Each transmitter shall include an integrally or externally mounted transient protector to protect the instrument against lightning produced voltage spikes and other transient surges. Transient protector shall be Rosemount Model 470. Each transmitter shall be furnished with a 3-valve manifold with NORMAL, ZERO, BLOCK, CALIBRATE and BLOWDOWN functions and shall be D/A PTM6 or approved equal. Transmitter shall have local indication of pressure. Transmitter shall be Rosemount 3051, Endress & Hauser with Hart protocol. No substitutions shall be allowed. Instrumentation 40 90 01 - 10 DTN18104 – Lake Lewisville WTP Phase II Improvements C. Tag Service Range LIT- Clearwell No.1 Level 0 – X’ LIT- Clearwell No.2 Level 0 – X’ LIT- Clearwell No.3 Level 0 – X’ LIT- Clearwell No.4 Level 0 – X’ 2.11 TEMPERATURE TRANSMITTER A. Transmitter shall be loop powered. Transmitter shall be equipped with a 1000 ohm platinum RTD, 4-20 mA output proportional to temperature, housing with integrally mounted RTD, -30C to + 60C operating range, 0-95% non-condensing relative humidity, 20V/m @ 20-1000 MHZ RFI/EMI Immunity, output accuracy = +0.2, stability. Temperature transmitter shall be Kele Solutions Model ST-T91E. Tag Service Range TT-XXX Electrical Room Temperature -10 C to + 50 C (14 F to 122 F) TT-XXX High Service Pump Room Temperature -10 C to + 50 C (14 F to 122 F) 3.00 EXECUTION 3.01 INSTALLATION A. Wire each device requiring power so that when wires are removed from any one device, power is not be disrupted to any other device. Ground the case of each device either by mounting directly on a steel frame or by a third wire. 3.02 FIELD QUALITY CONTROL A. The supervisory service of a factory-trained service engineer who is specifically trained on the type of equipment herein specified shall be provided during construction to assist the CONTRACTOR in the location of sleeves; methods of installing conduit and special cable; mounting, piping, and wiring one of each type of device, and the methods of protecting all of the equipment prior to placing it into service. Upon completion of the installation, the services of the above service engineer shall be provided for calibration and start up of the equipment and for instructing the operating personnel. The Manufacturer shall provide sufficient service to place the system in satisfactory operation. B. Check out and calibrate the system upon completion of the installation. Instrumentation 40 90 01 - 11 DTN18104 – Lake Lewisville WTP Phase II Improvements C. Prior to the OWNER turning on any form of energy to the system, the CONTRACTOR shall provide the ENGINEER with a certified statement of approval of the installation including his supplier's authorization for turning on energy to the system. END OF SECTION Supervisory Control And Data Acquisition (SCADA) System 40 90 02-1 DTN18104 – Lake Lewisville WTP Improvements Phase II 40 90 02 SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM 1.00 GENERAL 1.01 SCOPE A. This section specifies furnishing, installing, testing, and start-up operations of a complete control sub-system as indicated in the Plans and as specified herein. The system shall be set up to be totally integrated with the City of Denton’s system. The integrator shall provide consecutive registries for the City’s system to poll. The integrator shall also assign IP address as required by the Owner for all affected systems. The integrator shall also prepare a preliminary and final interface list in Microsoft Excel. Coordinate all requirements with the Owner. The SCADA system shall be set up as a stand alone system and shall be capable of connecting into the Owner’s system. The SCADA contractor shall set up address for the SCADA system at the Pump Station PLC such that the Owner’s system can pull all information from the from these systems. The system shall be configured to operate as a Distributed Control System having an open system architecture. 1. There are two areas of work in the Instrumentation Work in this project as described below: a. The Instrumentation System Integrator Contractor shall provide all hardware, software, and configuration and integration associated with the PLC based Instrumentation and Process Control system. Provide a complete and operational system in accordance with these Contract Documents: 1) Provide instrumentation, hardware, conductors and raceway required for a complete and operable system that is above that specified in the Contract Documents. Provide all labor and materials specified in the Contract Documents. 2) Provide a PLC with a UPS. The PLC shall be connected via fiber optic cable to the existing fiber loop routed around the plant. 3) Provide all required labor, materials and PLC programming and system configuration and integration to interconnect the PLC to the existing system located at the Lake Lewisville Water Treatment Plant. Provide fiber connections as required. 4) Provide an Ethernet switch to interconnect to the feeder protection relays for the main switchgear feeder protection relays, pump starters, switchgear power meters, and switchboard power meters. Refer to plans for more details. 5) Provide all required software and programming in the PLC for a complete and operational system in accordance with these Contract Documents. 6) Coordinate and fully cooperate with Prime Controls to provide all required hardware and PLC hardware and PLC programming necessary to interface with the existing SCADA system. 7) Provide personnel to check out, test and commission the system. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-2 DTN18104 – Lake Lewisville WTP Improvements Phase II 8) Provide personnel to train the Owner's staff as specified 9) Provide drivers necessary to communicate from the PLC in the Control Room of the Pump Station. Provide the required drivers, if required, to receive and transmit data over the radio system to fully communicate with the PLC systems. b. Prime Controls shall provide all required labor, materials and PLC programming and system configuration and integration in the PLC and I/O as required per the project to the PLC at the High Service Electrical Building, Pump Station, and the City of Denton Lake Lewisville WTP High Service Pump Station. 1) The contractor shall provide an RTU and PLC with a PLC at the High Service Electrical Building. The contractor shall provide all programming and wiring for the RTU and PLC. 2) Provide all required software and programming in the PLC and existing computer system at the City’s HMI at the High Service Electrical Building and at the High Service Pump Station for a complete and operational system in accordance with these Contract Documents. 3) Coordinate and fully cooperate with the OWNER to provide all required hardware and PLC hardware and PLC programming necessary to interface with the existing system. 4) Provide all required software and programming in the PLC at the High Service Electrical Building for a complete and operational system in accordance with these Contract Documents 5) Provide personnel to check out, test and commission the system. 6) Provide factory trained personnel to train the OWNER's staff as specified. 7) Provide software programming to create new screens on the computer system as specified. Provide a copy of all screens to the Owner as an official submittal when screens are developed. B. Provide PLC programming, interconnection, wiring, etc as required by the Process and Instrumentation Sheets and the Loop Descriptions System Components: The system will consist of the following major components and subsystems: 1. High Service Electrical Building: a. Free standing RTU cabinet b. Wall Mounted UPS for the RTU, mounted adjacent to the RTU. C. Software Requirements - Provide the following software modifications: 1. Program the Modicon PLC at the High Service Electrical Building. Integrate the I/O as shown on the Contract Documents. 2. Modify existing SCADA system and screens as required. 3. Program the Graphic User Interface touch screen to be installed on the front RTU cabinet. The touch screens shall have the capability to monitor and control all pumps and instrumentation at the Pump Stations. System Integrator shall field verify all conditions. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-3 DTN18104 – Lake Lewisville WTP Improvements Phase II D. Onsite Requirements - The Instrumentation System Integrator Contractor shall have technical staff on site and shall include as a minimum: 1. Preliminary Site Visit – Four (4) days. 2. Programming System Upgrades – Four (4) weeks at the pump station site. A representative from the City of Denton shall be present during the total period the SCADA System Integrator is making programming changes to the existing SCADA sy. The SCADA System Integrator Contractor shall contact the City of Denton, a minimum of two (2) weeks in advance for approval, prior to scheduling any programming modifications. 3. Startup Site Visit – Four (4) weeks 4. Owner Training – One (1) Day. E. Reference Standards: 1. American National Standards Institute (ANSI)/Institute of Electrical and Electronic Engineers (IEEE): a. C37.90.1, IEEE Standard Surge Withstand Capability (SWC) Tests for Protective Relays and Relay Systems. b. C37.90.2, Trial Use Standard Withstand Capability of Relay Systems to Radiated Electromagnetic Interference from Transceivers. c. Electronic Industries Association (EIA): d. RS-232-C, Interface Between Data Terminal Equipment and Data Communication Equipment Employing Serial Binary Data Interchange. e. RS-422-A, Electrical Characteristics of Balanced Voltage Digital Interface Circuits. 2. National Electrical Manufacturers Association (NEMA): a. ICS 1, General Standards for Industrial Control and Systems. b. ICS 1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid State Control. c. ICS 4, Terminal Blocks for Industrial Use. d. ICS 6, Enclosures for Industrial Controls and Systems. e. Publication No. 250, Enclosures for Electrical Equipment (1000 V maximum). 3. National Electrical Code. 4. ISA Standards 5. IEC 2 KV Isolation test 6. IEEE472/ANSI C37-90A Surge withstand capability test. 7. IEEE 802.3 F. Lightning/Surge Protection Supervisory Control And Data Acquisition (SCADA) System 40 90 02-4 DTN18104 – Lake Lewisville WTP Improvements Phase II 1. Lightning/Surge protection shall be provided to protect the Supervisory Control & Data Acquisition system from induced surges propagating along the communications, signal and power supply lines. The protection systems shall not interfere with normal operation, but shall be lower than the surge withstand level for the device they are protecting and be maintenance free and self-restoring. 2. All wiring, hardware, and connections means shall comply with the National Electrical Code and/or applicable local codes. 3. Lightning/Surge protection devices shall be mounted as close to the equipment they are protection as possible. Mounting guidelines will be followed as indicated in installation instructions provided by the manufacturer. Wires shall be attached by means of a cable-clamping terminal block activated by a screw. Connections shall be gas-tight, and the terminal block shall be fabricated on non-ferrous, non-corrosive materials. All wiring points and plug connections shall be “touch safe” with no live voltages that can make contact with a misplaced finger. 4. Panel mounted Lightning/Surge protection devices shall consist of two parts; a base terminal block and a plug protection module. Base shall directly connect to DIN rail. Replacing a plug shall not require the removal of any wires nor shall it interrupt the signal. Base and plug shall have the ability to be coded to accept only the correct voltage plug. Field mounted Lightning/Surge protection devices shall be contained in NEMA 4X housings. 1.02 SUBMITTALS A. Submittals shall conform to the requirements set forth in section 01 33 00, “Submittal Procedures” and section 40 90 00, “Instrumentation & Control for Process Systems”. B. Loop diagrams shall be prepared according to ISA Standard ISA-S5 and using loop numbers provided. C. Shop Drawings 1. Loop diagrams shall be prepared according to ISA Standard ISA-S5 and using loop numbers. 2. Schematic ladder diagrams shall include all terminal blocks, hardware devices, software interlocks, software data links, and control. 3. Project specific Interconnection diagrams of all devices. Interconnection diagrams shall include terminal blocks and wire tags. 4. Fiber optic and Ethernet project specific point to point interconnection diagrams for each pump station site. Diagrams shall include fiber optic cable, Ethernet cable, Ethernet switches, Power Meters, Protective Relays, UPSs, patch panels, patch cords, RTU cabinets and PLCs. 5. RTU panel layout, plans, elevations, sections, details, bill of materials, etc. 6. A schedule defining all I/O, database reference, and point of origin or destination, and PLC system internal address. 7. Software manuals shall be provided to configure the central system and technical review information. Provide sample program documentation from previous projects. 8. Complete spare parts list with catalog and part numbers and quantities. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-5 DTN18104 – Lake Lewisville WTP Improvements Phase II 9. UPS Battery Sizing Calculations 10. FAT Testing Agenda 11. Training Agenda. D. The Contractor shall submit upon approval of shop drawings and ordering of equipment but prior to beginning of construction the following documents to the Owner for review and approval: 1. Point to point wiring diagrams 2. Cable Schedule 3. AC and DC wiring diagram 4. Installation Details E. Factory Test Reports. F. Equipment Installation Report G. Radio Path Study results. H. OPERATION AND MAINTENANCE MANUALS 1. Operation and maintenance manuals shall contain the shop drawings, submittals, spare parts lists, schematics, and maintenance procedures. 2. Operating instructions shall incorporate a functional description of the entire system including the system schematics which reflect "as-built" modifications. Wiring diagrams shall be furnished as a part of the Operation and Maintenance Manuals which clearly show terminal numbers and wire numbers as they actually are in the instrumentation system. Instrument panel wiring shall be such that each wire installed has its own number designation at each end and such that no number is repeated. Instrument panel wire tagging instructions as specified in section 26 05 19, LOW VOLTAGE ELECTRICAL POWER CONDUCTORS & CABLES shall be followed. 3. Special maintenance requirements particular to the system shall be clearly defined along with special calibration and test procedures. 4. A schedule defining all I/O, database reference, and point of origin or destination, and PLC system internal address. 5. Submit written description of functions, loops, and logic. 6. Submit all SAMA Logic and Wiring Diagrams and ISA Logic Diagrams for all equipment requiring programming at the PLC, with all set points and ranges indicated. 7. Final point to point interconnection diagrams showing actual field terminals on both ends, cable numbers, wire tags, etc. An example of the final point to point interconnection diagrams shall be submitted to the Engineer for review and approval. Once the final point to point interconnection diagrams have been approved, the Contractor shall provide two copies of the AutoCAD files of the interconnection diagrams burned in on a CD as an official submittal. 8. The Contractor’s retainage will not be paid until the point to point interconnection diagrams have been submitted and approved by the Owner/Engineer. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-6 DTN18104 – Lake Lewisville WTP Improvements Phase II 9. One software copy of actual program files burned in on a CD/DVD. 10. Provide hardcopy of PLC programming logic in O&M manuals. 11. One PDF copy of the “as-built” wiring diagrams and associated drawings burned on a CD. a. Maximum file size is 5MB. If manual is greater than maximum allowable file size, provide individual files for each major section of manual. b. All files shall be compatible with the latest software version available. c. Filename shall identify the plant site, plant area, equipment manufacturer, and date equipment placed in service. d. Each electronic file shall contain a table of contents at the beginning of the file which includes hypertext links or bookmarks to navigate the file contents per section/chapter. The chapter labels shall identify the information included in that chapter i.e.: PLC Cabinet Layout. e. Scanned images of written documents are not acceptable. Document must allow character selection. Text within a file shall be transferable to other documents. f. Submit a preliminary version of the electronic format of the manual for review. Upon approval of the preliminary submittal, the Contractor shall provide the number of copies required per Division 01 of the electronic manual to the Owner. I. Factory Test Reports J. Equipment Installation Report 1.03 QUALITY ASSURANCE A. The following PLC programming and system configuration and integration are pre-qualified with the City of McKinney for PLC and HMI programming: 2. Prime Controls 3. No others shall be accepted. B. The following Instrumentation System Integrator Contractor's are pre-qualified with the City of Denton for Hardware. 1. Prime Controls 2. All others shall submit qualifications to the Owner and the Engineer for review and approval prior to bid submittal a minimum of 3 weeks prior to bid due date. Any submittals after this time period shall not be evaluated. Qualifications shall include SCADA Integrators who have had at least 10 years of successful experience in the integration of similar projects with a generator and pump station configurations. Qualifications shall include a list of similar projects within the last 5 years with the name of the project and contact information of the Owner C. Suppliers Qualifications: The complete system shall be configured, programmed, and installed by one qualified system supplier who is regularly engaged and qualified in Supervisory Control And Data Acquisition (SCADA) System 40 90 02-7 DTN18104 – Lake Lewisville WTP Improvements Phase II designing and building instrument control systems. The system suppliers shall assume complete systems responsibility, including coordination and interfacing with all subsystems and equipment suppliers and manufacturers. The installation supervisor shall have had experience in overseeing installation and start-up of at least three similar installations. The bidder shall submit, upon ENGINEER's request, complete company history, resumes of full time project manager for this project, other key full-time system analysts, programmers, technicians, and submit project list with costs, OWNER, contact person, phone number, etc. D. Tests: The complete system shall be assembled and tested at the job site. The OWNER'S representative and the ENGINEER'S presence will be required at the time of final testing at the job site. E. Standards: All applicable NEC, ISA, IEEE, NEMA, UL, ANSI, IEC, FCC, FM standards shall apply. All equipment shall be new and UL listed and labeled. F. Assembly, Storage, & Handling: Once assembled and tested, the system shall be stored in air-conditioned and heated rooms. Ship the unit to job site only after the Pump Station HVAC system is in operation. 1. The OWNER may approve partial payment for SCADA equipment ready to be onsite but is stored off site. Partial payment may be disallowed by the OWNER. a. For partial payment, the OWNER shall receive as a minimum a sales receipt, lien release, proof of insurance and the OWNER’s name shall be stenciled on the equipment being paid for. 1.04 SYSTEM DESCRIPTION A. Furnish and install a programmable controller-based supervisory control and data acquisition system configured as a distributed processing network as defined by the Contract Documents. Control functions shall include digital logic control, PID control, and setpoint control. B. Include all hardware, firmware, software, and application programming and configuration, as necessary, to make the system completely functional and operational in accordance with the Contract Documents. All necessary components and equipment which are not specifically described in the Contract Documents, but which are necessary to configure an operational distributed control system as described herein, shall be identified, furnished, and installed by the CONTRACTOR. The system provided shall be the vendor's standard; a prototype system will not be accepted. 1.05 WARRANTY A. The Equipment supplier and the CONTRACTOR shall warrant to the OWNER that the equipment delivered with reference to this specification complies with this specification. B. The equipment supplier and the CONTRACTOR shall warrant the equipment as to defects in material and workmanship for a period of one year from the date of final acceptance of the project. Vendor shall include a copy of his special equipment warranty with the shop Supervisory Control And Data Acquisition (SCADA) System 40 90 02-8 DTN18104 – Lake Lewisville WTP Improvements Phase II drawings. The warranty specified by this specification shall be exclusive, and in lieu of all other warranties whether written, implied, orally presented, or statutory. C. Warranty for equipment shall be through the equipment manufacturer and shall include the option to purchase additional service agreements/extended warranties after the initial warranty for up to five years. 2.00 PRODUCTS 2.01 COMPONENTS A. Components shall be Modicon M340 B. Components shall be new. C. Components shall be UL Listed. D. Provide the following components in sufficient quantities to enable the successful operation of the SCADA system as illustrated and described in the Contract Documents: 2.02 PROGRAMMABLE LOGIC CONTROLLER SYSTEM A. The following components are the City of Denton’s preferred hardware and software requirements. Contractor shall use these were the installation allows. Otherwise hardware and software shall be compatible and be from the same manufacture: 1. PLC: Modicon M340 PLC B. The control system shall be configured using microprocessor-based programmable controllers for local process control functions. The control system shall be equipped with power supplies and individual uninterruptible power supply (UPS) to perform logic control functions based on the program stored in memory and the status of inputs and outputs. Memory will be required such that there is a minimum of 100 percent spare memory capacity and 100 percent spare data capacity installed. The spare capacity shall be documented by submitting to the ENGINEER, during factory acceptance testing, a statement indicating the amounts of memory of all types being utilized and the total amount available. The statement shall include an estimate of the total program and data memory necessary, including spare capacity, based on the I/O hardware for the system, and previous programming experience. Control functions such as register loading, register reading, and diagnostics may be downloaded from the central computer system programming. Automatic shutdown feature shall be selectable such that the desired field condition will be the default condition in the event of power loss or system failure. Power supplies shall be provided for the process controller as required with built-in protection against short- circuits, overcurrent, and overvoltage. At least one communication port shall be provided for each programmable controller. C. The programmable controller shall be capable of complete control, including PID control, digital logic control, batch, and setpoint control. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-9 DTN18104 – Lake Lewisville WTP Improvements Phase II D. The entire PLC system shall immediately shut down and annunciate the occurrence of any of the following abnormal circumstances: 1. Memory parity error. 2. Loss of signal communication between CPU and I/O's. 3. Loss of logic power to any portion of the system. 4. Halt or interruption of memory scan. 5. Detection of any incomplete relay ladder rungs in memory. E. The PLC system shall accomplish the control requirements of the loop descriptions, and Contract Documents. F. The design application and installation of the PLC system shall conform to NEMA ICS 1.1. G. PLC programming shall be documented annotated in detail, and factory tested where allowed. H. Human-machine interface (HMI) at the University Pump Station shall utilize existing system viewable displays and keyboard(s). The HMI system at the Redbud Pump Station shall sue all new components. Interface functionality shall include: 1. Indication of process variables 2. Configuration of control loop parameters 3. Adjustment of controller output 4. Display of real time and historical process trends 5. Push button station controls 6. System and process status indicators 7. Graphic representation of plant operations with interactive status and measurement symbols 8. Annunciation I. The PLC system shall operate in ambient conditions of 32 to 140F temperature, in an ambient temperature of 45°C outside the enclosure, and 0 to 95 percent relative humidity without the need for purging or air conditioning. J. Environmental Controls: 1. Furnish circulation fans in solid state control system enclosures. 2. Over-temperature switches shall be utilized to provide special cooling if required to maintain operating temperatures within the manufacturer's specified range. 3. Air conditioning applications shall include means of preventing moisture condensation. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-10 DTN18104 – Lake Lewisville WTP Improvements Phase II K. Input/Output Connection Requirements: 1. Outputs shall be fused: a. External fusing shall be provided if output module does not possess internal fusing. b. Fuses provided external to output model shall: (ii) Be in accordance with module manufacturer's specifications. (ii) Be installed at terminal block. 2. Install bleeding resistors across input from field devices which leak current sufficiently to flicker input status light. 3. Make connections to I/O subsystem by terminating all field wiring on terminal blocks within the I/O enclosure. 4. Prewire I/O modules to terminal blocks. 5. Provide terminal blocks with continuous marking strip. 6. Size terminals to accommodate all active data base points and spares. Provide a minimum of 20% spare I/O of all active I/O points provided under this contract, plus the 20% spare I/O shall be wired to terminal blocks. 7. Provide terminals for individual termination of each signal shield. Stripping back twisted shielded pair and twisting together all the shields is not acceptable. 8. Field wiring shall not be disturbed when removing or replacing an I/O module. L. Where the PLC is utilized to control multiple trains of equipment, the PLC components (I/O modules, power supplies, etc.) shall be assigned so that the failure of one component does not affect equipment on all trains. I/O modules shall be segregated on a train basis unless required otherwise for safety reasons. M. All PLC control system components shall be capable of meeting or exceeding electromagnetic interference tests per ANSI/IEEE C37.90.2. N. Incorporate the following minimum safety measures: 1. Master Safety Relay: a. Cuts off power to I/O devices upon de-energization b. Multiple Master Safety Relays shall be available as required to provide ability to control separate designated blocks of the control program. 2. External Watchdog Function to Monitor: a. Internal processor clock failure b. Processor memory failure Supervisory Control And Data Acquisition (SCADA) System 40 90 02-11 DTN18104 – Lake Lewisville WTP Improvements Phase II c. Loss of communication between processor and I/O modules d. Processor ceases to execute logic program 3. Safety Function Wiring: a. Emergency shutdown switches shall not be wired into the controller. 4. An emergency power disconnect shall be placed in the power circuit feeding the power supply as a means of removing power from the entire PLC system. a. Capacitor shall be placed across the disconnect to protect against current outrush through trails. 5. Safe Wiring: a. Equipment failure mode shall be selected so that the loss of power or control signal to the equipment will result in the equipment either shutting down or operating safely unless specifically stated otherwise. b. Activation of alarms and stopping of equipment shall result from the de- energization of control circuits, rather than the energization of control circuits unless specifically stated otherwise. c. Low voltage control signal wires: 1) Place in conduit segregated for that purpose only 2) Twisted shielded wire pair Not located in the same conduit or bundle with power wiring 6. Initial Safety Conditions: a. Utilize program module to dictate output states in a known and safe manner prior to running of control program. b. Utilize program each time PLC is re-initiated and the control program activated. 7. PLC Fault Relay: a. Placed in series with any other emergency stop conditions b. Opening of PLC Fault Contact: 1) Upon unsafe or undesirable system operation, including: 2) Loss of memory 3) Processor fault 4) Power supply fault 5) Isolation failure 6) Communications failure Supervisory Control And Data Acquisition (SCADA) System 40 90 02-12 DTN18104 – Lake Lewisville WTP Improvements Phase II 7) Isolation failure 8) Communications failure 9) Scan time overrun 10) Module failure 11) Scan time overrun 12) Module failure 8. Monitoring of Internal Faults and Display: a. Internal PLC system status and faults shall be monitored and displayed. Monitored items shall include: 1) Memory ok/loss of memory 2) Processor ok/processor fault 3) Battery ok/battery low 4) Power supply ok/power supply fault 5) Isolation failure 6) High CPU temperature 7) Scan time overrun 8) Module failure 9. Effects of Failure: a. PLC system shall incorporate safe responses to the following failure effects: 1) Power losses, interruptions, excursions, dips, and transients. 2) Loss or corruption of memory 3) Information transfer corruption or loss 4) "Fail on" or "Fail off" of inputs or outputs 5) Unreadable signals 6) Addressing errors 7) Processor faults Supervisory Control And Data Acquisition (SCADA) System 40 90 02-13 DTN18104 – Lake Lewisville WTP Improvements Phase II 10. Design PLC system with high noise immunity to prevent occurrence of false logic signals resulting from switching transients, relay and circuit breaker noise or conducted and radiated radio frequency interference. 11. Incorporate noise suppression and inductive load suppression design into input, output, and logic modules 12. Operator Intervention: a. Logic system failure shall not preclude proper operator intervention b. Safety shutdown of equipment or a system shall require manual operator intervention before the equipment or system operation may be reestablished. 2.03 COMPONENTS A. PC Interface Software: 1. General: a. Contractor shall provide all SCADA software required to provide a fully operational SCADA system, including all Wonderware software and associated licenses, custom report generation software, network health monitoring, sniffers etc. All software shall be registered in Owners name. b. All required licenses for all software and documentation shall be provided for each computer and registered in Owners name and delivered to the Owner with the final product. All software provided shall be of the latest version of the software with the latest patches and service packs applied. c. Contractor shall develop and provide any and all SCADA architecture drawings that determine clearly and unambiguously all supervisory system hardware and software requirements. B. System Configuration: 1. An easy-to-use graphical database development environment shall be provided for building a data acquisition and control logic strategy. PLC programming shall be Function Block type, with thorough annotation of all code. Contractor shall provide to the Owner both hard and soft copies of the completed code upon final acceptance of the project. a. An object-oriented, icon driven color graphic display builder shall be provided for creation of real-time, dynamic operator displays. b. At power up, the system shall boot to a desktop screen where the user can easily activate the Strategy Builder, Graphics Builder, Runtime, or select a utility. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-14 DTN18104 – Lake Lewisville WTP Improvements Phase II c. The software shall run as a service, so that when a user logs off, the system will keep on running. All log-in authentication shall be password protected as required by the Owner. d. The graphical database shall be available as an output to a printer in tabular and graphic format for hard copy documentation. 2. Runtime: a. Runtime operation of the system shall execute the database strategy, graphic displays, and optional functions created during system configuration. For guaranteed data integrity, the system shall operate in a true prioritized, pre- emptive real-time multi-tasking operating environment for simultaneous execution of data collection, control, graphics, alarming, trending, data logging, file transfer, and other system activities. CPU operation shall be optimized during runtime for maximum system efficiency and performance. b. Operator color graphic displays shall update in real-time with a refresh rate defined by the user. The display screen shall be partitioned into three segments. c. The graphical screens shall have the same style, look and operation as the existing University Pump Station SCADA HMI system. Contractor shall conduct a series of interactive workshops with the Pump Station Operations and SCADA personnel during preliminary screen design and before being submitted to the Owner for review and /or approval. d. Sub-Window access shall be password protected to restrict access to authorized personnel. All log-in authentication shall be password protected as required by the Owner e. A color coded Alarm/Event screen shall list pertinent information on all system alarms and events (Operator actions) as they occur, are acknowledged, and return to normal. f. Alarm/Event screens shall include date, time, alarm/event type, tagname parameter, description, value, engineering units, and return-to-normal, as applicable. g. Operator access to Alarm squelch level shall be provided in the Sub-Window. Alarms with a squelch level less than the squelch level assigned are not displayed, sounded, printed, or logged to disk. h. Operator Events shall include: 1) Alarm Acknowledgement. 2) Parameter change (set point, output, etc.). 3) Auto/Manual change. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-15 DTN18104 – Lake Lewisville WTP Improvements Phase II 4) Setpoint Remote/Local Change. 5) Default Security Level Change. 6) Logging On and Logging Off. i. Alarm and Event messages may be printed to the same printer, or to different printers, as selected by the user. j. An on-line Trend function shall permit display of multiple selected data points in real-time as graphs of the values versus time. The system shall support multiple Trend Windows. k. The system shall be supplied with a Historian for collecting, saving, and replaying selected system data. l. Contractor shall be responsible for providing, installing and configuring of a rack- mount Network Archival Storage (NAS) device. Contractor shall configure NAS for regular, automatic historical data back-up. Contractor shall interact with the City’s Pump Station Operations and SCADA personnel during preliminary SCADA design to develop all historical data storage and collecting requirements. m. Historical data file may be replayed on-line, and viewed in graphical or tabular form. The History Window time span and variable amplitude may be compressed or expended in logical increments by the Operator. n. The on-line Historical Replay function shall permit viewing previously saved files and/or currently active historical files. 3. Report Generation: a. A consolidated Report function shall be furnished. It shall utilize a standard spreadsheet format for creation of system reports. Contractor shall provide any and all software required to fulfill all aspects of this Section. Reporting software shall be XLReporter (preferred) or software of similar capabilities. b. Contractor shall conduct a series of interactive workshops with the Pump Station Operations and SCADA personnel during preliminary SCADA design to develop all reporting requirements before being submitted to the Owner for review and /or approval. c. The Report generation function shall collect real-time and/or file data from the local node, or remote nodes via a network when used. File data shall include historical and alarm files at minimum. d. Report files shall be output on command to the local printer or to disk, as specified. Initiation of report output may be manual or automatic based on time of day, system event, or process condition. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-16 DTN18104 – Lake Lewisville WTP Improvements Phase II e. Freeform text may be integrated anywhere in the report. f. Provision shall be included for incorporation of Operator message fields. This shall permit capture and save of Operator comments made during runtime for inclusion in the report. g. The report shall also provide for capture and saving of text fields from system alarm and event messages. h. Report and event printer locations: 1) One (1) printer shall be located in the Redbud Pump Station. 2) Contractor shall be responsible for all materials required (cables, connectors, etc.) to make a fully operational reporting system. 4. Networking: a. An efficient high speed, real-time networking function shall be optimally available. It shall provide on-line real-time access to live data and file transfer simultaneously during runtime. b. Network switches shall be full Gigabit modular style managed Ethernet switches that include, but are not limited to the following options: 1) The network shall support all Ethernet network topologies. 2) Redundancy protocols capable of automatic fail-over. 3) Multi-Mode, Single Mode fiber optic and/or copper modular interface ports with hot-swap capabilities. 4) Capable of remote management. 5) Redundant power supplies (rack mounted switches). c. Each network node shall operate independently to permit unrestricted assignment of system functions in a true distributed architecture. d. Network data exchange shall be “exception driven” rather than “polled” for maximum throughput during runtime. e. A network timekeeper function must be supplied to insure synchronization of all network node time clocks. Any node may be designated as the master timekeeper to which all other node clocks are synchronized. Should the master node fail, multiple backup nodes may be designated to continue network time synchronization. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-17 DTN18104 – Lake Lewisville WTP Improvements Phase II f. A global alarm capability must be provided which will allow alarms that occur anywhere on the network to be automatically broadcast over the entire network. Individual nodes may be configured to receive all alarms, only certain alarm types, or all alarms from a single or multiple pre-selected nodes. g. In order to exchange data between different networks, the networking option shall support use of more than one network adapter on a node. h. Contractor shall provide all necessary network cables that may be required to complete network communications. i. Contractor shall be responsible for all network switch configuration and diagnostic notification as required and demonstrate their operation as part of the integrated system. Contractor shall work with Owner for switch address assignments as required. j. Contractor shall, upon delivery of system, image all server machines and provide instructions to the Owner (both in writing and in training) on how to restore machines from these images. Contractor shall provide copies of these images on separate storage media (CD, flash drive, etc.) and provide these copies to Owner upon system delivery. 5. Support: a. Technical support shall be available from a Factory Regional Office or local Representative of the software Supplier. b. Factory technical support shall be available from degreed engineers familiar with the software and typical industrial applications. c. Telephone technical support, voice and e-mail, shall be available weekdays and weekends and holidays. d. Technical support shall be offered for the life of the product, and for a minimum of 1 year after it is discontinued. e. The vendor must have a record of providing a continuous upgrade path for the product. 6. Upgrades: a. Maintenance releases for bug fixes shall be supplied when needed if requested by the user. (e.g. - change from Version 4.0 to Version 4.01). b. Contractor shall, no earlier than one (1) month prior to system acceptance, upgrade all supplied hardware and software with the latest versions of firmware and software. C. PLC System Central Processor Unit (CPU): Supervisory Control And Data Acquisition (SCADA) System 40 90 02-18 DTN18104 – Lake Lewisville WTP Improvements Phase II 1. Completely solid state CPU designed to provide: a. Digital relay logic b. Analog loop control c. Other required control functions: 1) Counting 2) Floating point math computations 3) Timing 2. To provide communications with other control systems and man-machine interfaces as specified. 3. To use electrical ladder diagram style programming for discrete logic applications. 4. Memory: a. Capacitor-based energy for RAM 5. 100 percent minimum spare useable memory capacity after all required programming is in place and operating. 6. Capable of executing all control functions required by the Contract Drawings including digital and analog loops. 7. Built-in three-mode (proportional-integral-derivative) control capabilities. a. As directly selectable algorithms requiring no user knowledge of programming languages. 8. On line reconfigurable. 9. Lighted status indicators for "RUN" and "FAILURE." 10. Capable of manual or automatic control mode transfer from the HMI system or from within the control strategy. Transfer shall be bumpless and balanceless. D. Input/Output (I/O) Modules 1. Provide plug-in modular-type I/O racks in each PLC enclosures if required, with cables to connect to all other required PLC system components. 2. Provide I/O system with: a. I/O solid state boards with status lights indicating I/O status and board failure. b. Electric isolation between logic and field device. c. Individually fused outputs with blown fuses indication. d. Interchangeable modules for similar I/O type to allow substitution of operating modules for failed units by the operator. e. Incorporate noise suppression design. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-19 DTN18104 – Lake Lewisville WTP Improvements Phase II f. Capable of meeting or exceeding surge-withstand capability tests, per ANSI/IEEE C37.90.1. g. Capable of meeting or exceeding electrical noise tests, NEMA ICS1-109.60-109.66. 3. Discrete I/O Modules: a. Interface to ON/OFF devices b. I/O status indicator module front c. Voltage rating to match circuit voltage d. Output module current rating: 1) Match maximum circuit current draw 2) Minimum 1.5 A/point for 120 V AC applications e. Isolated modules for applications where one module interfaces with devices utilizing different sources of power. f. Individually fused with blown fuse indication. 4. Analog I/O Modules: a. Input modules to accept signals indicated on Drawings or in the Specifications b. Minimum 16 bit resolution c. I/O chassis supplied power for powering connected field devices d. Isolated (differential) inputs and outputs e. User configurable for desired fault response state f. Provide output signals as indicated on Drawings and in the Specifications g. Individual D/A converter for each output module h. Individual A/D converter for each input module 2.04 POWER SUPPLY A. The power supply shall be fully enclosed and provide screw terminations by means of a cable clamping terminal block activated by a screw. Connections shall be gas-tight, and the terminal block shall be fabricated of non-ferrous, non-corrosive materials. All wiring points shall be touch safe with no live voltages that can make contact with a misplaced finger. Power supply shall have integral metal mounting feet to attach to 35-mm DIN-rail. B. The power supply shall conform to UL 508C standards and allow use at the full rated current. The power supply shall have a visual indicator for applied power. Operating temperature range shall be -25°C to 70°C. Power supply shall have means of limiting DC current in case of short circuit and shall automatically reset when fault is corrected. Power supply shall be able to be run in parallel mode without external circuitry to provide redundancy. Residual ripple shall not exceed 150 mV peak to peak. C. Power supply shall be Phoenix Contact, Power-One or approved equal. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-20 DTN18104 – Lake Lewisville WTP Improvements Phase II 2.05 CONTROL PANELS A. Control Panels shall be NEMA 4X, 316 stainless steel, unless noted otherwise. Panel shall have a hinged front door and have all indicating lights, control switches, etc. located on the outside door. Panels shall be Hoffmann, Hammond, Rittal or approved equal. 2.06 RTU CABINET A. Furnish and install the RTU cabinet at the location indicated. Cabinet shall be a NEMA 12, floor-mounted, free-standing enclosure and shall have a hinged front door with key interlocking handle. The enclosure shall be made of 14 gauge steel with a 11 gauge mounting panel inside. The I/O module and UPS shall be housed in the RTU cabinet. The enclosure shall be MINIMUM 72”H x 72”W x 24” D for the High Service Electrical Building. The UPS shall be wall mounted in a separate NEMA 12 enclosure and sized as required to house the UPS and bypass switch. B. All discrete inputs/outputs shall have interposing relays. Interposing relays contained in this cabinet shall be 3PDT, shall have 24VDC coils, shall each have a pilot light indicating energized coil, and shall each be mounted in a plug in socket with relay retainer clip and screw terminals. Relays shall be Square D KU13M1P14 or approved equal. C. Instrument panel wiring shall be as follows: 1. Single conductor wire shall be stranded, tinned 16 AWG and MTW insulation, as manufactured by American Insulated Wire or approved equal. Color-coding shall be purple for ungrounded conductors and white for grounded conductors. 2. Pair shielded cable for 4-20 mA DC loops shall be as specified in 26 05 19, LOW VOLTAGE ELECTRICAL POWER CONDUCTORS & CABLES. 3. Each conductor terminated under a screw head shall have a crimp on spade terminal applied to its end prior to its termination. 4. Each conductor has its own number and no number is used more than once. 5. The number of each wire is placed at both ends of the wire next to its end according to wire tagging instructions as specified in 26 05 53 IDENTIFICATION FOR ELECTRICAL SYSTEMS. 6. The wire numbers, as actually installed, match the numbers on the shop drawings, O&M manuals, wiring diagrams and interconnection diagrams for this instrument panel. 7. Wiring shall be run enclosed in plastic wireway wherever possible. Wireways shall be installed as required to enclose panel wiring. Where the use of plastic wireway is not practical, conductors shall be bundled and run open. Conductors run open shall be bundled and bound at regular intervals not to exceed 6" with nylon ties, or approved equal. Wires within a bundle are to be run parallel to one another and not twisted. Bundles shall have a uniform appearance, circular cross section, and shall be securely fastened to the panel framework. Conductors carrying different voltages that are from the same source may occupy the same wireway provided all are insulated for the maximum voltage of any conductor in the wireway. Wiring carrying voltages that originate at different source shall not run in the same wireway. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-21 DTN18104 – Lake Lewisville WTP Improvements Phase II 8. Terminal blocks shall be installed for wire terminations and shall be capable of mounting on a 35mm DIN-rail. Terminal blocks shall have a method of labeling for easy identification. Typewritten labels shall denote terminal block numbers and shall match numbers shown on shop drawings, O&M manuals and wiring diagrams. 25 percent additional terminals shall be provided for OWNER’s use. Terminal blocks shall be available with screw clamp technology and be made of a non-corrosive material. The metal body shall contain a serrated pressure plate that will provide a gas-tight connection with the conductor. All terminal block wiring points shall be “touch safe” with no live voltages that can make contact with a misplaced finger. Terminal blocks shall be rated 600V and shall be Phoenix Contact UT Series, Allen Bradley 1492-H1 Series or approved equal. 9. Wire ducts shall be insulated for the maximum voltage of any conductor in the wire duct. Wiring carrying voltages that originate at different source shall not run in the same wire duct. Wire ducts shall be color coded as follows: a. 24VDC shall be routed in a Wire duct with a Light Grey Color cover. b. 48VDC shall be routed in a Wire duct with a Blue Color cover. c. 120VAC shall be routed in a Wire duct with a White Color cover. d. 480VAC shall be routed in a Wire duct with a Black Color cover. 10. A separate 120VAC Terminal Block and circuit breaker shall be provided for PLC cabinet. 11. Cabinet shall be provided with a switched LED light and a separate 120V grounded duplex receptacle. Switch for light shall be mounted on inside of cabinet, easily accessible. D. A print pocket shall be provided in the panel and 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. E. All equipment shall be mounted in such a manner that all maintenance may be accomplished with easy access through the PLC cabinet doors. F. Panel shall be labeled in accordance with U.L. 508 and U.L. 508A and all other applicable U.L. standards. G. Acceptable RTU cabinet manufacturers: 1. Hoffman 2. Hammond 3. Rittal 2.07 UNINTERRUPTIBLE POWER SUPPLY A. The system supplier shall provide an Uninterruptible power supply (UPS) for the programmable controllers and its associated RTU cabinet. The systems supplier shall size the UPS for the connected load plus 100% spare capacity. UPS shall also be provided at each PLC and at each of the remote I/O locations. Utilize Gel-cell type batteries housed in their own enclosure mounted on the wall adjacent to the RTU for the High Service Pump Station Electrical Building. A standalone UPS with bypass switch shall be provided for the Supervisory Control And Data Acquisition (SCADA) System 40 90 02-22 DTN18104 – Lake Lewisville WTP Improvements Phase II HMI system. The UPS shall be equal to Liebert GXT3-2000RT120 or approved equal, and shall have capacity to supply power for a period not less than one hour continuously for the processing units (PLC), wireless I/O modules, 12VDC, 24VDC power supplies, and loop powered instruments connected to the PLC , I/O modules and HMI. 2.08 SURGE SUPPRESSOR A. Surge suppressor for AC power circuits shall be UL listed or recognized. Suppressor shall be designed to withstand a maximum 10 kA test current of a 8/20 µS waveform according to ANSI/IEEE C62.41 Category C Area. Suppressor shall consist of a multistage hybrid circuit with staging inductors or resistors to properly coordinate the components. Surge protection modules shall have a visual indication of circuit integrity. Devices shall include a SPDT contact rated for at least 120 VAC, 1 Amp, for remote failure indication. AC power surge suppressor shall be Phoenix Contact Mains-Plugtrab Series or approved equal. B. Surge suppressors for analog, discrete and data signals shall be UL listed or recognized. Suppressors shall be designed to withstand a maximum 10 kA test current of a 8/20 µS waveform according to ANSI/IEEE C62.41 Category C Area. Suppressors shall consist of a multistage hybrid circuit with staging inductors or resistors to properly coordinate the components. Analog, discrete and data signal surge suppressors shall be Phoenix Contact Plugtrab Series or approved equal. C. Surge suppressors for field protection of analog signals shall consist of a multistage hybrid circuit utilizing only diodes and/or gas discharge tubes but no metal oxide varistors (MOV). Suppressors shall be designed to withstand a maximum 10 kA test current of a 8/20 µS waveform according to ANSI/IEEE C62.41 Category C Area. Surge protection shall not have a cutoff frequency less than 400 kHz (for a 600 Ohm system) to allow HART protocol and other superimposed smart digital signals to function. 2-wire analog field surge suppressor shall be Phoenix Contact Pipetrab Series or approved equal. 4-wire analog field surge suppressor shall be Phoenix Contact Boxtrab or approved equal. 3.00 EXECUTION 3.01 INSTALLATION A. All work shall be in accordance with manufacturer’s recommended practices. Care shall be exercised to avoid damage to equipment during installation. Damaged equipment shall be replaced by CONTRACTOR at no expense to the OWNER. B. System equipment shall be installed where indicated in the Contract Documents. Power and signal connections between components shall provide the specified functions. Install according to equipment manufacturer's instruction. C. The system Supplier Contractor shall utilize their own printers, monitors, and computers for programming, testing, and start-up. The use of the OWNER's computers, monitors, or printers shall not be acceptable until the entire system has been installed, debugged, programmed, and operated to ENGINEER's satisfaction. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-23 DTN18104 – Lake Lewisville WTP Improvements Phase II 3.02 PROGRAMMING A. The loop descriptions and diagrams shown in the Contract Documents are functional only and do not attempt to specify detail program coding that may be required. The CONTRACTOR shall utilize this functional information to develop complete application programming for the PLC equipment provided under this CONTRACT. Programs shall be designed to provide fail-safe operation of equipment in case of PC logic or power supply failure. Fail-safe shall be defined as "stopped" for all drives and "closed" for valves, unless otherwise specified. 3.03 DOCUMENTATION A. Following delivery to the site, the equipment manufacturer, in the presence of the OWNER’S REPRESENTATIVE, shall demonstrate operation of the complete system. B. The CONTRACTOR shall provide documentation for all application software. Documentation system shall be diagrams in ladder-rung format, and shall show all input devices to the left of the left "power rail" and all outputs to the right of the right "power rail." The diagrams shall show all device codes and functional description used in the project manual, and shall also show PLC address codes, element codes, and I/O assembly codes, modules numbers, and terminal numbers. 3.04 TESTS A. All elements of the SCADA system, both hardware and software, shall be tested to demonstrate that the total system satisfies all of the requirements of the Specifications. B. The CONTRACTOR shall furnish and install the field instruments, remote input/output (RI/O), and interface equipment in a schedule to meet the construction sequencing. C. As a minimum, the testing shall include the following: 1. Software Acceptance Tests (SAT) 2. Factory Acceptance Tests (FAT) 3. Operational Readiness Tests (ORT) 4. Functional Demonstration Tests (FDT) 5. 30-Day Acceptance Test D. 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. E. All tests shall be conducted in accordance with Engineer-approved procedures and documented. Each specific test to be performed shall be described and a space provided after it for signoff by the appropriate party after its satisfactory completion. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-24 DTN18104 – Lake Lewisville WTP Improvements Phase II F. Copies of signoff test procedures, forms, and checklists will constitute the required test documentation. G. Provide all special testing materials and equipment. Wherever possible, perform tests using actual process variables, equipment, and data. Where it is not practical to test with real process variables, equipment, and data, provide suitable means of simulation. Define these simulations techniques in the test procedure. H. Coordinate all testing with other Contractors, the OWNER, and the OWNER’S REPRESENTATIVE. I. The OWNER and/or OWNER’S REPRESENTATIVE will actively participate in many of the tests. The OWNER and/or OWNER’S REPRESENTATIVE reserves the right to test or retest any and all specified functions whether or not explicitly stated in the approved test procedures. The OWNER and/or OWNER’S REPRESENTATIVE reserve the right to observe and/or inspect the work during any phase. J. The OWNER’S REPRESENTATIVE decision shall be final regarding the acceptability and completeness of all testing. 3.05 SOFTWARE ACCEPTANCE TEST (SAT) A. Prior to the start of the witnessed Software Acceptance Test (SAT), the entire system shall be installed at the SCADA System Integrator’s site, inspected and tested to ensure that it is fully operational and ready for the SAT demonstration testing. B. All panels and assemblies of the subsystem shall be completely installed except I/O signals to field elements or devices shall not be connected. The system shall be inspected and tested to verify that they are in conformance with related submittals and the Contract Documents. C. The remote I/O modules and subsystem primary elements shall be interconnected and tested to ensure that the system is fully operational. The system shall be operated without signals leaving or entering from the field elements or devices for at least one week to verify that it is capable of continuous operation. Outputs to and inputs from the excluded primary elements shall be simulated. D. The system shall be tested and installed on site to demonstrate that it is operational and in conformance with the Contract Documents. E. Notify the ENGINEER and OWNER’S REPRESENTATIVE in writing a minimum of 30 days in advance of the proposed starting date for the Software Acceptance Test. At the time of notification, submit any revisions to the detailed test procedure previously approved by the OWNER’S REPRESENTATIVE in the Project System Plan. F. The purpose of the test shall be to witness and verify the functionability, performance, and stability of the hardware and software. The system must operate continually for 24 hours without failure before the test shall be judged successful. Successful completion of this test shall be the basis for approval of the system. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-25 DTN18104 – Lake Lewisville WTP Improvements Phase II G. The Software Acceptance Tests shall be performed on all the equipment installed. The SAT shall be a two-part text procedure; Part I shall include the PLC sub-system to verify all I/O addresses and proper step sequence for all features. Part II shall add the HMI to verify all screen displays, addressing and report generation. H. Where hardware items are of standard manufacture and in current production, the manufacturer shall certify that applicable tests have been performed and met, in accordance with IEEE and ISA Standards, and be prepared to supply copies of data to OWNER’S REPRESENTATIVE upon request. Such statements shall accompany the equipment submittals called for in SUBMITTALS of this Section. Any assemblage of devices together with operating programs shall be tested together as provided herein. I. The various tests performed during Software Acceptance Test shall be designed to demonstrate that the hardware and software fulfill all the requirements of the Contract Documents. The test conditions shall resemble, as closely as possible, actual conditions. Any additional hardware or software that may be required to successfully verify system operation shall be supplied at no cost to the OWNER. J. Some of tests to be performed shall include, but not be limited to, the following: 1. Building and loading the system database. 2. Conduct online modifications to the database. 3. Demonstrate operability of the interfaces (hardware and software). 4. Demonstrate operability of the data communication network. 5. Demonstrate all system software functions specified. 6. Verify the displays and interactive capabilities of an operator's console. 7. Simulate selected normal and abnormal operating conditions to verify the performance of the monitoring and control functions. 8. Simulate every I/O point by opening or shorting digital inputs, inject appropriate signals into every analog input point, and measure the output signal from each analog output point. K. All deficiencies identified during these tests shall be corrected and retested prior to completing the Software Acceptance Test. L. The following documentation shall be made available to the OWNER’S REPRESENTATIVE at the test site both before and during the Software Acceptance Test. 1. All drawings and specifications, addenda, and change orders. 2. Master copy of the test procedure. 3. List of the equipment to be tested including make, model, and serial number. 4. Design-related hardware submittals applicable to the equipment being tested. 5. Preliminary software documentation submittal. M. The daily schedule during these tests shall be as follows: Supervisory Control And Data Acquisition (SCADA) System 40 90 02-26 DTN18104 – Lake Lewisville WTP Improvements Phase II 1. Testing and meetings: Nominally 8 hours per day; 24 hours per day if required to meet schedule. 2. Morning meetings to review the day's test schedule. 3. Evening meetings to review the day's test results and to review or revise the next day's test schedule. N. All test data and procedures followed during testing shall be logged, and certified copies of the logs shall be provided to the OWNER’S REPRESENTATIVE and OWNER. O. The OWNER’S REPRESENTATIVE will observe each test once on a pass-fail basis. The OWNER’S REPRESENTATIVE alone has the authority to determine if a test passes or fails. Only four (4) fifteen minute windows per day will be allowed during the test procedure to make corrections to software and successfully pass a re-test. Otherwise, that test will be declared a failure. If a test fails, it will be put on a retest schedule. If other tests to follow rely on a particular test passing, then the following tests will also be placed on a retest schedule even though they were not tested before. Retesting shall not interrupt the test schedule. The CONTRACTOR may schedule retest days during the testing period, but not more than two per week. All retesting shall only occur on a day designated in the schedule or at the end of testing. P. All time and expense incurred by the OWNER’S REPRESENTATIVE and/or OWNER’S staff for all retests shall be borne by the CONTRACTOR and paid to the OWNER. Time and expense incurred shall be on a time and material basis tracked by the OWNER’S REPRESENTATIVE and OWNER for their own staff and presented to the CONTRACTOR on a periodic basis. Q. The CONTRACTOR shall expedite the correction of any deficiency discovered during testing. The CONTRACTOR shall have personnel from each trade to standby during the test period to immediately correct, or adjust any item of software or hardware or equipment causing a test to fail. 3.06 FACTORY ACCEPTANCE TEST (FAT) A. The SCADA Contractor shall provide a factory acceptance test for each RTU Cabinet. The factory acceptance test shall be witnessed by the Owner/Engineer. Notify the ENGINEER and OWNER in writing a minimum of 14 days in advance of the proposed starting date for the Factory Acceptance Test. B. The manufacturer shall notify the Owner/Engineer at least 30 days in advance of the dates that tests will be made, so that the Owner can make arrangements for his representative to be present. The cost for the travel, lodging expenses, meals and transportation for OWNER personnel (one maximum) to witness the factory acceptance tests shall also be included in the bid price. The Owner’s travel will originate in McKinney, Texas. The SCADA System Integrator or Vendor will pay for the cost of the representative’s (travel, lodging, meals and other expenses for the tests, for a maximum of two trips. The manufacturer shall bear all other costs for performing the factory acceptance test. If a test must be re-run due to failure in meeting the specified requirements, then the witness expenses for the re-test shall be borne by the manufacturer. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-27 DTN18104 – Lake Lewisville WTP Improvements Phase II a. Factory acceptance tests shall be conducted in continental United States. No testing shall be conducted in Mexico nor any other foreign country. b. All travel arrangements are subject to approval by the OWNER and ENGINEER. The SCADA System Integrator shall be responsible for making all travel arrangements. c. The SCADA System Integrator shall notify the Owner/Engineer a minimum of one month in advance of the dates when equipment is scheduled for the factor acceptance tests so that the Owner/Engineer can schedule accordingly. d. The costs to perform the factory acceptance tests shall be included in the bid price. The travel, transportation, and lodging expenses for Owner/Engineer personnel (one maximum) to attend the factory acceptance tests shall also be included in the bid price. e. If an inspection and/or test must be re-run due to failure in meeting the specified requirements, then the labor and travel expenses for the re-test shall be borne by the Manufacturer or Vendor C. Testing shall include the following: 1. Loop/Component Inspections and Tests: The 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. Actual real-time signals generated from the field devices shall be used. Simulation of field signals shall not be permitted. This test is intended to actually operate the entire process and to find and correct all real-time operational deficiencies. 2. The Loop/Component Inspections and Tests shall be implemented using 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: 1) Project name 2) Loop number 3) Tag number for each component 4) Check offs/sign offs for each component a) Tag/identification b) Installation c) Termination - wiring d) Termination - tubing e) Calibration/adjustment Supervisory Control And Data Acquisition (SCADA) System 40 90 02-28 DTN18104 – Lake Lewisville WTP Improvements Phase II 5) Check offs/ sign offs for the loop a) Panel interface terminations b) I/O interface terminations c) I/O signal operation d) Inputs/outputs operational: received/sent, processed, adjusted e) Total loop operational 6) Space for comments 7) Space for signoff by Contractor b. Each active analog subsystem element and each I/O module shall have a Component Calibration Sheet. These sheets shall include the following: 1) Project name 2) Loop number 3) Component tag number or 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, for example: a) For indicators and recorders: Scale and chart ranges b) For transmitters/converters: Input and output ranges c) For computing elements: Function d) For controllers: Action (direct/reverse) control modes (PID) e) For switching elements: Unit range, differential (fixed/adjustable), reset (auto/manual) f) For I/O modules: Input or output 8) Calibrations; for example: a) For analog devices: Required and actual inputs and outputs at 0, 10, 50, and 100 percent of span, rising and falling Supervisory Control And Data Acquisition (SCADA) System 40 90 02-29 DTN18104 – Lake Lewisville WTP Improvements Phase II b) For discrete devices: Required and actual trip points and reset points c) For controllers: Mode settings (PID) d) For I/O modules: Required and actual inputs or outputs of 0, 10, 50, and 100 percent of span, rising and falling 9) Space for comments 10) Space for signoff by the Contractor 3. Maintain the Loop Status Reports and Component Calibration Sheets at the jobsite and make them available to the Engineer and Owner upon request. D. These inspections and tests do not require witnessing. However, the Engineer will review the Loop Status Reports and Component Calibration Sheets and spot-check their entries periodically and upon completion of the Operational Readiness Test. Any deficiencies found shall be corrected. 3.07 OPERATIONAL READINESS TEST (ORT) A. General: Prior to start-up, the installed system shall be certified (inspected, tested, and documented) that it is ready for operation. Download all database on job computers from this test onwards. The OWNER and OWNER’S REPRESENTATIVE shall be notified when ORT starts. Copies of ORT forms that have been signed off by the CONTRACTOR shall be copied and sent to the OWNER and OWNER’S REPRESENTATIVE on a daily basis for record purposes only. No signature by the OWNER’S REPRESENTATIVE or OWNER is required for ORT forms. B. Loop/Component Inspections and Tests: The 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. Actual real-time signals generated from the field devices shall be used. Simulation of field signals shall not be permitted. This test is intended to actually operate the entire process and to find and correct all real-time operational deficiencies. 1. The Loop/Component Inspections and Tests shall be implemented using 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: 1) Project name 2) Loop number 3) Tag number for each component 4) Checkoffs/signoffs for each component a) Tag/identification b) Installation c) Termination - wiring d) Termination - tubing e) Calibration/adjustment Supervisory Control And Data Acquisition (SCADA) System 40 90 02-30 DTN18104 – Lake Lewisville WTP Improvements Phase II 5) Checkoffs/signoffs for the loop a) Panel interface terminations b) I/O interface terminations c) I/O signal operation d) Inputs/outputs operational: received/sent, processed, adjusted e) Total loop operational f) Space for comments g) Space for signoff by CONTRACTOR b. Each active analog subsystem element and each I/O module shall have a Component Calibration Sheet. These sheets shall include the following: 1) Project name 2) Loop number 3) Component tag number or 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, for example: a) For indicators and recorders: Scale and chart ranges b) For transmitters/converters: Input and output ranges c) For computing elements: Function d) For controllers: Action (direct/reverse) control modes (PID) e) For switching elements: Unit range, differential (fixed/adjustable), reset (auto/manual) f) For I/O modules: Input or output 8) Calibrations; for example: a) For analog devices: Required and actual inputs and outputs at 0, 10, 50, and 100 percent of span, rising and falling. b) For discrete devices: Required and actual trip points and reset points c) For controllers: Mode settings (PID) d) For I/O modules: Required and actual inputs or outputs of 0, 10, 50, and 100 percent of span, rising and falling. 9) Space for comments 10) Space for signoff by the CONTRACTOR 2. Maintain the Loop Status Reports and Component Calibration Sheets at the jobsite and make them available to the OWNER’S REPRESENTATIVE and OWNER upon request. 3. These inspections and tests do not require witnessing. However, the OWNER’S REPRESENTATIVE will review the Loop Status Reports and Component Calibration Sheets and spot-check their entries periodically and upon completion of the Operational Readiness Test. Any deficiencies found shall be corrected. 3.08 FUNCTIONAL DEMONSTRATION TEST (FDT) A. Once ORT has been completed and operational readiness has been confirmed, a witnessed Functional Demonstration Test shall be performed on the complete system to demonstrate that it is operating and in compliance with the Contract Documents. Each specified function shall be demonstrated on a paragraph-by-paragraph, loop-by-loop, and component-by- Supervisory Control And Data Acquisition (SCADA) System 40 90 02-31 DTN18104 – Lake Lewisville WTP Improvements Phase II component basis. This test shall be scheduled and conducted only after all new pipeline construction is complete and the new pipeline and metering construction is completed and operational. B. Loop-specific and non-loop-specific tests shall be the same as specified under SOFTWARE and OPERATIONAL READINESS TESTS except that the entire installed PICS shall be tested and all functions demonstrated. C. Simulation of field signals, or simulation of the response of the process, or the response of individual components, or the functions being monitored or controlled, shall not be permitted. Simulation may be permitted with the express permission of the OWNER’S REPRESENTATIVE. The decision to simulate is the OWNER’S REPRESENTATIVE's alone. The CONTRACTOR shall include in the Contract Price the time necessary to wait for all process responses. D. Updated versions of the documentation called for under SOFTWARE and OPERATIONAL READINESS TESTS shall be made available to the OWNER’S REPRESENTATIVE at the jobsite both before and during the test. In addition, one copy of the approved Instrumentation O&M Manual shall be made available to the OWNER’S REPRESENTATIVE at the jobsite both before and during testing. The approved schedule shall be followed strictly on an item-by- item basis. Combining of test items shall be at the discretion of the OWNER’S REPRESENTATIVE alone. The CONTRACTOR shall include in the Control Price adequate time necessary to complete each test item one at a time. E. The daily schedule called for under SOFTWARE and OPERATIONAL READINESS TESTS shall also be followed during the Functional Demonstration Test. F. The OWNER’S REPRESENTATIVE will observe each test once on a pass-fail basis. The OWNER’S REPRESENTATIVE alone has the authority to determine if a test passes or fails. Only one (1) fifteen minute window per day will be allowed during the test procedure to make corrections to software or to field equipment and successfully pass a re-test; otherwise, that test will be declared a failure. If a test fails, it will be put on a retest schedule. If other tests to follow rely on a particular test which has failed, then the following tests will also be placed on a retest schedule even though they were not tested. Retesting shall not interrupt the test schedule. The CONTRACTOR may schedule retest days during the testing period, but not more than two per week. All retesting shall only occur on a day designated in the schedule or at the end of testing. G. All time and expense incurred by the OWNER’S REPRESENTATIVE and/or OWNER’S staff for all retests shall be borne by the CONTRACTOR and paid to the OWNER. Time and expense incurred shall be on a time and material basis tracked by the OWNER’S REPRESENTATIVE and OWNER for their own staff and presented to the CONTRACTOR on a periodic basis. H. The CONTRACTOR shall expedite the repair or correction of any deficiency discovered during testing. The CONTRACTOR shall have personnel representing each trade to standby during the test period to immediately correct, repair, or adjust any item of hardware, software or field equipment causing a test to fail. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-32 DTN18104 – Lake Lewisville WTP Improvements Phase II I. The system shall operate continuously for 100 hours without failure before this test will be considered successful. 3.09 30-DAY ACCEPTANCE TEST A. All database errors must be corrected prior to the start of the 30-Day Acceptance Test. The 30-Day Acceptance Test will not be considered successful until all databases are correct. B. Any malfunction during the test shall be analyzed and corrections made by the CONTRACTOR. The OWNER’S REPRESENTATIVE and OWNER will determine whether any such malfunctions are sufficiently serious to warrant a repeat of the test. The cost of a retest shall be borne by the CONTRACTOR as specified. C. After completion of the Functional Demonstration Test and Plant Start-up, the CONTRACTOR shall be responsible for operation of the entire System for a period of 30 consecutive days, under conditions of full plant process operation, without single non-field repairable malfunction. D. During this test, CONTRACTOR personnel shall be present as required. The CONTRACTOR shall provide personnel for this test who have an intimate knowledge of the hardware and software of the system and also are familiar with the overall plant process. The Supplier shall be on call for the 30-Day Acceptance Test. During the test period the supplier shall be available and on the job site within 48 hours of any failure. E. While this test is proceeding, the OWNER shall have full use of the system. Only plant operating personnel shall be allowed to operate equipment associated with live plant processes. F. Any malfunction, during this 30 consecutive day test period, which cannot be corrected within 24 hours of occurrence by the CONTRACTOR's personnel, or more than two similar failures of any duration, will be considered as a non-field-repairable malfunction. G. Upon completion of repairs, by the Supplier, the test shall be repeated as specified herein. H. In the event of rejection of any part or function, the Supplier shall perform repairs within 5 days or replacement within 30 days. I. Upon successful completion of the 30-Day Acceptance Test, approval of all as-built drawing and O&M Manuals, completion of all related OWNER training, and delivery of all spare, expendable, and test equipment, the systems shall be considered substantially complete and the warranty period shall commence. 3.10 TRAINING A. Provide an integrated training program for the Owner's personnel at the jobsite. The Contractor shall submit a detailed training schedule and syllabus for approval. Tailor the training program to meet the specific needs of the Owner's personnel. Include training sessions, classroom and field, for managers, engineers, operators, and maintenance personnel. Supervisory Control And Data Acquisition (SCADA) System 40 90 02-33 DTN18104 – Lake Lewisville WTP Improvements Phase II B. System Integrator shall submit the proposed training agenda to the Owner/Engineer for review a minimum of 30 days prior to the training taking place. C. The training shall be carried out by technically competent and experienced instructors. D. An "instructor week" shall consist of 40 hours of actual instruction time. An "instructor day" shall consist of 8 hours of actual instruction time. Provide instruction on as needed to accommodate the Owner's personnel schedule. The actual training schedule shall be coordinated with the Owner. Training shall be a minimum of one day. E. The Contract shall hire a professional firm regularly engaged in video tape and/or film productions to video tape of all of the factory and on-site training sessions. The video tape and all rights there to shall become the property of the Owner. The Owner may re-use or distribute the video tape at their discretion. 3.11 OPERATIONS AND MAINTENANCE TRAINING A. O&M training for each subsystem shall be in accordance with the requirements specified under the related Instrumentation specification sections. B. All training shall be given using only equipment identical to the equipment provided on this Contract or currently owned by the Owner. C. Unless otherwise specified, hardware maintenance training shall be suitable for instrument technicians who have at least a 2-year associate engineering or technical degree, or equivalent education and experience in electronics, instrumentation, or digital systems. 3.12 ON-SITE SUPERVISION A. The Supplier shall provide, on-site, an experienced resident engineering manager to supervise and coordinate all of the on-site activities. This resident engineering manager shall be on-site as required during the total period to affect all the activities relating to the PICS. 3.13 START-UP AND TESTING TEAM A. The Supplier shall provide, on-site, a team of experienced engineering, technician, trades personnel, and software/configuring personnel during the total construction period to: 1. Thoroughly check the installation, termination, and adjustment of all the subsystems and their components. 2. Perform and complete all on-site tests. 3. Provide start-up assistance. END OF SECTION Bridge Crane Rehabilitation 41 22 13.13 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 41 22 13.13 BRIDGE CRANE REHABILITATION 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to evaluate and rehabilitate bridge crane and hoist assemblies at the Lake Lewisville Raw Water Pump Station and at the Lake Lewisville Water Treatment Plant High Service Pump Station. Confirm structural and mechanical soundness of the bridge and travel mechanism for the rated capacity, as well as the existing support rails. Replace the trolley hoist with new equipment matching the rated capacity of the existing unit. 1.02 QUALITY ASSURANCE A. Acceptable Manufacturers, subject to limitations indicated in this Section and the Drawings: 1. Ace Industries, Inc. 2. Konecranes, Inc. 3. OMi Crane Systems Inc. 4. ProservCrane Group. 5. Or approved equal. B. Design Criteria: 1. Crane design, including stress limitations, factors of safety, bearing life and contactor rating, shall be in accordance with the latest editions of CMAA 70 and 74 specifications as applicable. a. Duty Classification: Class C (moderate service). 1). Trolley and Hoist: H3. b. Service Environment: Interior 2. Equipment shall be in accordance with all safety features required by OSHA standards. 3. Components of each bridge crane shall be designed for not less than the rated capacity indicated on drawings and specified herein. C. Factory Test: New equipment shall be subjected to no-load running tests before shipment. D. Manufacturer’s Representative for Startup and Testing: The services of the Manufacturer’s technical representative shall be provided for pre-startup installation checks, startup assistance, training of Owner’s operating personnel, troubleshooting and other services as required in Section 01 75 00 “Starting and Adjusting.” Bridge Crane Rehabilitation 41 22 13.13 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Product Data: Data sheets for miscellaneous equipment. Data sheets shall clearly indicate the model number being provided. Including disconnect, fuses, cable, pushbutton station, etc. 2. Existing bridge crane evaluation report for each location, prepared and sealed by a licensed professional engineer. Report shall assess the following: a. Structural integrity and capacity for rated load. b. Material condition. c. Mechanical integrity and capacity for rated load. d. Compatibility with proposed trolley hoist unit. e. Electrical protective devices required to comply with current NEC requirements. 3. Shop Drawings, including: a. Trolley hoist cut sheets. b. Project specific electrical equipment wiring diagrams. 4. Operation and Maintenance Manuals (O&M): a. Shall be prepared by the bridge crane manufacturer and shall contain the final certified shop drawings, product data submittals, list of manufacturer recommended spare parts, schematics, and maintenance procedures. b. All field changes made during startup and testing shall be included. c. Shall include warranty information, including: 1). Warranty start and end date. 2). Contact information for service. 5. May be manufacturer’s standard instructions, but shall be supplemented as necessary to cover any special feature not included on standard models. 1.04 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: AGMA American Gear Manufacturer’s Association ANSI / ASME B30.11 Monorails and Underhung Cranes ANSI / ASME B30.16 Overhead Hoists (Underhung) ANSI / ASME B30.17 Cranes and Monorails (With Underhung Trolley or Bridge) ANSI / ASME B30.2 Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist) ASTM American Society of Testing and Materials Bridge Crane Rehabilitation 41 22 13.13 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements AWS American Welding Society CMAA 70 Crane Manufacturers Association of America, Inc. – Specifications for Top Running Bridge & Gantry Type Multiple Girder Electric Overhead Traveling Cranes CMAA 74 Crane Manufacturers Association of America, Inc. – Specifications for Top Running Bridge & Under Running Single Girder Electric Traveling Cranes Utilizing Under Running Trolley Hoist NEC National Electrical Code NEMA National Electrical Manufacturers Association OSHA Part 1910.179 Occupational Safety and Health Administration - Overhead and Gantry Cranes OSHA Part 1926.554 Occupational Safety and Health Administration - Overhead Hoists 2.00 PRODUCTS 2.01 GENERAL A. All components shall be designed and constructed to meet or exceed specified duty class. B. Wheels shall be hardened. 320 Brinell or better. C. Tapered or flat tread design as required by the construction documents or referenced specifications. D. Bearings shall be combined radial and thrust type, double-row, spherical ball bearings, anti- friction type, either pre-lubricated and sealed, or fitted for pressure lubrication. E. Pressure lubrication fittings shall be located in accessible locations for ease of maintenance. 1. Bearing assemblies shall ensure correct wheel alignment. F. Heat treated alloy steel axles or pinions shall be supported on each side of the supporting frame. When rotating axles are used, wheels shall be mounted on axles with a press fit and keys, or with keys alone. G. Gears shall be made from rolled or cast steel, with machine cut teeth. Truck reductions within reach of personnel are to be guarded. H. Provide electrically operated shoe or disc brakes. I. The crane manufacturer shall furnish and assemble all electrical equipment and items on the bridge crane in accordance with applicable requirements of the latest edition of the National Electrical Code (NEC), Article 610. 2.02 BRIDGE GIRDER A. Construction shall either be of rolled structural shapes, full reinforced, or fabricated box type sections with diaphragms as required to maintain girder stiffness. B. The girders shall be either unnotched or notched at each end to meet design requirements. Bridge Crane Rehabilitation 41 22 13.13 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements C. End trucks shall be of welded construction and shall provide: 1. Centrally locate wheels in each truck to distribute equal loading to each truck side. 2. Energy absorbing rubber bumpers at each end to operate against runway stops. 3. Rail sweeps in front of bridge wheels. 4. Brakes shall have a 75 percent torque rating and be adjustable. 2.03 TROLLEY A. Frame shall be of welded construction. B. Brakes shall have a 50 percent torque rating and be adjustable. 2.04 HOIST A. Hoists shall be electric, wire rope type, as specified herein. B. The hoisting machinery shall consist of a rope drum, driven through suitable gear reductions by an electric motor operator, load blocks, hooks, hoisting rope, sheaves, and hoist braking. C. Hoist gearing shall be enclosed in an oil tight gear case. Bearings and gears shall be splash lubricated and bearings selected to provide a L-10 life or greater. D. Gear case shall be provided with a bolt-on cover for full access to bearings and gears. E. The hoist drum shall be cast or welded steel, grooved to take the full length of each cable in one layer. 1. At least two wraps of rope shall remain on the drum when the bottom block is in the lowest position. F. Hooks shall have: 1. Sufficient ductility to open noticeably before hook failure as a result of overload. 2. Equip hooks with safety latch. G. Load hook shall be free to rotate 360 degrees with rated load, and shall be positively held in place with locknuts, collars, or other suitable devices. H. Hoist brake shall be capable of holding the load when power to the hoist motor is off. 2.05 ELECTRICAL EQUIPMENT A. The Crane Manufacturer shall furnish and install on the bridge crane: 1. All electrical equipment, including but not limited to, motors, motor starters, pendant control, and conduits, in accordance with Article 610 of NEC, latest issue. B. All wiring, as much as practical for shipment, in accordance with Section 26 05 00 “Common Work Results for Electrical.” 1. Bridge conductors may be removed for shipment. C. Refer to scheduled electrical power requirements in table below and power supply from a non-fused disconnect switch. If larger ampacity is provided as an alternate, then provide, at no cost to the Owner, all required electrical system modifications servicing the bridge crane. Bridge Crane Rehabilitation 41 22 13.13 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements This includes disconnects, feeders to the equipment, feeders from the switchboard, circuit breaker at switch board, etc. 1. All modifications required shall be tracked for incorporation into Record Drawings. D. Motors shall be squirrel-cage type and shall be built in accordance with NEMA Standards, Design D. E. Bridge conductors shall be of the enclosed bus bar or festooned cable type as indicated herein, and trolley conductors shall be of festooned cable type, as hereinafter specified. F. Festooned flat, multi-conductor cables shall be, supported by lubricated bearing systems that will dispense and retrieve the flexible conductor cable during trolley travel without twisting, tangling, or causing sharp bends. Provide 20 percent spare conductors in each cable assembly. G. Controls shall be fully magnetic of the plain reversing type: 1. Housed in NEMA Type 12enclosure. 2. Logically arranged and neat wiring, secured at each end. 3. Fully marked terminal strips at the bottom of each panel for all external wiring connections. 4. Provide a block operated, upper limit switch. 5. Supply 120 volts AC to the controls. H. Pushbuttons for control of the entire bridge crane and an ON/OFF switch. 1. Festooned and suspended from a track running the full length of the bridge permitting operation from any point along the span independent of trolley location. I. Pendant control having momentary contact pushbuttons, and shall be provided with a device which will disconnect motors from the line on failure of power and will not permit any motor to be restarted until the controller handle is brought to the OFF position, or a reset switch or button is operated. 2.06 CRANE INTERCONNECTION WIRING A. Bridge crane shall be wired in accordance with NEC, Article 610, latest issue. Wiring shall be enclosed in galvanized steel conduit or steel raceway. B. On cranes which must be disassembled for shipment, conduit runs shall be furnished and made up, wires cut to proper length and tagged. Junction boxes shall be provided at all places where electrical reconnections must be made in the field. 2.07 ACCESSORIES A. Equipment Identification Plates: Stainless steel identification plates shall be securely mounted on the equipment in a readily-visible location. The plate shall bear the 1/4-inch die-stamped equipment identification number indicated in the specification and/or shown on the drawings. The equipment identification number shall be mounted on each of the separate components of the equipment to facilitate assembly in the field. B. Equipment weighing over 100 pounds shall be equipped with lifting lugs. Bridge Crane Rehabilitation 41 22 13.13 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 3.00 EXECUTION 3.01 PREPARATION A. Existing bridge crane shall be prepared and coated in accordance with this specification. B. Prepare steel substrates to not less than SSPC-SP3. C. Three-Coat Epoxy System: Manufacturer’s standard epoxy system with an inorganic zinc rich primer. Minimum 8 mil total DFT. D. Finish coat of Manufacturer’s standard colors. 3.02 INSTALLATION A. Carefully handle and install the bridge crane in strict accordance with the Manufacturer’s recommendations and as indicated on the plans. B. The crane shall be provided with the necessary lubrication fittings and lubrication. Before initial startup at final installation, lubricate bearings, gears, etc., in accordance with the Manufacturer’s recommendations. 3.03 FIELD QUALITY CONTROL A. Conduct field tests with the equipment in its installed position. Tests shall include a load test in compliance with OSHA requirements and demonstration to the Owner’s Representative that under this load condition, the equipment shall perform satisfactorily throughout the complete range of operation. The unit shall be checked for excessive noise, vibration, alignment, speeds, and general operation. The unit must perform in a manner acceptable to the Owner’s Representative before final acceptance will be made by the Owner. END OF SECTION Centrifugal Magnetic Drive Sealless End Suction Pumps 43 21 13.16 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 43 21 13.16 CENTRIFUGAL MAGNETIC DRIVE SEALESS END SUCTION PUMPS 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, services, equipment and incidentals required to furnish and install centrifugal magnetic drive sealless end suction pumps, complete and operational, with motors and accessories as shown and specified. This Section includes, but is not limited to the following: a. Carrier water pumps. b. Pump appurtenances. c. Anchor bolts. B. Coordination: 1. Review installation procedures under this and other Sections and coordinate the installation of items that must be installed with, or before the centrifugal magnetic drive sealless end suction pumps Work. 1.02 REFERENCES A. Standards referenced in this Section are listed below: 1. American Bearing Manufacturers Association (ABMA). 2. American Gear Manufacturer's Association (AGMA). 3. American National Standards Institute, (ANSI). 4. American Society for Testing and Materials, (ASTM). a. ANSI B73.1, Horizontal End Suction Centrifugal Pumps for Chemicals. 5. American Water Works Association (AWWA). 6. Institute of Electrical and Electronics Engineers, (IEEE). 7. National Electrical Code, (NEC). 8. National Electrical Manufacturers' Association, (NEMA). 9. National Sanitary Foundation (NSF). 1.03 QUALITY ASSURANCE A. Manufacturer’s Qualifications: 1. Manufacturer shall have a minimum of five years of experience of producing substantially similar equipment, and shall be able to show evidence of at least five installations in satisfactory operation for at least five years. Centrifugal Magnetic Drive Sealless End Suction Pumps 43 21 13.16 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2. Pumps and appurtenances shall be supplied by a single pump manufacturer who shall be responsible for proper applications, engineering, testing and operation and start-up of the equipment as specified herein B. Component Supply and Compatibility: 1. Obtain all equipment included in this Section regardless of the component manufacturer from a single centrifugal magnetic drive sealless end suction pumps manufacturer. 2. The centrifugal magnetic drive sealless end suction pumps equipment manufacturer to review and approve or to prepare all Shop Drawings and other submittals for all components furnished under this Section. 3. All components shall be specifically constructed for the specified service conditions and shall be integrated into the overall assembly by the centrifugal magnetic drive sealless end suction pumps equipment manufacturer. 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Product Data: a. Manufacturer's literature, illustrations, specifications and engineering data including: dimensions, materials, size, weight, performance data and curves showing overall pump efficiencies, required net positive suction head, allowable suction lift, flow rate, head, brake horsepower, motor horsepow¬er, speed and shut off head. b. Motor tests and data as described in Part 2. 2. Shop Drawings: a. Fabrication, assembly, installation and wiring diagrams. B. Informational Submittals: Submit the following: 1. Source Quality Control: a. Certified pump tests. C. Closeout Submittals: Submit the following: 1. Operation and Maintenance Data: a. Submit complete installa¬tion, operation and maintenance manuals including test reports, maintenance data and schedules, description of operation and spare parts information. b. Furnish Operation and Maintenance Manuals in conformance with the requirements of Section 01 78 23, Operations and Maintenance Data. 2.00 PRODUCTS 2.01 SERVICE CONDITIONS A. General: Centrifugal Magnetic Drive Sealless End Suction Pumps 43 21 13.16 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1. All wetted surfaces of the pumps and appurtenances and all sealing gaskets shall be suitable for continuous exposure to the chemical service and concentration shown on the Centrifugal Magnetic Drive Sealless End Suction Pumps Schedule, below. 2. All wetted surfaces shall be of materials suitable for contact with chemicals in service and shall not leach out any organic or inorganic constituent which is not permitted by local or federal regulations. B. Pumps shall be of close coupled, end suction, top discharge, back pullout design, centrifugal magnetic drive sealless design with separate motor. Pumps shall be specially designed, constructed and installed for the service intended and shall comply with the conditions as shown on the following schedule: CENTRIFUGAL MAGNETIC DRIVE SEALLESS END SUCTION PUMPS SCHEDULE Chemical Service Chemical Concentration: 0.7% Specific Gravity, (68°F): 1.0 Liquid Temperature Range, (°F): 40 – 85 Quantity of Pumps: 2 (1 duty, 1 standby) Pump Designation: Carrier Water Pumps Location: Chemical Building (LLWTP RWPS) Design Flow, (gpm): 80 Design Discharge Head, (feet): * 245 Shutoff Head, (feet): * 250 Pump Speed, (RPM, maximum): 3550 Efficiency at Design, (%): 32.5 Motor, (Hp): 20 Motor, (Volts/Phase/Hertz) 240/3/60 *Ft. of Chemical in service. 2.02 MANUFACTURERS A. Products and Manufacturers: Provide one of the following: 1. ANSI MAG, Inc., Model K1518 2. Ingersoll – Dresser 3. Or equal Centrifugal Magnetic Drive Sealless End Suction Pumps 43 21 13.16 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2.03 DETAILS OF CONSTRUCTION A. Dimension Interchangeableness: 1. Sealless magnetically driven pumps shall conform to all dimension standards of ANSI B73.1. The sealless pumps shall be dimensionally interchangeable with the standard sealed ANSI pump of the same size designation. B. Pump Materials of Construction: 1. The outer bearing system for frame-mounted pumps shall consist of two interchangeable ball bearings, oil lubricated by a constant level oilier. The outer bearing housing shall be sealed from the elements by spring loaded lip seals on both the outboard and inboard ends to keep oil spray out of the magnet drive area of the pumps. The outer bearing housing shall be capable of oil mist lubrication, as required. The bearings shall have a minimum B-10 life of 100,000 hours. 2. The outer bearing housing for frame-mounted pumps shall be constructed of ductile iron material free from blowholes and leaks. The outer shaft shall be one piece and the outer magnet carrier shall be attached by threading against rotation into the outer shaft or keyed. 3. The magnetic drive system shall consist of an outer and inner permanent magnet drive system, separated by a containment shell and air and liquid gaps. Magnets shall be rare earth and made of Neodymium Iron Boron and shall be designed for zero slippage for full range of operation. 4. Outer Magnet Carrier: The outer magnet carrier shall be made of carbon steel and shall be spin balanced after the magnets are installed. The magnet shall be attached to the outer magnet carrier by high temperature epoxy for pump temperatures anticipated. Magnets shall be covered by a stainless steel cup and not exposed to the atmosphere. 5. Magnets: The magnets shall be of suitable materials for operating fluid temperatures less than 250°F, and shall be entirely suitable for the load at any point on the pump operating curve when pumping the chemical indicated on the Magnetic Drive Sealless End Suction Pump Schedule. a. The containment shell shall be furnished in a non-metallic material selected for the service. Containment shell shall be made to have a maximum operating pressure of 150 psi and a design pressure of 225 psi. Containment shell shall be designed to eliminate any energy loss in the magnet coupling. Rear casing shall be rated to a minimum 900-psi burst pressure. b. The liquid gap between the containment shell and the inner magnet encapsulation shall be no less than 0.045-inch on a side or 0.090-inch diametral clearance. c. The containment shell shall be attached to the rear casing cover with socket head stainless steel cap screws. Provide O-ring seal between the containment shell and the casing cover that is compatible with the pumped fluid. Welding of the containment shell to the casing cover is unacceptable. 6. Inner Bearings: a. The inner bearing system shall be product lubricated as standard. The lubrication path shall minimize pressure drop and shall always remain under a pressure greater Centrifugal Magnetic Drive Sealless End Suction Pumps 43 21 13.16 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements than suction pressure to prevent flashing in the bearing system under low NPSHA operating conditions. 7. Impeller: a. Type: The impeller shall be of enclosed design. b. Construction: Shaft shall be non-rotating and supported on both ends to prevent overhung loads. Material shall be suitable for the service and no smaller than 1-1/4- inch in diameter. A groove, minimum 1/16-inch along length of shaft, shall be provided for passage of occasional solids. c. Materials: The impeller material for shall be suitable for the service and shall be non-metallic. d. A silicon carbon fiber reinforced mouth ring shall be provided with the impeller. The mouth ring shall be removable and replaceable. 8. Casing: a. Construction: Pump casing shall be furnished with 150-pound ANSI flanges. Casing material and lining shall be suitable for the service intended. b. Assembly: The casing shall provide for back pullout maintainability without disconnecting the suction or discharge flanges. c. Casing shall be provided with a drain. d. Provide a removable silicon carbide thrust ring and press fit into the casing. 9. Bedplate: a. Fiberglass reinforced vinylester composite or Type 316 stainless steel bedplate shall be provided. Bedplate shall be provided with molded-in stainless steel hardware complete with devices to prevent those devices from spinning when the bolting is tightened. Provide Type 316 stainless steel anchor bolts and hardware. C. Motors: 1. Motors shall conform to requirements of Section 40 05 93, Common Motor Requirements for Process. 2. Provide a standard NEMA frame, TEFC, severe duty, horizontal, electric motor. Motors shall have a minimum service factor of 1.15. Motor shall be sized to be non-overloading at any point on the pump-operating curve when pumping the chemical indicated in the Magnetic Drive Sealless End Suction Pumps Schedule. 2.04 TOOLS, SPARE PARTS AND MAINTENANCE MATERIALS A. Each pump shall be furnished with the following spare parts. 1. Recommended spare parts kit. 2. One set of special tools required for maintenance and operations. 3. One quart of touch-up paint. Centrifugal Magnetic Drive Sealless End Suction Pumps 43 21 13.16 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements B. 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 completion of the project. C. SURFACE PREPARATION AND SHOP PAINTING D. Pumps, motors, drives, frames, baseplates, appurtenances, etc., shall receive shop primer and finish coating conforming to the requirements of Section 09 91 00, Painting. If any damage to the paint system occurs, the equipment shall be repainted as directed by the ENGINEER. E. Surface preparation and painting shall conform to the requirements of Section 09 91 00, Painting. F. All gears, bearing surfaces, machined surfaces and other surfaces which are to remain unpainted shall receive a heavy application of grease or other rust-resistant coating. This coating shall be maintained during storage and until the equipment is placed into operation. G. CONTRACTOR shall certify, in writing, that the shop primer and finish paint system conforms to the requirements of Section 09 91 00, Painting. 2.05 SOURCE QUALITY CONTROL A. Shop Tests: 1. Each pump casing shall be hydrostatically tested to twice the discharge head or 1-1/2 times the shutoff head, whichever is greater. 2. Running Test: Each pump assembly shall be operated from zero to maximum capacity as shown on the approved pump curve. Results of the test shall be shown in a plot of test curves showing head, flow, horsepower, efficiency, current and NPSH. Readings shall be taken at a minimum of five evenly spaced capacity points including shut-off, design point and minimum head for which pump is designed to operate. 3. Each test shall be witnessed by a Registered Professional Engineer who may be an employee of the manufacturer. The Registered Professional Engineer shall sign and seal all copies of curves and shall certify that hydrostatic tests were performed. Tests shall be conducted in conformance with the Standards of the Hydraulics Institute. 4. Pumps shall not be shipped until the ENGINEER has approved the test reports. 3.00 EXECUTION 3.01 INSPECTION A. Inspect all equipment immediately upon delivery to Site. All surfaces shall be smooth, free of voids and porosity, without dry spots, crazes or unreinforced areas. Any damaged equipment shall be replaced. 3.02 INSTALLATION A. Installation shall be in complete accordance with manufacturer's instructions and recommendations and the approved Shop Drawings. Centrifugal Magnetic Drive Sealless End Suction Pumps 43 21 13.16 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements B. Pump shall be installed on concrete base, secured with anchor bolts, and grouted with non- shrink grout conforming to Section 03 60 00, Grouting. C. Installation shall include furnishing and applying an initial supply of grease and oil, recommended by the manufacturer. D. Support piping independent of pump. E. Check and align all pump motors and shafting. 3.03 START-UP AND TEST A. CONTRACTOR shall verify that structures, pipes and equipment are compatible. B. Make adjustments required to place system in proper operating condition. C. Initial testing shall be performed using potable water to ensure the system operates as specified, prior to testing with dilute (0.7%) sodium permanganate, according to the requirements of Section 01 75 00, Starting and Adjusting. 3.04 MANUFACTURER’S SERVICES A. A factory trained representative shall be provided for installation supervision, start-up and test services and operation and maintenance personnel training services. The representative shall make a minimum of 2 visits, minimum 4 hours on-Site for each visit, to the Site. The first visit shall be for assistance in the installation of equipment. Subsequent visits shall be for checking the completed installation, start-up and training of the system. Manufacturer's representative shall test operate the system in the presence of the ENGINEER and verify that the equipment conforms to the requirements. Representative shall revisit the Site as often as necessary until all trouble is corrected and the installation is entirely satisfactory. B. All costs, including travel, lodging, meals and incidentals, for additional visits shall be at no additional cost to the OWNER. END OF SECTION Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 46 33 44 SKID-MOUNTED PERISTALTIC METERING PUMPS 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment, and incidentals required to furnish and install skid-mounted peristaltic metering pumps, complete and operational with pumps, motors, control equipment and appurtenances as shown and indicated in the Contract Documents. B. Coordination: 1. Review installation procedures under this and other Sections and coordinate installation of items that must be installed with or before peristaltic metering pumps and appurtenances Work. 1.02 REFERENCES A. Standards referenced in this Section are: 1. American Bearing Manufacturers Association, (ABMA). 2. American Gear Manufacturers' Association (AGMA). 3. American National Standards Institute (ANSI). 4. API 675, Positive Displacement Pumps Controlled Volume. 5. American Society for Testing and Materials (ASTM). 6. Institute of Electrical and Electronics Engineers (IEEE). 7. National Electrical Code (NEC). 8. National Sanitation Foundation (NSF). 1.03 QUALITY ASSURANCE A. Qualifications: 1. Manufacturer: Shall have minimum of five years’ experience producing substantially similar equipment to that required and shall be able to document of at least five installations in satisfactory operation for at least five years. The pump skid integrator, if other than the manufacturer, shall have at least five years’ experience installing similar pump skids and shall be able to provide references for at least ten installations of a similar size, that are in satisfactory operation for at least five years. B. Component Supply and Compatibility: 1. Obtain all materials and equipment included in this Section regardless of component manufacturer, from a single peristaltic metering pump Supplier. 2. Peristaltic metering pumps and appurtenances equipment manufacturer shall review and approve or prepare all Shop Drawings and other submittals for components Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements furnished under this Section. 3. Materials and equipment shall be fully compatible with specified service conditions, and shall be integrated into overall assembly by peristaltic metering pumps and appurtenances equipment Supplier. The equipment manufacturer has the option to hire a third-party installer of the pump skid, but the manufacturer shall be responsible for the completeness and functionality of the pump skid. 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Shop Drawings: a. Complete layout and installation drawings for each pump skid and shall include the type and size of pump, dimensions, mounting details, dimensions, piping, fittings, metering pump appurtenances, instruments, control panels, and materials of construction. b. Wiring diagrams. c. Drawings of control panels in accordance with Section 40 61 13, Process Control System General Provisions. 2. Product Data: a. Complete product data for each size and type of pump, motor, pump accessories, and instruments. Data shall include manufacturer’s brochure, specifications, weight, performance data, turndown, and capacity. 3. Testing Plans: a. Source quality control testing plan. b. Field quality control testing plan. B. Informational Submittals: Submit the following: 1. Certificates: a. Paint certification. 2. Manufacturer’s Instructions: a. Setting drawings, templates, and directions for installing anchor bolts and other anchorage devices. b. Instructions for handling, storing, and installing equipment. 3. Source Quality Control Submittals: a. Results of source quality control tests and inspections. b. Assembled chemical feed skids shall be pressure and leak tested at the point of assembly before shipping to the site. Submit a report of the leak tests. 4. Site Quality Control Submittals: a. Results of field quality control tests. Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements b. Manufacturer’s Reports: Submit a written report of results of each visit to Site by Supplier’s service technician, including purpose and time of visit, tasks performed, and results obtained. c. Manufacturer’s certificate of proper installation 5. Qualifications Statements: a. When requested by ENGINEER, submit qualifications data for manufacturer. C. Closeout Submittals: 1. Operation and Maintenance Data: Furnish Operation and Maintenance Manuals in conformance with the requirements of Section 01 78 23, Operations and Maintenance Data. 2. Spare Parts, Extra Stock Materials, and Tools: a. Furnish the following for each type and size of pump furnished: 1). One spare pump head assembly. 2). For each chemical application, one 50-inch roll of tubing. 3). One quart of touch-up paint. 4). Two complete sets of special tools required for normal maintenance and operation. 1.05 WARRANTY A. General Warranty: The special warranty specified in this Article shall not deprive OWNER of other rights or remedies OWNER may otherwise have under the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by CONTRACTOR under the Contract Documents. Obligations of CONTRACTOR under the Contracts Documents shall not be limited in any way by provisions of the specified special warranty. B. Special Warranty: Provide manufacturer’s written warranty, running to the benefit of OWNER, agreeing to correct, or at option of OWNER, remove or replace materials and equipment specified in this Section found to be defective during the warranty period. All warranties shall start after the date of Substantial Completion of the Work under this Section. Warranty periods of the pump skid components shall be as follows: 1. Peristaltic Metering Pumps: 5 years 2. All other pump appurtenances listed under this Section: 2 years 2.00 PRODUCTS 2.01 EQUIPMENT PERFORMANCE A. System Description: 1. Provide skid-mounted peristaltic metering pumps, complete with pump head, flexible extruded tube, and integral variable speed drive. 2. Provide all components of the metering pump skid compatible with specified service conditions. Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements B. Metering Pump Performance Criteria: Service Conditions Location Chemical Building – LLWTP RWPS Chemical Building – RRWTP RWPS Number Required 2 2 Equipment Tag Nos. SPP-1, SPP-2 SPP-1, SPP-2 Service (Chemical and % Solution) 20 – 40% Sodium Permanganate 20 – 40% Sodium Permanganate Specific Gravity of Pumped Fluid at 60 degrees F 1.16 – 1.32 1.16 – 1.32 Temperature Range of Pumped Fluid (degrees F) 30 – 110 30 – 110 Minimum Flow Rate (gallons per hour) 2.5 1.0 Maximum Flow Rate (gallons per hour) 30.0 9.0 Max Discharge Pressure (psi) 60 60 Net Positive Suction Head Available at Max Flow Rate (psia) 10 10 Pump Speed Range (rpm) 0.004 - 125 0.004 - 125 Input Voltage 115 VAC, 60 Hz, 1 Phase 115 VAC, 60 Hz, 1 Phase Pump Type Tubing Tubing Speed Control Integral to Pump Integral to Pump Model for the 1st named manufacturer (Refer to Section 2.2 for alternatives) Watson Marlow QDOS 120 Watson Marlow QDOS 120 2.02 MANUFACTURERS A. Products and Manufacturers: Provide peristaltic metering pumps by one of the following. No substitutions or “equals” will be allowed. 1. Watson-Marlow 2. Blue White 2.03 DETAILS OF CONSTRUCTION A. Pump Head: 1. Pump head shall consist of fixed track with hinged or removable guard door or front cover, adjustable tube retainer mechanism, and roller rotor assembly. 2. Tubing shall be replaceable with no disassembly of pump head and without using tools. Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 3. Capable of delivering continuous discharge pressure specified in table in Article 2.1 of this Section. 4. Capable of accepting different-diameter tubing. 5. Rotor shall be capable of rotating in either direction without damaging pump or tubing. 6. Capable of self-priming with suction lift capability of 30 feet of water. 7. Able to run dry without damaging pump or tubing. 8. Pump shall not require use of check valves or dynamic seals in contact with pumped fluid. 9. Speed Adjustment: a. Two modes: manual scale with zero to 100 percent scale indication, and automatic via remote 4-20 mA DC flow proportional signal. b. Adjustment shall be possible while pump is operating. c. Infinitely-variable to meet or exceed minimum-to-maximum flow range specified in table in Article 2.1. 10. Pump drive shall be completely contained within integral enclosure, complete with brackets, supports, fasteners, and appurtenances suitable for mounting as shown or indicated in the Drawings. Enclosure finish shall provide long-term protection from environmental conditions. Unpainted enclosures are not acceptable. Each pump shall have stainless steel nameplate with manufacturer name, model, serial number, rating, range, speed, and other pertinent data. B. Tubing: 1. During normal operation, tubing’s inner wall shall be the only surface in contact with pumped fluid. 2. Tubing shall be extruded from material compatible with the pumped fluid at the pressures shown in the Design Conditions in Section 2.1. C. Drive: 1. Drive motor shall be variable speed, brushless DC with integral gearbox. 2. Circuitry shall be microprocessor-controlled with pulse width modulation, and with temperature- and load-compensation and protection. 3. Drive Speed: Infinitely variable to meet or exceed associated pump speed range specified in table in Article 2.1. 4. Enclosure: NEMA 4X 5. Housing: Pressure cast aluminum with Alocrom pre-treatment and exterior grade corrosion resistant polyester powder coat. By nature of the environmental conditions, unpainted housings, including 316SS, are not acceptable. 6. Rating: Continuous 24-hour per day operation, 40 degrees C ambient temperature. 7. Power Supply: 110/120-volt, single phase, 50/60 Hertz, field switchable and fused. Supply ten-foot length main power cord with NEMA 5/15 (USA) standard three prong Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements plug. 8. Controls shall have manual override. Provide interface for the following signals: a. Analog Input: 4-20 mA DC (250 ohms) speed reference signal b. Analog Output: 4-20 mA DC (250 ohms) pump speed signal. c. Digital Input (dry contact closure): start/stop signals. d. Digital Output (dry contact closure, rated five amps at 120 volts AC): In Remote status, Running status, and Fail (general alarm) status signals. 9. Minimum requirements for operator interface functionality: a. Backlit graphical liquid crystal display (LCD) capable of up to four lines of text with 16 characters per line to display pump speed, running status, flow rate, and programming instructions. b. Keypad for start, stop, speed increment, speed decrement, forward/reverse direction, rapid prime, and programming. c. Menu-driven, on-screen programming of manual (local) or auto (remote) control, flow, and remote signal calibration, and general programming. d. Programmable “Keypad Lock” to allow operator lockout of all keys except emergency start/stop. e. Programmable “Maximum Speed” to allow operator to set maximum speed of pump. D. Termination Enclosure: 1. Provide a NEMA 4X wall mounted termination enclosure for each pump system for connection of pump control cable to field wiring provided under Division 26. Connections shall be made via terminal blocks mounted in the enclosure. Refer to Section 26 05 33.33 for requirements. 2.04 METERING PUMP SKIDS A. The metering pumps, associated piping, valves, instruments, and appurtenances, shall be mounted to a wall-mounted metering pump skid. B. The internal piping of the skid shall be sized to have a maximum flow velocity of 0.15 ft/sec through it. C. General 1. Overall skid dimensions shall not exceed the maximum dimensions shown on the Drawings. 2. Placement of commonly accessed or maintained pump accessories (valves, instruments, electrical, etc.) are not to exceed 6.5 feet in height above the finished floor. 3. Provide easy access for any normal replacement parts on skid, including ability to switch out replacement parts without disconnecting hard piping. 4. End partitions shall extend at least 6 inches behind the edge of pump shelving. Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements D. Details of Construction: 1. The materials of construction for the metering pump skids shall be as follows: a. Skid Frame: The frame shall be of all welded construction, with 1-1/2 inch Type 316 stainless steel square tubing, with at a minimum, 1/16 inch wall thickness. All welds shall be ground flush with the frame. b. Skid Mounting Board: 1/2 inch thick HDPE panels. The maximum piece size shall be 4-ft x 8-ft. c. Skid Pump Shelf: 1-1/2 inch Type 316 stainless steel square tubing, with 1/16 inch wall thickness and 1/2 inch thick HDPE panels. The shelf shall be of all welded construction. All welds shall be ground flush with the frame. d. Skid Hardware: Type 316 stainless steel e. Pipe Clamps: Non-metallic clamps that accommodate pipe thermal expansion and contraction. Pipe clamps with threaded closure systems will not be accepted. 2. The piping within the metering pump skid shall comply with Section 40 05 23.23, Stainless Steel Process Pipe for Liquid Service and Section 40 05 05, Exposed Piping Installation. 3. The valves within the metering pump skid shall comply with Section 40 05 53, Process Valves. 2.05 APPURTENANCES A. Calibration Columns: 1. Construction: Transparent, clear tube. Calibration columns must have an inlet port (bottom) and outlet port (top) that can be connected to piping via threaded or solvent welded joints. 2. Calibration columns shall be calibrated in milliliters. 3. Provide ball-type isolation valve at pump inlet port. 4. Size calibration columns to provide at least 30 seconds of storage at maximum rated pump flow. B. Pulsation Dampeners: 1. Provide pulsation dampener on discharge piping of each peristaltic tube metering pump as shown or indicated on the Drawings, and as specified in this Section. Provide pulsation dampeners on suction piping when shown on the Drawings. 2. Pulsation dampeners shall be air-charged, diaphragm type, complete with valved air charge connection and pressure gauge graduated for zero to 100 psi. 3. Size pulsation dampeners to allow no more than five percent discharge pressure fluctuation. Pulsation dampener bladder and lower housing shall be fabricated of materials recommended by manufacturer and suitable for the chemical being pumped. 4. Provide each pulsation dampener with four, extra-long bolts at 90 degrees to one another for mounting to dampener support brackets. Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 8 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements C. Pressure Relief Valves: 1. Size relief valves for each specific application. 2. Valves shall be field-adjustable without removing from piping, and shall initially be set ten psi higher than design discharge pressure of the associated pumps. 3. Pressure relief valve material shall be compatible with pumped fluid and piping system material. Valve size shall be as shown on the Drawings. D. Backpressure Valves: 1. Backpressure valves pressure setting shall be field adjustable, without removing valve from piping, between zero and 30 psi. Initial setting shall be 10 psi for each installation unless otherwise recommended by Supplier. 2. Backpressure valve material shall be compatible with pumped fluid and piping system material. Valve size shall be as shown on the Drawings. E. Field Instruments – the manufacturer shall provide all the field instruments shown on the Instrumentation drawings. These instruments shall comply with Section 40 70 05, Primary Sensors and Field Instruments, and shall include, but are not limited to the following: 1. Pressure Gauge 2. High Pressure Switch 3. Low Pressure Switch F. Sight Glasses: 1. Provide sight glass with streamers on each pump discharge line. Sight Glass shall be the same size as the pumps discharge piping. Connection reducers are not acceptable. 2. Materials of Construction shall be compatible with the chemical being pumped. 3. Manufacturers: Provide sight glass by Plast-O-Matic (Series GX). G. Equipment Identification Plates: An identification plate shall be securely mounted on the equipment in a readily visible location. The identification plates shall comply with Section 10 14 00, Signage of the Contract Documents. 2.06 FINISHING A. Shop Painting: 1. Surface preparation and painting shall conform to Section 09 91 00, Painting. 2. Apply in the shop primer coating to metallic parts (excluding surfaces exempted) of pumps, motors, drives, frames, supports, and appurtenances. 3. Do not paint corrosion-resistant parts such as plastic, fiberglass, and stainless steel. 4. Gears, bearing surfaces, machined surfaces, and other surfaces that are to remain unpainted shall receive heavy application of grease or other rust-resistant coating. Maintain coating during storage and until equipment is placed into operation. B. Field Painting: 1. Conform to Section 09 91 00, Painting. Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 9 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2. CONTRACTOR shall certify in writing that shop primer and finish coating systems are compatible with each other and conform to Section 09 91 00, Painting. 2.07 SOURCE QUALITY CONTROL A. Peristaltic Metering Pumps: Test each pump in the shop as follows: 1. Calibration test. 2. Inspect all components prior to and during shop testing. 3. Capacity/head tests, including pump’s rated design point, at shutoff, and at maximum flow. B. Controls: Test controls in the shop as follows: 1. Verify operation in all operating modes. 2. Inspect control components and panels for defects. 3. Perform manufacturer’s standard quality tests. C. Valves: Test valves and appurtenances in the shop as follows: 1. Inspect components for defects. 2. Perform manufacturer’s standard quality tests. 3.00 EXECUTION 3.01 INSPECTION A. Examine conditions under which products are to be installed and notify ENGINEER in writing of conditions detrimental to proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions have been corrected. 3.02 INSTALLATION A. Install materials and equipment in conformance with Laws and Regulations, applicable standards, manufacturer’s instructions and recommendations, and the Contract Documents. B. General: 1. Perform drilling and fitting required for installation. Set equipment accurately in location, alignment, and elevation, plumb, true, and free of rack. 2. Making plate cutouts or openings at the Site is not allowed. 3. Fit exposed connections accurately together to form tight hairline joints. 4. Provide utility connections in accordance with the Contract Documents. 5. Align and adjust equipment including motors, belts, drives, support stands, and appurtenances in presence of ENGINEER. 6. Prior to energizing electric motor drive equipment, rotate drive motor by an external source to demonstrate free operation of all mechanical parts. Do not energize equipment until safety devices are installed, connected, and functional. Skid-Mounted Peristaltic Metering Pumps 46 33 44 - 10 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 7. Install valves in accordance with applicable provisions. 3.03 FIELD QUALITY CONTROL A. Site Tests: 1. Following installation, CONTRACTOR and qualified field service representative of Supplier shall conduct operating tests of all equipment, functions, and controls at the Site in presence of ENGINEER. 2. Comply with Section 01 75 00, Starting and Adjusting. 3. Field Operating Test: a. Field test equipment and its controls in local mode, followed by demonstrating proper operation and controls in automatic mode. Demonstrate that each part individually and all parts together function properly in manner intended. Total duration of testing shall be 12 hours, continuous and uninterrupted, in automatic mode. All testing equipment and labor shall be by CONTRACTOR. b. Should tests result in malfunction, make necessary repairs, revisions, and adjustments and restart test from the beginning. Repeat tests and repairs, revisions, and adjustments until, in opinion of ENGINEER, installation is complete and equipment is functioning properly and accurately, and is ready for permanent operation. B. Manufacturer’s Services: Provide a qualified, factory trained serviceman to perform the following: 1. Instruct CONTRACTOR in installing equipment. 2. Supervise installation of materials and equipment. 3. Inspect, calibrate, adjust, and test equipment after installation and ensure proper operation. 4. Instruct OWNER’s personnel in operating and maintaining the equipment. 5. Manufacturer’s representative shall make a minimum of three (3) visits, with minimum of eight (8) hours at the Site for each visit. First visit shall be for instructing CONTRACTOR and supervising installation of equipment; second visit shall be for checking, adjusting, and calibrating completed installation and starting up the system; third visit shall be to instruct operations and maintenance personnel. Representative shall revisit the Site as often as necessary until installation is acceptable. 6. Training: Furnish services of Supplier’s qualified factory trained specialists to instruct OWNER’s operations and maintenance personnel in recommended operation and maintenance of materials and equipment. Training requirements, duration of instruction, and qualifications shall be in accordance with Section 01 79 23, Instruction of Operations and Maintenance Personnel. 7. All costs, including expenses for travel, lodging, meals and incidentals, and cost of travel time, for visits to the Site shall be included in the Contract Price. END OF SECTION Copper Ion Solution Generator 46 35 11 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 46 35 11 COPPER ION SOLUTION GENERATOR 1.00 GENERAL 1.01 DESCRIPTION A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment, and incidentals required to furnish and install copper ion solution generator, complete and operational with equipment and appurtenances as shown and indicated in the Contract Documents. B. Coordination: 1. Review installation procedures under this and other Sections and coordinate installation of items that must be installed with or before the copper ion solution generator. 1.02 REFERENCES A. Standards referenced in this Section are: 1. American National Standards Institute (ANSI). 2. American Society for Testing and Materials (ASTM). 3. Institute of Electrical and Electronics Engineers (IEEE). 4. National Electrical Code (NEC). 5. National Sanitation Foundation (NSF). 1.03 QUALITY ASSURANCE A. Qualifications: 1. Manufacturer: Shall have minimum of five years’ experience producing substantially similar equipment to that required and shall be able to document of at least five installations in satisfactory operation for at least five years. B. Component Supply and Compatibility: 1. Obtain all materials and equipment included in this Section regardless of component manufacturer, from a single Supplier. 2. Copper ion solution generator manufacturer shall review and approve or prepare all Shop Drawings and other submittals for components furnished under this Section. 3. Materials and equipment shall be fully compatible with specified service conditions, and shall be integrated into overall assembly by the copper ion solution generator Supplier. 1.04 SUBMITTALS A. Action Submittals: Submit the following: 1. Shop Drawings: a. Copper ion solution generator manufacturer shall submit detailed drawings showing layout along with technical data to indicate materials of construction and note any Copper Ion Solution Generator 46 35 11 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements exceptions as part of the manufacturer’s proposal per requirements in the Contract Documents. b. Control and wiring diagrams. c. Drawings of control panels. 2. Product Data: a. Complete product data for each size and type of equipment, accessories, and instruments. Data shall include manufacturer’s brochure, specifications, weight, performance data, turndown, and capacity. 3. Testing Plans: a. Source quality control testing plan. b. Field quality control testing plan. B. Informational Submittals: Submit the following: 1. Certificates: a. Paint certification. 2. Manufacturer’s Instructions: a. Setting drawings, templates, and directions for installing anchor bolts and other anchorage devices. b. Instructions for handling, storing, and installing equipment. 3. Source Quality Control Submittals: a. Results of source quality control tests and inspections. b. Assembled copper ion solution generators shall be pressure and leak tested at the point of assembly before shipping to the site. Submit a report of the leak tests. 4. Site Quality Control Submittals: a. Results of field quality control tests. b. Manufacturer’s Reports: Submit a written report of results of each visit to Site by Supplier’s service technician, including purpose and time of visit, tasks performed, and results obtained. c. Manufacturer’s certificate of proper installation 5. Qualifications Statements: a. When requested by ENGINEER, submit qualifications data for manufacturer. C. Closeout Submittals: 1. Operation and Maintenance Data: Furnish Operation and Maintenance Manuals in conformance with the requirements of Section 01 78 23, Operations and Maintenance Data. 2. List of spare Parts, extra stock materials, and tools Copper Ion Solution Generator 46 35 11 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 1.05 WARRANTY A. General Warranty: The special warranty specified in this Article shall not deprive OWNER of other rights or remedies OWNER may otherwise have under the Contract Documents and shall be in addition to, and run concurrent with, other warranties made by CONTRACTOR under the Contract Documents. Obligations of CONTRACTOR under the Contracts Documents shall not be limited in any way by provisions of the specified special warranty. B. Special Warranty: The copper ion solution generator shall be warrantied against all defects in equipment, instruments, and controls for a period of two (2) years from the date of Substantial Completion. 2.00 PRODUCTS 2.01 EQUIPMENT PERFORMANCE A. System Description: 1. Provide skid-mounted copper ion solution generators, complete with all components required. 2. Provide all components of the copper ion solution generators with specified service conditions. B. Copper Ion Solution Generator Performance Criteria: Service Conditions Location Chemical Building – LLWTP RWPS Chemical Building – RRWTP RWPS Number Required 1 1 Equipment Tag Nos. CIG-1 CIG-1 Raw Water Flow Rate (MGD) 5 – 30 5 – 20 Target copper ion concentration in raw water (mg/L) 0.005 – 0.010 0.005 – 0.010 Number of Ionization Chambers 4 4 Max System Pressure Rating (psi) 120 120 Max Headloss through system (psi) 5 5 Input Voltage 240 VAC, 60 Hz, 3 Phase 240 VAC, 60 Hz, 3 Phase 2.02 MANUFACTURERS A. Products and Manufacturers: Provide copper ion solution generators by one of the following. No substitutions or “equals” will be allowed. 1. ONG Consulting, LLC. Model Fortress MC40 Copper Ion Solution Generator 46 35 11 - 4 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 2. MacroTech, Inc. 2.03 DETAILS OF CONSTRUCTION A. General Requirements: 1. No materials containing lead shall be used. 2. Copper anodes shall be of high purity 99.99% ETP Copper. Manufacturer shall submit certified mill test reports to confirm composition and acceptability of the anodes. B. Ionization Chambers: 1. Shall be made of passivated, Type 316 stainless steel with electrically insulated interior surface and powder-coated exterior surface. 2. Each ionization chamber shall have access on both ends using grooved coupling connection, thereby providing access to ionization chamber without the need for overhead-clearance or lifting hoists. C. Skid / Frame – Shall be made of powder coated Type 304 SS. D. Piping, Fittings, and Accessories: 1. Copper ion solution generator connecting inlet and outlet piping shall be passivated Type 316 stainless steel. 2. Pipe fittings shall be flanged and light-weight grooved, rigid couplings. 3. Grooved coupling gasket materials shall be C-style EDPM. 4. Full face gaskets for #150 ANSI flange gasket material shall be Neoprene material. 5. CIG-01/02 shall have a high contrast 316 stainless steel pressure indicator gauge at the inlet piping. 6. Equipment supports, anchors, and accessories shall be of stainless steel construction. E. Valves: 1. Inlet and Outlet Isolation Valves: ¼ turn 2-inch stainless steel ball valve. 2. Drain Valve/Plug: ¼ turn ½-inch stainless steel ball valve or plugs. F. Flowmeter: 1. Provide Type 316L stainless steel non-contacting, non-fouling, magnetic flow meter resistant to fouling and erosion wear due to suspended solids and organic material in raw water. 2. Wetted parts of the flow meter shall be made of Type 316L stainless steel and Viton materials only. 2.04 SYSTEM CONTROL PANEL: A. CIG-01/02 shall be provided with a control panel. All electrical components including transformers shall be housed within the control panel. The control panel enclosure shall be made of carbon steel -powder coated ANSI 61gray inside and outside. CIG-01/02 control panel shall be designed for use with 240 VAC, 60 Hz, 40A. All controls and operations of Copper Ion Solution Generator 46 35 11 - 5 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements CIG-01/02 shall be carried out automatically by a programmable logic controller (PLC). Control panels utilizing relay logic control and relying on operator to manually adjust settings and parameters will not be allowed. B. The front of CIG-01/02 control panel shall have clearly labeled components and indicator lights for easy operator access and identification. The control panel shall have only 1. One (1) front panel mounted ON/OFF switch, ¼ turn 2. One (1) front-panel mounted Power ON LED indicator light that turns Green when the controller is energized. 3. One (1) front-panel mounted Fault/Alarm LED Indicator light that turns Red when a fault or alarm condition is detected and turns OFF only if no fault/alarm condition is detected. 4. Control panels cluttered with numerous selector switches, push-buttons and adjustment knobs will not be permitted. C. CIG-01/02 Control panel shall have an integrated, password-protected, operator screen for Touch-Screen displaying real-time generator operational status including the following: 1. Identifying fault / no fault / alarm conditions. 2. Raw water flow treated. 3. Flow through CIG unit (Carrier Water Flow). 4. Current and voltage to Each ionization chamber. 5. Control panels using similar looking analog voltage and amp meter which can easily mistakenly read will not be permitted. D. CIG-01/02 control panel shall have a redundant power module design. Copper ion generators using the same power module for powering multiple ionization chamber and all other functionalities will not be allowed. E. The operational status of each power module and Each ionization chamber shall be prominently displayed on the operator display screen. F. Safety, EMC and Isolation Resistance; CIG manufacturer shall submit Safety, EMC and Isolation Resistance certification for ionization chamber power modules/power supply with a minimum of Input to Output, Input to Ground, Output to Ground: 100 Mega Ohms/500VDC. G. All electrical connections between the ionization chambers and the control panel shall use heavy duty industrial-grade finger-safe connectors rated at least IP67 and free from water and moisture intrusion. Ionization chambers using threaded studs, bolts, nuts and terminal ring crimp wire connectors will not be allowed. H. Required Input / Output Signals: 1. Input: a. Pump station flow: 4-20mA - BY OWNER b. Ready Signal: Dry Contact Switch – BY OWNER 2. Output to OWNER’s SCADA: TBD Copper Ion Solution Generator 46 35 11 - 6 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements a. TBD b. Alarm/Fault Outputs: 1). General Alarm Output Dry Contact Alarm 2). Loss of Control Signal Dry Contact Alarm- Optional 3). Loss of Carrier Supply Water Dry Contact Alarm- Optional 2.05 FINISHING A. Shop Painting: 1. Surface preparation and painting shall conform to Section 09 91 00, Painting. 2. Apply in the shop primer coating to metallic parts (excluding surfaces exempted) of the copper ion solution generator. 3. Do not paint corrosion-resistant parts such as plastic, fiberglass, and stainless steel. 4. Bearing surfaces, machined surfaces, and other surfaces that are to remain unpainted shall receive heavy application of grease or other rust-resistant coating. Maintain coating during storage and until equipment is placed into operation. B. Field Painting: 1. Conform to Section 09 91 00, Painting. 2. CONTRACTOR shall certify in writing that shop primer and finish coating systems are compatible with each other and conform to Section 09 91 00, Painting. 3.00 EXECUTION 3.01 INSPECTION A. Examine conditions under which products are to be installed and notify ENGINEER in writing of conditions detrimental to proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions have been corrected. 3.02 INSTALLATION A. Install materials and equipment in conformance with Laws and Regulations, applicable standards, manufacturer’s instructions and recommendations, and the Contract Documents. B. General: 1. Perform drilling and fitting required for installation. Set equipment accurately in location, alignment, and elevation, plumb, true, and free of rack. 2. Making plate cutouts or openings at the Site is not allowed. 3. Fit exposed connections accurately together to form tight hairline joints. 4. Provide utility connections in accordance with the Contract Documents. 5. Align and adjust equipment including motors, belts, drives, support stands, and appurtenances in presence of ENGINEER. Copper Ion Solution Generator 46 35 11 - 7 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 6. Prior to energizing electric motor drive equipment, rotate drive motor by an external source to demonstrate free operation of all mechanical parts. Do not energize equipment until safety devices are installed, connected, and functional. 7. Install valves in accordance with applicable sections. C. Conform to Section 01 75 00, Starting and Adjusting. 3.03 FIELD QUALITY CONTROL A. Installation Certification: 1. Upon completion of installation, the manufacturer shall inspect the installation and certify, in writing, the installation is complete and satisfactory. B. Testing: 1. Upon certification of the installation, the equipment shall be field tested to verify the system meets performance requirements. 2. All testing shall be by the Manufacturer with periodic observation by the ENGINEER and OWNER. 3. The OWNER shall provide copper testing kit and reagent for sampling and testing: a. Hach DR 900 Multi-parameter Handheld Meter with reagents for low and medium copper test or equivalent b. Manufacturer shall provide test equipment, tools, and instruments necessary to accomplish equipment testing. Test equipment shall include but not be limited to: 1). Fluke 323 True RMS Clamp Meter or equivalent. 2). Two (2) 4-inch OD rubber end caps for ionization chamber cleaning. C. Manufacturer's Field Services: 1. Manufacturer’s representative(s) shall; a. Inspect and certify installation b. Conduct start-up of equipment, perform operational checks, conduct operator training, conduct field functional testing, and respond to issues. 2. Provide OWNER with a written statement that manufacturer's equipment has been installed properly, has been started up, and is ready for operation by OWNER's personnel. 3. Start-up and Testing Plan: a. Manufacturer shall submit a start-up and testing plan for review / approval by the OWNER and ENGINEER at least 30 calendar days prior to delivery of the CIG-01/02 System. b. Start-up and testing plan shall include proposed schedule for each day of start-up and testing activities, clearly outlining manufacturer activities. c. Plan shall outline start-up checks and equipment functionality checks. 4. Site Technical Training: The manufacturer shall provide operator training at the site for a Copper Ion Solution Generator 46 35 11 - 8 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements period no less than 2 days (16 hours). Training shall include operation, maintenance and troubleshooting for each component of CIG-01/02 System. a. Training Plan: Manufacturer shall submit a training plan at least 30 days prior to training date. The training plan shall provide a proposed outline for training activities including classroom and hands-on activities. Training schedule shall accommodate OWNER’s operations staff shifts. 5. OWNER shall coordinate with the manufacturer to schedule services, and assist manufacturer’s field service representative as necessary in the performance of these services. 6. Manufacturer shall provide all services required under the equipment warranty at no additional cost to the OWNER. END OF SECTION Liquid Polymer Feed System 46 36 11.16 - 1 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 46 36 11.16 LIQUID POLYMER FEED SYSTEM 1.00 GENERAL 1.01 WORK INCLUDED A. Furnish labor, materials, equipment, and incidentals necessary to install three polymer feeders as specified herein. The polymer feeder shall have a standard manufacturer’s nameplate securely affixed in a conspicuous place, showing the ratings, serial model number, manufacturer, and other pertinent nameplate data. B. The polymer feeder shall be furnished complete with the parts and appurtenances required to make the system operable. The polymer feeder shall inject polymer into the raw water as an aid to coagulation performance. 1.02 QUALITY ASSURANCE A. Acceptable Manufacturers: 1. UGSI Chemical Feed, Inc. 2. Approved equal. B. Manufacturer’s Representative for Startup and Testing: The services of the Manufacturer’s technical representative shall be provided for pre-startup installation checks, startup assistance, training of Owner’s operating personnel, troubleshooting and other services as required in Section 01 75 00 “Starting and Adjusting.” 1.03 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Shop Drawings. 2. Operation and Maintenance Manuals. 3. Installation List: The Equipment Manufacturer shall submit a list of 10 similar installations which have been in satisfactory operation for at least 1 year. Shop drawings not including this required information shall not be accepted. 2.00 PRODUCTS 2.01 POLYMER FEED SYSTEM A. Polymer feeder shall be a PolyBlend Model M1200-D10AA as manufactured by UGSI Chemical Feed, Inc. or approved equal. B. Concentrated polymer and water shall be blended in two sequential zones: a high-shear zone with a mixing impeller and a low shear zone without impeller. Solution shall pass through a tapered intensity zone with a baffle to separate the high and low shear zones. The mixing chamber shall be constructed with a clear acrylic barrel, PVC impeller and stainless steel mixer shaft. Liquid Polymer Feed System 46 36 11.16 - 2 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements C. System shall include a diaphragm type polymer transfer pump, capable of pumping solution type polymers with apparent viscosities of 75,000 cps at a range of 0.1-10 gph, neat polymer. At no time shall polymer be exposed to rotating centrifugal pump impeller or other cause of excessive shear. The system shall include a calibration column with isolation ball valves, mounted to the frame. D. Dilution water shall be divided into two streams: a primary water flow to the mixing chamber, and a secondary flow for post-dilution. A static mixer shall be provided to blend the primary solution from the mixing chamber with the post-dilution water. System shall have a solenoid valve for on-off control of dilution water supply and each stream shall be equipped with a rotameter-type flow indicator equipped with integral rate-adjusting valve. Water flow rate for each stream shall be adjustable from 60-600 gph. Water flow input fitting shall be 1-inch FNPT. Mixed solution output fitting shall be 1-1/2-inch FNPT. E. System electrical requirement shall be 120 VAC, 15 amps. System shall include a motor thermal overload protection device capable of being manually reset. F. System shall include the component parts mounted within a floor space of approximately 40 inches wide by 30 inches deep. 2.02 CONTROLS A. Unit shall be controlled through an on-off-remote circuit controlled by a three-position switch. 1. In the remote switch position, the unit shall accept a run signal. 2. Unit is manually controlled in the on position. B. Unit shall accept a 4-20 mA analog signal to pace the polymer metering pump. 1. This signal shall be processed by a pump controller that may be mounted remotely. 2. The controller shall have an LCD readout of capable of displaying strokes per minute, strokes per hour, gallons per minute, gallons per hour, liters per minute, or liters per hour. 3. The controller shall have touchpad control for pump stroke frequency and a mode touchpad (internal-off-external) for pacing signal selection. C. Unit shall detect loss of water flow, sensing that water flow has been interrupted for any reason, will place the polymer pump and mix chamber on standby and will restart it automatically when flow is restored. D. An integral timer shall monitor loss of flow and energize contacts indicating alarm after 15 seconds of continuous loss. 2.03 SPARE PARTS KIT A. Provide one Spare Parts Kit, including mechanical seal, mixing chamber o-rings, injection check valve, pump liquid end rebuild kit. Liquid Polymer Feed System 46 36 11.16 - 3 DTN18104 – Lake Lewisville Water Treatment Plant Phase II Improvements 3.00 EXECUTION 3.01 INSTALLATION A. Install the equipment in strict accordance with the Manufacturer’s recommendations. 3.02 FIELD QUALITY CONTROL A. Upon completion of installation of the equipment, an acceptance test to verify the satisfactory operation of each unit shall be conducted. The test shall be conducted in a manner approved by and in the presence of the Engineer. The unit shall be checked for excessive noise, vibration, alignment, general operation, etc. The unit must perform in a manner acceptable to the Engineer before final acceptance will be made by the Owner. END OF SECTION