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IFB 7096 LLWTP_Specifications Volume 2 rev 6.17.19 100% DESIGN SPECIFICATIONS – BID SET PROJECT MANUAL VOLUME 2 (DIVISIONS 22 – 46) FOR THE CONSTRUCTION OF Lake Lewisville Water Treatment Plant Dewatering Improvements Denton Purchase Order No. 186564 Ordinance 18-1234 Garver Project No. 18088080 Chris Watts Todd Hileman Mayor City Manager Todd Estes, P.E. Director of Capital Projects Timothy Fisher, PE Director of Water Utilities Mamun Yusuf, PE Water Utilities Senior Engineer Prepared for The City of Denton 2019 by Garver CERTIFICATIONS Project No. 18088080 1 Section 00 00 01 Lake Lewisville WTP Dewatering Improvements Certifications LAKE LEWISVILLE WATER TREATMENTPLANT DEWATERING IMPROVEMENTS GARVER PROJECT NO. 18088080 CITY OF DENTON PO NO. 186564 ORDINANCE NO. 18-1234 I hereby certify that the applicable portions of this project plans and specifications were prepared by me or under my direct supervision and that I am a duly Licensed Engineer under the laws of the State of TX. SEAL AND SIGNATURE APPLICABLE DIVISION OR PROJECT RESPONSIBILITY Robert W. Warden, P.E. Digitally Signed: 05/20/2019 Division 01 Division 22 Division 23 Division 40 Division 41 Division 43 Division 44 Division 46 Kipp Martin, P.E. Digitally Signed: 05/20/2019 Division 02 Division 03 Division 04 Division 05 Division 07 Division 08 Division 09 Division 10 KIPP A. MARTIN 113605 CERTIFICATIONS Project No. 18088080 2 Section 00 00 01 Lake Lewisville WTP Dewatering Improvements Certifications SEAL AND SIGNATURE APPLICABLE DIVISION OR PROJECT RESPONSIBILITY Jonathan White, P.E. Digitally Signed: 05/20/2019 Division 26 Chris Gatling, P.E. Digitally Signed: 05/20/2019 Division 31 Division 32 Division 33 GARVER, LLC CERTIFICATE OF AUTHORIZATION: TX ENGINEERING FIRM REGISTRATION NO. F-5713 Expiration Date: 1/31/2020 Adopted September 2018 City of Denton Standard Construction Specification Documents 00 00 00 - 1 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 1 of 7 CITY OF DENTON Denton PO No. 186564 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Garver Project No. 18088080 LEWISVILLE LAKE WTP DEWATERING IMPROVEMENTS SECTION 00 00 00 TABLE OF CONTENTS Division 00 - General Conditions 00 05 10 Construction Contract Ordinance 00 05 15 Addenda 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 42 43 Proposal Form Unit Price 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 45 43 Corporate Resolution of Authorizing Signatories 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 00 72 00 General Conditions 00 73 00 Supplementary Conditions 00 73 73 Form 1295 – Certificate of Interested Parties Division 01 - General Requirements 01 11 00 Summary of Work 01 11 60 Project Manual Language 01 14 00 Work Restrictions 01 26 00 Contract Modification Procedures 01 29 00 Payment Procedures 01 31 00 Project Management and Coordination 01 31 19 Project Meetings 01 32 00 Construction Progress Documentation 01 32 90 Safety Plan 01 33 00 Submittal Procedures 01 34 00 Photographic and Videographic Documentation 01 35 00 Special Procedures 01 35 20 Alteration Project Procedures 01 41 00 Regulatory Requirements 01 42 00 References 01 42 40 Abbreviations 01 45 00 Quality Control 01 45 24 Special Tests and Inspections 01 50 00 Temporary Facilities and Controls 01 60 00 Product Requirements 01 72 20 Field Engineering 01 73 20 Cutting and Patching 01 73 40 Work Within Public Right-of-Way 00 00 00 - 2 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 2 of 7 CITY OF DENTON Denton PO No. 186564 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Garver Project No. 18088080 LEWISVILLE LAKE WTP DEWATERING IMPROVEMENTS 01 73 80 Selective Demolition 01 75 60 Testing, Training, and Facility Start-Up 01 77 00 Closeout Procedures 01 78 23 Operation and Maintenance Data 01 79 00 Demonstration and Training 01 79 00.1 Manufacturers Certificate of Proper Installation 01 79 00.2 Unit Process Startup Form 01 79 00.3 Facility Performance Demonstration Certification Form 01 79 01 Spare Parts and Maintenance 01 80 00 Post Final Inspection 01 80 01 Commissioning 01 81 00 Project Design Criteria 01 81 02 Seismic Design Criteria 01 81 04 Wind Design Criteria Division 02 – Existing Conditions 02 41 00 Demolition Division 03 – Concrete 03 01 00 Concrete Surface Repair 03 11 00 Concrete Formwork 03 15 00 Concrete Accessories 03 15 14 Strip-Type Waterstops 03 20 00 Concrete Reinforcement 03 30 00 Cast-In-Place Concrete 03 41 00 Precast Concrete 03 60 00 Grout 03 60 00.1 Grout Supplement 03 60 01 Basin Bottom Grout 03 64 00 Concrete Repair Crack Injection Division 04 – Masonry 04 05 17 Mortar and Masonry Grout 04 05 23 Masonry Accessories 04 22 00 Unit Masonry Assemblies 04 22 16 Anchored CMU Veneer Division 05 – Metals 05 12 00 Structural Steel 05 31 00 Steel Deck 05 40 00 Cold-Formed Metal Framing 05 50 00 Metal Fabrications 05 51 00 Metal Stairs 05 52 13 Pipe and Tube Railings 05 53 00 Metal Gratings and Plank Division 07 – Thermal and Moisture Protection 07 19 00 Water Repellent Coating 07 21 00 Building Insulation 07 41 13 Metal Roof and Wall Panels 00 00 00 - 3 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 3 of 7 CITY OF DENTON Denton PO No. 186564 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Garver Project No. 18088080 LEWISVILLE LAKE WTP DEWATERING IMPROVEMENTS 07 50 00 Roofing, Insulation, Damp Proofing 07 71 00 Manufactured Roof Specialties 07 72 00 Roof Accessories 07 92 00 Joint Sealants Division 08 – Openings 08 16 13 FRP Doors and Frames 08 33 23 Overhead Coiling Doors 08 71 00 Door Hardware 08 80 00 Glazing 08 90 00 Louvers and Vents Division 09 – Finishes 09 29 00 Gypsum Drywall and Metal Support Systems 09 90 00 Painting and Protective Coatings 09 90 00.1 Painting & Protective Coatings 09 91 23 Interior Painting Division 10 – Specialties 10 42 50 Sign Letters 10 43 00 Interior Signage 10 43 60 Exterior Post and Panel Signs 10 44 16 Fire Extinguishers Division 22 – Plumbing 22 05 00 Plumbing General 22 05 29 Process Supports and Anchors 22 05 53 Mechanical Identification 22 11 16 Plumbing Piping 22 13 16 Sanitary Waste & Vent Piping 22 45 17 Emergency Eye-Face Wash and Shower Equipment Division 23 – HVAC 23 05 00 Mechanical General 23 05 17 Common Work Results for Mechanical 23 05 29 Hangers and Supports for Mechanical Piping and Equipment 23 05 53 Identification for HVAC Piping & Equipment 23 05 93 Testing, Adjusting, and Balancing 23 07 00 Duct Insulation 23 07 13 Mechanical Insulation 23 09 13 HVAC Controls 23 31 13 Metal Ducts 23 33 00 Air Duct Accessories 23 34 23 Fans 23 37 13 Air Outlets and Inlets 23 74 13 Packaged Rooftop Air Conditioning Units 23 83 01 Heating Units 00 00 00 - 4 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 4 of 7 CITY OF DENTON Denton PO No. 186564 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Garver Project No. 18088080 LEWISVILLE LAKE WTP DEWATERING IMPROVEMENTS Division 26 – Electrical 26 05 00 Common Work Results for Electrical 26 05 13 Medium-Voltage Cables 26 05 14 Wiring Devices 26 05 15 Electric Motors 26 05 19 Low Voltage Elec Power Conductors and Cables 26 05 26 Grounding and Bonding for Elec Systems 26 05 29 Hangers and Supports for Elec Systems 26 05 33 Raceway and Boxes for Elec Systems 26 05 43 Underground Ducts and Raceways for Elec Systems 26 05 48 Vibration and Seismic Controls for Electrical Systems 26 05 53 Identification for Electrical Systems 26 05 70 Power System Study 26 09 43 Fiber Optic Network 26 12 19 Medium Voltage Transformers 26 22 00 Low Voltage Transformers 26 24 16 Panelboards 26 28 13 Fuses 26 28 16 Enclosed Switches and Circuit Breakers 26 29 13 Enclosed Controllers 26 29 23 Variable Frequency Motor Controllers 26 41 13 Lightning Protection for Structures 26 51 00 Interior Lighting 26 56 00 Exterior Lighting 26 67 05 Communication Cable and Equip 26 70 00 Video Surveillance 26 80 00 Access Control 26 90 00 General Instrumentation and Control 26 90 10 Process and Analytical Instruments 26 90 20 PLC Control Panels 26 90 35 PLC and HMI Programming 26 90 40 Process Control Descriptions (to be included in 90% deliverable) Division 31 – Earthwork 31 05 19 Geotextile Filter Fabric 31 11 00 Site Preparation 31 22 13 Subgrade Preparation 31 22 19 Grading 31 23 16 Excavation 31 23 16.13 Trenching for Site Utilities 31 23 19 Dewatering 31 23 23.13 Fill and Backfill 31 23 23.16 Trench Backfill 31 23 23.33 Flowable Fill 31 32 00 Soil Erosion Stabilization 31 37 00 RIP RAP 31 50 00 Excavation Support Systems 31 63 30 Drilled Concrete Piers 00 00 00 - 5 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 5 of 7 CITY OF DENTON Denton PO No. 186564 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Garver Project No. 18088080 LEWISVILLE LAKE WTP DEWATERING IMPROVEMENTS Division 32 – Exterior Improvements 32 10 00 Concrete Sidewalks 32 11 00 Base Course, TX 32 13 13 Portland Cement Concrete Paving 32 31 13 Chain Link Fence and Gates 32 92 19 Seeding, Fertilizing and Mulching Division 33 – Utilities 33 01 20 Wastewater Liquid and Solids Removal 33 11 16.13 Domestic Water Piping Specialties 33 13 00 Disinfection of Water Systems 33 31 23 Testing Sanitary Sewer Systems 33 39 13 Concrete Manholes 33 40 00 Storm Drainage Piping 33 41 19 Pipe Laying Division 40 – Process Integration 40 05 00 Piping Systems Testing 40 23 39 Process Piping - General 40 23 39.1 Process Piping Schedule 40 23 39.13 DS CM Lined DIP and Fittings 40 23 39.40 DS C900 & C905 PVC Pipe and Fittings 40 23 39.42 Polyvinyl Chloride (PVC) Pipe and Fittings (DWV) 40 23 39.43 DS Polyvinyl Chloride (PVC) Pipe and Fittings 40 23 39.46 DS Chlorinated Polyvinyl (CPVC) Pipe & Fittings 40 23 39.53 DS Copper Pipe, Tubing and Fittings 40 23 43 Process Valves 40 23 43.1 Power Operated Valve Schedule 40 24 00 Process Piping Specialties 40 50 41.01 Rubber Hose 40 91 23.33 Magnetic Flow Meter 40 92 13 Motorized Operators 40 92 16 Valve and Gate Operators Division 41 – Material Processing and Handling Equipment 41 12 13 Dumpster-Veyor Patented Container Handling System Division 43 – Process Gas and Liquid Handling, Purification and Storage Equipment 43 21 43 Washwater Equalization Sump Pump Division 44 – Pollution Control Equipment 44 42 56.23 Vertical Turbine Pumps 44 42 56.23.1 DS Vertical Turbine Pump (Low Lift Pumps) Data Sheet 44 42 56.29 Wet-Pit Submersible Pumps 44 42 56.29.1 DS Wet-Pit Submersible Pumps Data Sheet 44 42 56.53 Progressive Cavity Pumps 44 42 56.53.1 DS Thickened Residuals Transfer Pumps Data Sheet 44 44 63 Liquid Polymer Feed System 44 46 26.13 Gravity Thickener Mechanisms 44 46 26.13.1 DS Gravity Thickener Mechanisms Data Sheet 00 00 00 - 6 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Page 6 of 7 CITY OF DENTON Denton PO No. 186564 STANDARD CONSTRUCTION SPECIFICATION DOCUMENTS Garver Project No. 18088080 LEWISVILLE LAKE WTP DEWATERING IMPROVEMENTS Division 46 – Water and Wastewater Equipment 46 07 53 Plant Booster Pump Station 46 21 75 Shaftless Screw Conveyors 46 21 75.1-DS Shaftless Screw Conveyors from BFPs Data Sheet 46 21 75.2 DS Shaftless Screw Conveyors Inclined Data Sheet 46 21 75.3 DS Shaftless Screw Conveyors to Bins Data Sheet 46 76 21 Belt Filter Press System Appendix GC-4.02 Subsurface and Physical Conditions END OF SECTION DIVISION 22 PLUMBING Project No. 18088080 1 Section 22 05 00 Lake Lewisville WTP Dewatering Improvements Plumbing General SECTION 22 05 00 - PLUMBING GENERAL PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Basic requirements of plumbing methods. B. Related section: 1. The Contract Documents are complementary; what is called for by one is as binding as if called for by all. 2. It is the CONTRACTOR’s responsibility for scheduling and coordinating the Work of sub- contractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work. 3. The following Sections are related to the Work described in this Section. This list of Re- lated Sections is provided for convenience only and is not intended to excuse or other- wise diminish the duty of the CONTRACTOR to see that the completed Work complies accurately with the Contract Documents. a. Division 26 Electrical Specifications. 1.2 REFERENCES A. Definitions: 1. Concealed: Materials or systems not visible. Work installed above a ceiling, furred behind a wall or enclosed in a chase. 2. Exposed: Materials or systems that is visible. Work installed in a room without a ceiling. Work not enclosed by walls. 3. Provide: Furnish, install and make complete. 4. Install: Receive, unload, move into place, and make connections. 5. Work: Materials completely installed and connected. 6. ADC: Air Diffusion Council. 7. AGA: American Gas Association. 8. AMCA: Air Movement and Control Association. 9. ANSI: American National Standard Institute. 10. API: American Petroleum Institute. 11. ARI: American Refrigeration Institute. 12. ASHRAE: American Society of Heating, Refrigerating and Air Conditioning Engineers. 13. ASME: American Society of Mechanical Engineers. 14. ASTM: American Society of Testing Materials. 15. AWS: American Welding Society. 16. FM: Association of Factory Mutual Fire Insurance Company. 17. International: Building Code, Gas Code, Mechanical Code, Plumbing Code. 18. MSS: Manufacturer's Standard Society of the Valve and Fittings Industry, Inc. 19. NEC: National Electrical Code. 20. NEMA: National Electrical Manufacturer's Association. 21. NFPA: National Fire Protection Association. 22. NRCA: National Roofing Contractors Association. 23. NSF: National Sanitation Foundation. 24. OSHA: Occupational Safety and Health Act. 25. PDI: Plumbing Drainage Institute. 26. PFMA: Power Fan Manufactures Association. 27. SMACNA: Sheet Metal and Air Conditioning Contractors National Association. 28. UL: Underwriters Laboratories. Project No. 18088080 2 Section 22 05 00 Lake Lewisville WTP Dewatering Improvements Plumbing General 1.3 DESCRIPTION OF WORK A. Provide equipment, labor, material, etc., required to make a complete working installation as shown or as specified. B. Equipment and materials used in the work shall be: 1. In accordance with the contract documents. 2. The best quality and grade for the use intended. 3. New and unused. 4. The manufacturer's latest standard or current model. C. All equipment and method shall be installed and connected in accordance with the best engineering practices and in accordance with the manufacturer's recommendations. D. Mechanical work includes, but is not limited to: 1. Make arrangements with local utility company for services as shown or specified. 2. Obtain all permits and inspections including: Building permits, health department permits and sewer tap permits. 3. Disconnect, remove and re-install mechanical services located on or crossing through contract limits, above or below grade, obstructing construction of project or conflicting with completed project or any applicable codes. 4. Modify, extend or tie-into existing mechanical services or systems. 5. Complete alterations and additions to the domestic water distribution system. 6. Provide cutting of pavement, sidewalks, driveways, etc., excavating, trenching, shoring and de-watering. Provide backfill material and perform backfilling. 7. Restore site to original condition or new final grades. Provide paving, concrete, seed, or sod. 8. Complete alterations and additions to the domestic hot and cold water system. Provide sanitary rinse and flush. 9. Complete alterations and additions to the interior sanitary sewer. 10. Provide roofing including flashing, and counter flashing for roof mounted equipment; roof penetrations and supports for work in this Division, unless noted otherwise. E. Work Not Included: 1. Electrical wiring and conduits shown on the electrical drawings. 2. Asbestos removal. 1.4 GENERAL JOB REQUIREMENTS A. Shop and Erection Drawings: 1. Drawings are drawn to a small scale and are diagrammatic only. The drawings indicate size and general arrangement of equipment. 2. Do not scale drawings for exact locations. Refer to dimensional plans. Field measurements take precedence. 3. Shop drawings shall be submitted on a timely basis to allow adequate lead time for review, resubmission if necessary, manufacture and delivery to allow access of material to project at correct time based on schedule established by Engineer/Contractor. On each shop drawing include the specification section that applies to that submittal. Include complete descriptive data with dimensions, operating data and weight for each item of equipment. Carefully examine shop drawings to assure compliance with drawings and specifications prior to submittal to Engineer. Shop drawings and submittals shall bear the stamp of approval of the Contractor as evidence that the drawings have been checked by him. Drawing submitted without this stamp of approval will not be considered and will be returned for proper resubmission. Project No. 18088080 3 Section 22 05 00 Lake Lewisville WTP Dewatering Improvements Plumbing General 4. Drawings larger than 8-1/2" x 11", submit three (3) copies and one (1) reproducible of each drawing. Engineer will retain two (2) copies and return one (1) reproduction and one (1) copy to Contractor. Contractor is responsible for copying for distribution. 5. 8-1/2" x 11" drawings in brochure: Submit six (6) original copies for review. Engineer (and) Engineer will retain two (2) copies and return four (4) copies to Contractor. Division 01 "General Conditions" take precedence over this specification. 6. Review of shop drawings does not relieve Contractor of responsibility for errors and omissions in shop drawings. Contractor’s responsible for meeting the requirements of the contract documents. 7. Contractor is responsible for dimensions and sizes of equipment. Inform Engineer in writing of equipment differing from that shown. 8. Prepare erection drawings when required by Engineer. Investigate thoroughly all conditions affecting work and indicate on drawing. Engineer will review erection drawings before work commences. B. Provide all necessary offsets, elbows and fittings in piping as required to avoid conflict with work of other trades. Maintain proper headroom and clear passageways to allow adequate access and working clearances for equipment dampers, valves, etc. This shall be done at no additional cost to the Owner. C. Visit to Site/Work in other Division: 1. Examine not only the plans and specifications for this Division, but plans and specifications of the other Divisions of work and visit the site to become acquainted with existing conditions. Execution of Contract is evidence that Contractor has examined all drawings and specifications, and that all conditions which have a bearing in any way on the manner of installing the work in this Division are known. Later claims for labor and materials required due to difficulties encountered will not be recognized. D. Underground Utilities/Concealed Utilities: 1. All utilities and services, whether shown on the drawings or not, shall be suitably protected and maintained, and any damages thereto shall be promptly repaired. Owner shall be advised immediately of any damages sustained. If any extra expense is incurred due to the existence of buried utilities not shown on the drawings, or the location of which is not made known to the Contractor, the contract price shall be adjusted in accordance with the General Conditions. The Contractor shall advise the Owner three (3) days in advance of any operation which could possibly disrupt any underground utility. The Contractor shall utilize locator services to mark any underground utilities in the area he is working in, and shall make any other measure deemed necessary to avoid utility disruption. E. Workmanship, Warranty and Acceptance: 1. Work under this Division shall be first class with emphasis on neatness and workmanship. 2. Install work using competent mechanics, under supervision of foreman, all duly certified by local authorities. Installation subject to Engineer's observation, final approval, and acceptance. Engineer may reject unsuitable work. 3. Furnish Engineer written warranty, stating that if workmanship and/or materials executed under this Division are proven defective within two (2) years after final acceptance, such defects and other work damaged will be repaired and/or replaced. 4. In event that project is occupied or system placed in operation in several phases at Owner's request, warranty will begin on date each system or item of equipment is accepted by Owner. F. Observations of Work and Demonstration of Operation: 1. When observations are scheduled, provide sufficient personnel to expedite removal of access doors, cover plates, manholes covers, etc. Project No. 18088080 4 Section 22 05 00 Lake Lewisville WTP Dewatering Improvements Plumbing General 2. Contractor to assist Engineer in demonstration of operation of new systems to satisfaction of Owner. Contractor to have manpower available for demonstration of systems where requested by Owner. G. Materials and Substitutions: 1. All materials shall be new. All materials and equipment, for which a UL Standard, an AGA approval, an AWWA standard, FM listing or ASME requirements is established, shall be so approved and labeled or stamped. 2. Wherever in these specifications products are specified by manufacturer's name, bids shall be based on the named products. Where more than one manufacturer's name is mentioned, the one first listed establishes the standard for that product. If the bidder desires to submit a product of a manufacturer other that listed first, it must be the equivalent of the one listed first. 3. The drawings are based on the use of products specified and listed first. If any revision in piping, ductwork, conduit work, foundations, anchor bolts, connections, etc., is required by other named products or approved substitutions, it shall be the Contractor's responsibility to make such revisions at no additional expense to the Owner. 4. If any bidder desires to submit products of manufacturers not listed, he may submit a request for prior approval to the Engineer no later than 10 days prior to the bid date. If the Engineer decides to accept the manufacturers, they will be listed as "Approved" by written addendum. 5. If the manufacturers are not listed as approved either by addendum or in the specifications, they will not be accepted. H. Operating and Maintenance Manuals: 1. Provide maintenance and operating manuals bound in 8-1/2" x 11" hardback, three-post binders. Manuals shall contain written instructions for each system, shop drawings, schematic drawings, equipment catalog cuts, manufacturer's instructions, manufacturer’s warranties, and valve tag list. 2. Arrange information in the following sequence: title of job, Owner, address, date of submittal, name of Contractor, name of Engineer, index, shop drawings, operating instruction, Contractor's purchase order numbers, supplier's name and address, date of start-up of each piece of equipment and valve tag list. 3. Submit one (1) copy for review. Make required corrections, and submit two (2) record copies. I. Record Drawings: 1. Contractor shall maintain at the site one (1) copy of the drawings in good order and marked to record all changes made during construction. 2. Contractor shall update all drawings to incorporate all changes and deliver one (1) set of reproducible plans and one (1) electronic copy of the project in the latest “AutoCAD” version to the Owner upon completion of the work. 1.5 UTILITY CONNECTIONS A. Arrange with local utility companies for utility service connections, taps, meters and installation. Pay all fees and charges (if any) necessary for the utility services shown on the drawings or listed in the specifications. B. It is the responsibility of the Contractor to re-confirm with the Utility Companies, prior to bidding, that locations, arrangements, line sizes, pressures, interruptions, shut downs, etc. are in accordance with their regulations and requirements. C. If the utility company requirements are at variance with these drawings and specifications, this Contractor shall include the utility company requirements in his work without additional cost to the Owner. Project No. 18088080 5 Section 22 05 00 Lake Lewisville WTP Dewatering Improvements Plumbing General D. Obtain from Utility Company any additional charges for service of type, size and location called for. Include charges in bid to be paid by Contractor to appropriate party. Provide payment of these charges so as to allow logical progression of construction and avoid delay of completion. E. Should cost above not be available prior to bid, submit with bid a letter signed by responsible Utility Company personnel stating that cost is not available. Prime Contractor shall submit letter with his bid to Owner. Cost will then be omitted from contract and become responsibility of Owner. F. Furnish with shop drawings a signed document from each utility company describing location and type of service to be supplied and requirements for service. Document shall be signed by the appropriate responsible representative of the respective utility company. 1.6 REQUIREMENTS OF REGULATORY AGENCIES A. Obtain and pay for all permits required for the work. Comply with all ordinances pertaining to work described herein. B. Install the work under this Division in accordance with drawings and specifications and the standards and codes (latest edition) that apply to this work. In the event of a conflict, install work in accordance with the most stringent code requirements determined by Engineer. C. Arrange, pay for and complete work to pass required tests by agencies having authority over work. Deliver to Engineer Certificates of Inspection and approval issued by authorities. 1.7 PROTECTION AND STORAGE A. Provide warning lights, bracing, shoring, rails, guards and covers necessary to prevent damage or injury. B. Protect all equipment and materials, from damage by weather, entrance of water or dirt. Cap open piping, use plastic covers made for that purpose. Do not use rags or construction debris. C. Avoid damage to materials and equipment in place. Repair, or remove and replace damaged work and materials. D. Protect all surfaces from weld spatter, solder and cutting oil. E. Deliver equipment and materials to job site in original, unopened, labeled container. Store to prevent damage and injury. Store ferrous materials to prevent rusting. Store finished materials and equipment to prevent staining and discoloring. Store materials affected by condensation in warm dry areas. Provide heaters. Storage space on site and in building designated by Owner/Engineer. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION (NOT USED) END OF SECTION Project No. 18088080 1 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors SECTION 22 05 29 - PROCESS SUPPORTS AND ANCHORS PART 1 - GENERAL 1.1 SUMMARY A. Section includes the following hangers and supports for mechanical system piping and equipment: 1. Steel pipe hangers and supports. 2. Trapeze pipe hangers. 3. Metal framing systems. 4. Thermal-hanger shield inserts. 5. Fastener systems. 6. Pipe positioning systems. 7. Equipment supports. B. Related Sections: 1. Section 09 90 00 – Painting and Protective Coatings. 2. Section 23 31 13 - Metal Ductwork for duct hangers and supports. 3. Section 40 23 39 - Process Piping - General for pipe guides and anchors. 1.2 DEFINITIONS A. MSS: Manufacturers Standardization Society for the Valve and Fittings Industry Inc. B. Terminology: As defined in MSS SP-90, "Guidelines on Terminology for Pipe Hangers and Supports." 1.3 PERFORMANCE REQUIREMENTS A. Design supports for multiple pipes, capable of supporting combined weight of supported systems, system contents, and test water. B. Design equipment supports capable of supporting combined operating weight of supported equipment and connected systems and components. C. Design seismic-restraint hangers and supports for piping and equipment. 1.4 SUBMITTALS A. Product Data: For the following: 1. Steel pipe hangers and supports. 2. Thermal-hanger shield inserts. 3. Pipe positioning systems. B. Shop Drawings: 1. Show fabrication and installation details and include calculations for the following: a. Trapeze pipe hangers. Include Product Data for components. b. Metal framing systems. Include Product Data for components. c. Equipment supports. 2. Drawings of piping support system, locating each support, brace, hanger, guide, component and anchor. Identify support, hanger, guide, and anchor type by catalog number and Shop Drawing detail number. 3. Revisions to support systems resulting from changes in related piping system layout or addition of flexible joints. Project No. 18088080 2 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors C. Welding certificates. D. Contract Closeout Submittals: Maintenance information on piping support system. 1.5 QUALITY ASSURANCE A. Welding: Qualify procedures and personnel according to AWS D1.1, "Structural Welding Code- -Steel and ASME Boiler and Pressure Vessel Code: Section IX. B. Welding: Qualify procedures and personnel according to the following: 1. AWS D1.1, "Structural Welding Code--Steel." 2. AWS D1.2, "Structural Welding Code--Aluminum." 3. AWS D1.3, "Structural Welding Code--Sheet Steel." 4. AWS D1.4, "Structural Welding Code--Reinforcing Steel." 5. ASME Boiler and Pressure Vessel Code: Section IX. 1.6 DESIGN REQUIREMENTS A. General: 1. Contractor shall be responsible for the design, size, and location of process piping support systems in accordance with the requirements specified herein and in general conformance with the Drawings and the Design Details. The design shall be provided by a company specifically specializing in the design of support systems. The pipe support system design company shall demonstrate that they have at least five years of experience in pipe support design and have successfully completed at least three designs in the previous year. The Contractor shall provide Certification of Compliance with these requirements. 1. Seismic Load: Seismic Design Category C; IBC Seismic Site Class D, with seismic loads in accordance with the structural notes found on the Drawings. 2. Piping smaller than 30”: Supports are shown only where specific types and locations are required; additional pipe supports may be required. 3. Piping 30” and larger: Support systems have been designed for piping shown. 4. Meet requirements of MSS SP 58, MSS SP 69, and MSS SP 89. B. Pipe Support Systems: 1. Support Load: Dead loads imposed by weight of pipes filled with water, except air and gas pipes, plus insulation and capable of supporting combined weight of supported systems, system contents, and test water. 2. Safety Factor: Minimum of 5. 3. Maximum Support Spacing and Minimum Rod Size: a. Steel or Ductile Iron Piping: Project No. 18088080 3 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors Pipe Size Maximum Support/ Hanger Spacing Minimum Rod Size Single Rod Hangers 1-inch & smaller 6 feet 1/4-inch 1-1/2-inch thru 8 feet 1/4-inch 2-1/2-inch 3-inch & 4-inch 10 feet 3/8-inch 6-inch 12 feet 3/8-inch 8-inch 12 feet 1/2-inch 10-inch & 12-inch 14 feet 5/8-inch 14-inch 16 feet 3/4-inch 16-inch & 18-inch 16 feet 7/8-inch 20-inch 18 feet 1-inch 24-inch 18 feet 1-1/4-inch 30-inch & larger As shown on Drawings As shown on Drawings b. Copper Piping: Maximum Support Spacing: 2 feet less per size than listed for steel pipe, with 1” and smaller pipe supported every 5 feet. Minimum Hanger Rod Sizing: Same as listed for steel pipe. c. Plastic and Fiberglass Piping: Maximum support spacing: As recommended by manufacturer for flow temperature in pipe. Minimum Hanger Rod Sizing: Same as listed for steel pipe. d. Stainless Steel Piping: SST Pipe Maximum Support/ Minimum Rod Size Size Hanger Spacing Single Rod Hangers 1/2-inch thru 3/4-inch 7 feet 1/4-inch 1-inch thru 8 feet 1/4-inch 4-inch 6-inch 8 feet 3/8-inch 8-inch & 10 feet 1/2-inch 10-inch 12-inch 10 feet 1/2-inch 14-inch & 12 feet 5/8-inch 16-inch 18-inch & 14 feet 3/4-inch 20-inch 24-inch 14 feet 7/8-inch Project No. 18088080 4 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors C. Framing Support System: 1. Beams: Size such that beam stress does not exceed 25,000 psi and maximum deflection does not exceed 1/240 of span. 2. Column Members: Size in accordance with Manufacturer’s recommended method. 3. Support Loads: Calculate using weight of pipes filled with water. 4. Maximum Spans: a. Steel and Ductile Iron Pipe, 3” Diameter and Larger: 10-foot centers, unless otherwise shown. b. Other Pipelines and Special Situations: May require supplementary hangers and supports. 5. Electrical Conduit Support: Include in design of framing support system. D. Anchoring Devices: Design, size, and space support anchoring devices, including anchor bolts, inserts, and other devices used to anchor support, to withstand shear and pullout loads imposed by loading and spacing on each particular support. E. Vertical Sway Bracing: 10-foot maximum centers, or as shown. F. Existing Support Systems: Use existing supports systems to support new piping only if Contractor can show that they are adequate for additional load, or if they are strengthened to support the additional load. PART 2 - PRODUCTS 2.1 GENERAL A. When specified items are not available, fabricate pipe supports of correct material and to general configuration indicated by catalogs. B. Special support and hanger details are shown for cases where standard catalog supports are inapplicable. C. Materials: 1. Wetted and Submerged: Stainless steel. 2. Atmospheric Exposed: Galvanized or painted steel in accordance with Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. 3. Corrosive Areas: FRP. 2.2 MANUFACTURERS A. 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. 2.3 STEEL PIPE HANGERS AND SUPPORTS A. Description: MSS SP-58, Types 1 through 58, factory-fabricated components. Refer to Part 3 "Hanger and Support Applications" Article for where to use specific hanger and support types. B. Manufacturers: 1. B-Line Systems, Inc.; a division of Cooper Industries. 2. Empire Industries, Inc. 3. ERICO/Michigan Hanger Co. 4. Globe Pipe Hanger Products, Inc. Project No. 18088080 5 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors 5. Grinnell Corp. 6. GS Metals Corp. 7. National Pipe Hanger Corporation. C. Galvanized, Metallic Coatings: Pre-galvanized or hot dipped. D. Nonmetallic Coatings: Plastic coating, jacket, or liner. E. Padded Hangers: Hanger with fiberglass or other pipe insulation pad or cushion for support of bearing surface of piping. 2.4 TRAPEZE PIPE HANGERS A. Description: MSS SP-69, Type 59, shop- or field-fabricated pipe-support assembly made from structural-steel shapes with MSS SP-58 hanger rods, nuts, saddles, and U-bolts. 2.5 METAL FRAMING SYSTEMS A. Description: MFMA-3, shop- or field-fabricated pipe-support assembly made of steel channels and other components. B. Manufacturers: 1. B-Line Systems, Inc.; a division of Cooper Industries. 2. Power-Strut Div.; Tyco International, Ltd. 3. Thomas & Betts Corporation. 4. Tolco Inc. 5. Unistrut Corp.; Tyco International, Ltd. C. Coatings: Manufacturer's standard finish, unless bare metal surfaces are indicated. D. Nonmetallic Coatings: Plastic coating, jacket, or liner. 2.6 THERMAL-HANGER SHIELD INSERTS A. Description: 100-psig- minimum, compressive-strength insulation insert encased in sheet metal shield. B. Manufacturers: 1. Carpenter & Paterson, Inc. 2. ERICO/Michigan Hanger Co. 3. PHS Industries, Inc. 4. Pipe Shields, Inc. 5. Rilco Manufacturing Company, Inc. 6. Value Engineered Products, Inc. C. Insulation-Insert Material for Cold Piping: Water-repellent treated, ASTM C533, Water-repellent treated, ASTM C533, Type I calcium silicate or ASTM C552, Type II cellular glass with vapor barrier. D. Insulation-Insert Material for Hot Piping: Water-repellent treated, ASTM C533, Type I calcium silicate or ASTM C552, Type II cellular glass. E. Trapeze or Clamped Systems: Insert and shield shall cover entire circumference of pipe. F. Clevis or Band Hangers: Insert and shield shall cover lower 180° of pipe. Project No. 18088080 6 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors G. Insert Length: Extend 2” beyond sheet metal shield for piping operating below ambient air temperature. 2.7 FASTENER SYSTEMS A. Powder-Actuated Fasteners: Threaded-steel stud, for use in hardened Portland cement concrete with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used. 1. Manufacturers: a. Hilti, Inc. b. ITW Ramset/Red Head. c. Masterset Fastening Systems, Inc. d. MKT Fastening, LLC. e. Powers Fasteners. B. Mechanical-Expansion Anchors: Insert-wedge-type stainless steel, for use in hardened Portland cement concrete with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used. 1. Manufacturers: a. B-Line Systems, Inc.; a division of Cooper Industries. b. Empire Industries, Inc. c. Hilti, Inc. d. ITW Ramset/Red Head. e. MKT Fastening, LLC. f. Powers Fasteners. 2.8 PIPE POSITIONING SYSTEMS A. Description: IAPMO PS 42, system of metal brackets, clips, and straps for positioning piping in pipe spaces for plumbing fixtures for commercial applications. B. Manufacturers: 1. C & S Mfg. Corp. 2. HOLDRITE Corp.; Hubbard Enterprises. 3. Samco Stamping, Inc. 2.9 EQUIPMENT SUPPORTS A. Description: Welded, shop- or field-fabricated equipment support made from structural-steel shapes. 2.10 MISCELLANEOUS MATERIALS A. Structural Steel: ASTM A36/A36M, steel plates, shapes, and bars; black and galvanized. B. Grout: ASTM C1107, factory-mixed and -packaged, dry, hydraulic-cement, nonshrink and nonmetallic grout; suitable for interior and exterior applications. 1. Properties: Nonstaining, noncorrosive, and nongaseous. 2. Design Mix: 5000-psi, 28-day compressive strength. Project No. 18088080 7 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors PART 3 - EXECUTION 3.1 GENERAL A. Install support systems in accordance with MSS SP 69, Pipe Hangers and Supports-Selection and Application and MSS SP 89, Pipe Hangers and Supports-Fabrication and Installation, unless shown otherwise. B. Support piping connections to equipment by pipe support and not by the equipment. C. Support large or heavy valves, fittings, and appurtenances independently of connected piping. D. Support no pipe from the pipe above it. E. Support pipe at changes in direction or in elevation, adjacent to flexible joints and couplings, and where shown. F. Do not install pipe supports and hangers in equipment access areas or bridge crane runs. G. Brace hanging pipes against horizontal movement by both longitudinal and lateral sway bracing. H. Install lateral supports for seismic loads at all changes in direction. I. Install pipe anchors where required to withstand expansion thrust loads and to direct and control thermal expansion. J. Repair mounting surfaces to original condition after attachments are made. 3.2 HANGER AND SUPPORT APPLICATIONS A. Specific hanger and support requirements are specified in Sections specifying piping systems and equipment. B. Comply with MSS SP-69 for pipe hanger selections and applications that are not specified in piping system Sections. C. Use hangers and supports with galvanized, metallic coatings for piping and equipment that will not have field-applied finish. D. Use nonmetallic coatings on attachments for electrolytic protection where attachments are in direct contact with copper tubing. E. Use padded hangers for piping that is subject to scratching. F. Horizontal-Piping Hangers and Supports: Unless otherwise indicated and except as specified in piping system Sections, install the following types: 1. Adjustable, Steel Clevis Hangers (MSS Type 1): For suspension of non-insulated or insulated stationary pipes, NPS 1/2 to NPS 30. 2. Yoke-Type Pipe Clamps (MSS Type 2): For suspension of 120 to 450 °F pipes, NPS 4 to NPS 16, requiring up to 4” of insulation. 3. Carbon- or Alloy-Steel, Double-Bolt Pipe Clamps (MSS Type 3): For suspension of pipes, NPS 3/4 to NPS 24, requiring clamp flexibility and up to 4” of insulation. 4. Steel Pipe Clamps (MSS Type 4): For suspension of cold and hot pipes, NPS 1/2 to NPS 24, if little or no insulation is required. Project No. 18088080 8 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors 5. Pipe Hangers (MSS Type 5): For suspension of pipes, NPS 1/2 to NPS 4, 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 non- insulated stationary pipes, NPS 3/4 to NPS 8. 7. Adjustable, Steel Band Hangers (MSS Type 7): For suspension of non-insulated stationary pipes, NPS 1/2 to NPS 8. 8. Adjustable Band Hangers (MSS Type 9): For suspension of non-insulated stationary pipes, NPS 1/2 to NPS 8. 9. Adjustable Swivel-Ring Band Hangers (MSS Type 10): For suspension of non-insulated stationary pipes, NPS 1/2 to NPS 2. 10. Split Pipe-Ring with or without Turnbuckle-Adjustment Hangers (MSS Type 11): For suspension of non-insulated stationary pipes, NPS 3/8 to NPS 8. 11. Extension Hinged or 2-Bolt Split Pipe Clamps (MSS Type 12): For suspension of non- insulated stationary pipes, NPS 3/8 to NPS 3. 12. U-Bolts (MSS Type 24): For support of heavy pipes, NPS 1/2 to NPS 30. 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, 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, 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, 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, from 2 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, 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, 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, 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, if vertical and lateral adjustment during installation might be required in addition to expansion and contraction. G. Vertical-Piping Clamps: Unless otherwise indicated and except as specified in piping system 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. 2. Carbon- or Alloy-Steel Riser Clamps (MSS Type 42): For support of pipe risers, NPS 3/4 to NPS 20, if longer ends are required for riser clamps. H. Hanger-Rod Attachments: Unless otherwise indicated and except as specified in piping system Sections, install the following types: 1. Steel Turnbuckles (MSS Type 13): For adjustment up to 6” for heavy loads. 2. Steel Clevises (MSS Type 14): For 120 to 450 °F 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 piping installations. Project No. 18088080 9 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors I. Building Attachments: Unless otherwise indicated and except as specified in piping system 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. 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. b. Medium (MSS Type 32): 1500 lb. c. Heavy (MSS Type 33): 3000 lb. 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 headroom is limited. J. Saddles and Shields: Unless otherwise indicated and except as specified in piping system 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 in writing by manufacturer to prevent crushing insulation. 3. Thermal-Hanger Shield Inserts: For supporting insulated pipe. K. Spring Hangers and Supports: Unless otherwise indicated and except as specified in piping system 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”. 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% 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% 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% to absorb expansion and contraction of piping system from trapeze support. Project No. 18088080 10 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors 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. L. Comply with MSS SP-69 for trapeze pipe hanger selections and applications that are not specified in piping system Sections. M. Comply with MFMA-102 for metal framing system selections and applications that are not specified in piping system Sections. N. Use mechanical-expansion anchors instead of building attachments where required in concrete construction. O. Use pipe positioning systems in pipe spaces behind plumbing fixtures to support supply and waste piping for plumbing fixtures. 3.3 HANGER AND SUPPORT INSTALLATION A. Steel Pipe Hanger 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. Trapeze Pipe Hanger Installation: Comply with MSS SP-69 and MSS SP-89. Arrange for grouping of parallel runs of horizontal piping and support together on field-fabricated trapeze pipe hangers. 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 D1.1. C. Fiberglass Pipe Hanger Installation: Comply with applicable portions of MSS SP-69 and MSS SP-89. Install hangers and attachments as required to properly support piping from building structure. D. Metal Framing System Installation: Arrange for grouping of parallel runs of piping and support together on field-assembled metal framing systems. E. Thermal-Hanger Shield Installation: Install in pipe hanger or shield for insulated piping. F. Fastener System Installation: 1. Install powder-actuated fasteners for use in lightweight concrete or concrete slabs less than 4” thick in concrete after concrete is placed and completely cured. Use operators that are licensed by powder-actuated tool Manufacturer. Install fasteners according to powder-actuated tool Manufacturer's operating manual. 2. Install mechanical-expansion anchors in concrete after concrete is placed and completely cured. Install fasteners according to Manufacturer's written instructions. G. Pipe Positioning System Installation: Install support devices to make rigid supply and waste piping connections to each plumbing fixture. Project No. 18088080 11 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors H. Install hangers and supports complete with necessary inserts, bolts, rods, nuts, washers, and other accessories. I. Equipment Support Installation: Fabricate from welded-structural-steel shapes. J. 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. K. Install lateral bracing with pipe hangers and supports to prevent swaying. L. Install building attachments within concrete slabs or attach to structural steel. Install additional attachments at concentrated loads, including valves, flanges, and strainers, NPS 2-1/2 and larger 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. M. Load Distribution: Install hangers and supports so piping live and dead loads and stresses from movement will not be transmitted to connected equipment. N. Pipe Slopes: Install hangers and supports to provide indicated pipe slopes and so maximum pipe deflections allowed by ASME B31.1 (for power piping) and ASME B31.9 (for building services piping) are not exceeded. O. Insulated Piping: Comply with the following: 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 B31.1 for power piping and ASME B31.9 for building services piping. 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 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 an arc of 180°. a. Option: Thermal-hanger shield inserts may be used. Include steel weight- distribution plate for pipe NPS 4 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: 12” long and 0.048” thick. b. NPS 4: 12” long and 0.06” thick. c. NPS 5 and NPS 6: 18” long and 0.06” thick. d. NPS 8 to NPS 14: 24” long and 0.075” thick. e. NPS 16 to NPS 24: 24” long and 0.105” thick. 5. Pipes NPS 8 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. 3.4 EQUIPMENT SUPPORTS A. Fabricate structural-steel stands to suspend equipment from structure overhead or to support equipment above floor. B. Grouting: Place grout under supports for equipment and make smooth bearing surface. Project No. 18088080 12 Section 22 05 29 Lake Lewisville WTP Dewatering Improvements Process Supports and Anchors C. Provide lateral bracing, to prevent swaying, for equipment supports. 3.5 METAL FABRICATIONS A. Cut, drill, and fit miscellaneous metal fabrications for trapeze pipe hangers 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. 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. 3.6 ADJUSTING A. Hanger Adjustments: Adjust hangers to distribute loads equally on attachments and to achieve indicated slope of pipe. B. Trim excess length of continuous-thread hanger and support rods to 1-1/2”. 3.7 PAINTING A. Paint exposed surfaces immediately after erecting hangers and supports as specified in Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. B. Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply galvanizing-repair paint to comply with ASTM A780. END OF SECTION Project No. 18088080 1 Section 22 05 53 Lake Lewisville WTP Dewatering Improvements Mechanical Identification SECTION 22 05 53 - MECHANICAL IDENTIFICATION PART 1 - GENERAL 1.1 SUMMARY A. Extent of mechanical identification work required by this section is indicated on drawings and/or specified in other sections. B. Types of identification devices specified in this section include the following: 1. Painted Identification Materials. 2. Equipment Labels. 3. Plastic Pipe Markers. 4. Plastic Tape. 5. Underground-Type Plastic Line Marker. 6. Valve Tags. 7. Valve Schedule Frames. 8. Engraved Plastic-Laminate Signs. 1.2 QUALITY ASSURANCE A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of identification devices of types and sizes required, whose products have been in satisfactory use in similar service for not less than 5 years. B. Codes and Standards: 1. ANSI Standards: Comply with ANSI A13.1 for lettering size, length of color field, colors, and viewing angles of identification devices. 1.3 SUBMITTALS A. Product Data: Submit Manufacturer's technical product data and installation instructions for each identification material and device required. B. Schedules: Submit valve schedule for each piping system, typewritten and reproduced on 8- 1/2" x 11" bond paper. Tabulate the valve number, piping system, system abbreviation (as shown on tag), location of valve (room or space), and variations for identification (if any). Mark valves which are intended for emergency shut-off and similar special uses, by special "flags", in margin of schedule. In addition to mounted copies, furnish extra copies for Maintenance Manuals as specified in Division 1. C. Maintenance Data: Include product data and schedules in maintenance manuals; in accordance with requirements of Division 01. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering mechanical identification materials which may be incorporated in the work include; but are not limited to, the following: 1. Allen Systems, Inc. 2. Brady (W.H.) Co.; Signmark Div. 3. Industrial Safety Supply Co., Inc. 4. Seton Name Plate Corp. Project No. 18088080 2 Section 22 05 53 Lake Lewisville WTP Dewatering Improvements Mechanical Identification 2.2 MECHANICAL IDENTIFICATION MATERIALS A. General: Provide Manufacturer's standard products of categories and types required for each application as referenced in other sections. Selection is Installer's option where more than a single type is specified for applications but provide single selection for each product category. 2.3 PAINTED IDENTIFICATION MATERIALS A. Stencils: Standard fiberboard stencils, prepared for required applications with letter sizes generally complying with recommendations of ANSI A13.1 for piping and similar applications, but not less than 1-1/4" high letters for ductwork and not less than 3/4" high letters for access door signs and similar operational instructions. Stencil 3/4 inch high letters on 3/4 through 4- inch pipe or coverings, or 5-inch high letters of 5-inch and larger pipe or coverings. B. Stencil Paint: Standard exterior type stenciling enamel; black, except as otherwise indicated; either brushing grade or pressurized spray-can form and grade. C. Identification Paint: Standard identification enamel of colors indicated or, if not otherwise indicated for piping systems, complying with ANSI A13.1 and/or Owner Selection for colors. D. See Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. 2.4 EQUIPMENT LABELS A. Metal Labels for Equipment: 1. Material and Thickness: Stainless steel, 0.025-inch minimum thickness, and having predrilled or stamped holes for attachment hardware. 2. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch. 3. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering. 4. Fasteners: Stainless-steel rivets or self-tapping screws 5. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate. 6. Text: a. Manufacturer’s name, equipment model number and serial number, identification tag number; and when appropriate, drive speed, motor horsepower with rated capacity, pump rated total dynamic head, and impeller size. 2.5 PLASTIC PIPE MARKERS A. Snap-On Type: Provide Manufacturer's standard pre-printed, semi-rigid snap-on, color-coded pipe markers, complying with ANSI A13.1. B. Pressure-Sensitive Type: Provide Manufacturer's standard pre-printed, permanent adhesive, color-coded, pressure-sensitive vinyl pipe markers, complying with ANSI A13.1. C. Insulation: Furnish 1" thick molded fiberglass insulation with jacket for each plastic pipe marker to be installed on un-insulated pipes subjected to fluid temperatures of 125 °F or greater. Cut length to extend 2" beyond each end of plastic pipe marker. 1. Small Pipes: For external diameters less than 6" (including insulation if any), provide full- band pipe markers, extending 360° around pipe at each location, fastened by one of the following methods: a. Snap-on application of pre-tensioned semi-rigid plastic pipe marker. Project No. 18088080 3 Section 22 05 53 Lake Lewisville WTP Dewatering Improvements Mechanical Identification b. Adhesive lap joint in pipe marker overlap. c. Laminated or bonded application of pipe marker to pipe (or insulation). d. Taped to pipe (or insulation) with color-coded plastic adhesive tape, not less than 3/4" wide; full circle at both ends of pipe marker, tape lapped 1-1/2". 2. Large Pipes: For external diameters of 6" and larger (including insulation if any), provide either full-band or strip-type pipe markers, but not narrower than 3 times letter height (and of required length), fastened by one of the following methods: a. Laminated or bonded application of pipe marker to pipe (or insulation). b. Taped to pipe (or insulation) with color-coded plastic adhesive tape, not less than 1-1/2" wide; full circle at both ends of pipe marker, tape lapped 3". c. Trapped-to-pipe (or insulation) application of semi-rigid type, with Manufacturer's standard stainless steel bands. D. Lettering: Manufacturer's standard pre-printed nomenclature which best describes piping system in each instance, as selected by Architect/Engineer in cases of variance with name as shown or specified. Nominal Pipe Diameter Lettering Size Less than 1.5 1/2 inch 1.5 inches to 2 inches 3/4 inch 2.5 inches to 6 inches 1-1/4 inches 8 inches to 10 inches 2-1/2 inches Over 10 inches 3-1/2 inches E. Marker Colors Service Lettering Background Flammables, chemicals, toxics Black Yellow Water, nontoxic solutions or low hazard liquids White Green Nonflammable or nontoxic gases White Blue Fire quenching fluids (foam, fire water, CO2 Halon) White Red F. Arrows: Print each pipe marker with arrows indicating direction of flow, either integrally with piping system service lettering (to accommodate both directions), or as separate unit of plastic. 2.6 PLASTIC TAPE A. General: Provide Manufacturer's standard color-coded pressure-sensitive (self-adhesive) vinyl tape, not less than 3 mils thick. B. Width: Provide 1-1/2" wide tape markers on pipes with outside diameters (including insulation, if any) of less than 6", 2-1/2" wide tape for larger pipes. C. Color: Comply with ANSI A13.1, except where another color selection is indicated. Project No. 18088080 4 Section 22 05 53 Lake Lewisville WTP Dewatering Improvements Mechanical Identification 2.7 UNDERGROUND-TYPE PLASTIC LINE MARKERS A. General: Manufacturer's standard permanent, bright-colored, continuous-printed plastic tape, intended for direct-burial service; not less than 6" wide x 4 mils thick. Provide tape with printing which most accurately indicates type of service of buried pipe. B. Provide multi-ply tape consisting of solid aluminum foil core between 2-layers of plastic tape. 2.8 VALVE TAGS A. Brass Valve Tags: Provide 19-gauge polished brass valve tags, with a stamp-engraved piping system abbreviation in 1/4" high letters and sequenced valve numbers 1/2" high, and with 5/32" hole for fastener. 1. Provide 1-1/2" diameter tags, except as otherwise indicated. 2. Provide size and shape as specified or scheduled for each piping system. 3. Fill tag engraving with black enamel. B. Valve Tag Fasteners: Provide Manufacturer's standard solid brass chain (wire link or beaded type), or solid brass S-hooks of the sizes required for proper attachment of tags to valves, and manufactured specifically for that purpose. C. Access Panel Markers: Provide Manufacturer's standard 1/16" thick engraved plastic laminate access panel markers, with abbreviations and numbers corresponding to concealed valve. Include 1/8" center hole to allow attachment. 2.9 VALVE SCHEDULE FRAMES A. General: For each page of valve schedule, provide glazed display frame, with screws for removable mounting on masonry walls. Provide frames of finished hardwood or extruded aluminum, with SSB-grade sheet glass. 2.10 ENGRAVED PLASTIC-LAMINATE SIGNS A. General: Provide engraving stock melamine plastic laminate, complying with FS L-P-387, in the sizes and thicknesses indicated, engraved with engraver's standard letter style of the sizes and wording indicated, black with white core (letter color) except as otherwise indicated, punched for mechanical fastening except where adhesive mounting is necessary because of substrate. B. Thickness: 1/16" for units up to 20 sq. in. or 8" length; 1/8" for larger units. C. Fasteners: Self-tapping stainless steel screws, except contact-type permanent adhesive where screws cannot or should not penetrate the substrate. 2.11 LETTERING AND GRAPHICS A. General: Coordinate names, abbreviations and other designations used in mechanical identification work, with corresponding designations shown, specified or scheduled. Provide numbers, lettering and wording as indicated or, if not otherwise indicated, as recommended by manufacturers or as required for proper identification and operation/maintenance of mechanical systems and equipment. B. Multiple Systems: Where multiple systems of same generic name are shown and specified, provide identification which indicates individual system number as well as service (as examples; Boiler No. 3, Air Supply No. 1H, Standpipe F12). Project No. 18088080 5 Section 22 05 53 Lake Lewisville WTP Dewatering Improvements Mechanical Identification PART 3 - EXECUTION 3.1 GENERAL INSTALLATION REQUIREMENTS A. Coordination: Where identification is to be applied to surfaces which require insulation, painting or other covering or finish including valve tags in finished mechanical spaces, install identification after completion of covering and painting. Install identification prior to installation of acoustical ceilings and similar removable concealment. 3.2 PREPARATION A. Clean piping and equipment surfaces of substances that could impair bond of identification devices, including dirt, oil, grease, release agents, and incompatible primers, paints, and encapsulants. 3.3 EQUIPMENT LABEL INSTALLATION A. Install or permanently fasten labels on each major item of mechanical equipment. B. Locate equipment labels where accessible and visible. 3.4 PIPING SYSTEM IDENTIFICATION A. General: Install pipe markers of one of the following types on each system indicated to receive identification, and include arrows to show normal direction of flow: 1. Stenciled markers, including color-coded background band or rectangle, and contrasting lettering of black or white. Extend color band or rectangle 2" beyond ends of lettering. 2. Stenciled markers, with lettering color complying with ANSI A13.1. 3. Plastic pipe markers, with application system as indicated under "Materials" in this section. Install on pipe insulation segment where required for hot non-insulated pipes. 4. Stenciled markers, black or white for best contrast, wherever continuous color-coded painting of piping is provided. 5. Locate pipe markers and color bands as follows wherever piping is exposed to view in occupied spaces, machine rooms, accessible maintenance spaces (shafts, tunnels, plenums) and exterior non-concealed locations. a. Near each valve and control device. b. Near each branch, excluding short take-offs for fixtures and terminal units; mark each pipe at branch, where there could be question of flow pattern. c. Near locations where pipes pass through walls or floors/ceilings, or enter non- accessible enclosures. d. At access doors, manholes and similar access points which permit view of concealed piping. e. Near major equipment items and other points of origination and termination. f. Spaced intermediately at maximum spacing of 50' along each piping run, except reduce spacing to 25' in congested areas of piping and equipment. g. On piping above removable acoustical ceilings, except omit intermediately spaced markers. 6. Metal Tags a. Where outside diameter of pipe or pipe covering is 5/8 inch or smaller, provide metal pipe identification tags instead of lettering. b. Fasten pipe identification tags to pipe with chain. c. Where tags are used, color code pipe as scheduled. Project No. 18088080 6 Section 22 05 53 Lake Lewisville WTP Dewatering Improvements Mechanical Identification B. Place markers on piping so they are visible from operator’s position in walkway or working platform near piping. Locate markers along horizontal centerline of pipe, unless better visibility is achieved elsewhere. 3.5 UNDERGROUND PIPING IDENTIFICATION A. General: During back-filling/top-soiling of each exterior underground piping system, install continuous underground-type plastic line marker, located directly over buried line at 6" to 8" below finished grade. Where multiple small lines are buried in common trench and do not exceed overall width of 16", install single line marker. For tile fields and similar installations, mark only edge pipe lines of field. 3.6 VALVE IDENTIFICATION A. General: Provide valve tag on every valve, cock and control device in each piping system; exclude check valves, valves within factory-fabricated equipment units, plumbing fixture faucets, convenience and lawn-watering hose bibs, and shut-off valves at plumbing fixtures, HVAC terminal devices and similar rough-in connections of end-use fixtures and units. List each tagged valve in valve schedule for each piping system. B. Mount valve schedule frames and schedules in machine rooms where indicated or, if not otherwise indicated, where directed by Contracting Officer. C. Where more than one major machine room is shown for project, install mounted valve schedule in each major machine room, and repeat only main valves which are to be operated in conjunction with operations of more than single machine room. 3.7 ADJUSTING AND CLEANING A. Adjusting: Relocate any mechanical identification device which has become visually blocked by work of this division or other divisions. B. Cleaning: Clean face of identification devices, and glass frames of valve charts. 3.8 EXTRA STOCK A. Furnish minimum of 5% extra stock of each mechanical identification material required, including additional numbered valve tags (not less than 3) for each piping system, additional piping system identification markers, and additional plastic laminate engraving blanks of assorted sizes. B. Where stenciled markers are provided, clean and retain stencils after completion of stenciling and include used stencils in extra stock, along with required stock of stenciling paints and applicators. END OF SECTION Project No. 18088080 1 Section 22 11 16 Lake Lewisville WTP Dewatering Improvements Plumbing Piping SECTION 22 11 16 - PLUMBING PIPING PART 1 - GENERAL 1.1 SUMMARY A. Section includes: All work necessary for a complete installation of domestic water piping inside the building to 5 feet outside the building, and sanitary waste piping to a point as indicated on the drawings. B. The work of this section is subject to the requirements of the Plumbing General Section. 1.2 SUBMITTALS A. Submit schedule of pipe and fittings for each service. 1.3 CODES AND STANDARDS A. International Plumbing Code, 2015 PART 2 - PRODUCTS 2.1 GENERAL A. Refer to design drawings for approximate locations of pipe and for pipe size. B. Insulate piping in accordance with 23 07 13 – Mechanical Insulation. C. Domestic Water Piping: 1. Water piping within building: a. 3 inch and smaller shall be copper tube, type "L" hard temper, ASTM. 2. Piping below ground: a. 2" and smaller type "K" soft temper; ASTM B88. D. Sanitary Waste and Vent Piping: 1. Schedule 40 PVC-DWV, ASTM D2665 using solvent cement ASTM D2564, for below slab only. 2. No-Hub Cast Iron meeting CISPI Standards for all above slab piping. 3. Ductile Iron, Class 51 for all piping beneath structures. E. Fittings - Domestic Water Piping: 1. Wrought copper, solder type, ASTM B75, ANSI B16.22 F. Fittings - Sanitary Waste and Vent Piping: 1. Below ground: a. Schedule 40 PVC-DWV, ASTM D2855 using solvent cement ASTM D2564 2. Beneath structures: a. Restrained push-on. G. Unions: 1. Solder unions shall be wrought copper, with copper ground joint. ASTM B75, ANSI B16.22. 2. Di-electric, EPSO, 250 lb. WOG. H. Solder: Project No. 18088080 2 Section 22 11 16 Lake Lewisville WTP Dewatering Improvements Plumbing Piping 1. Solder Metal shall conform to ASTM B32-alloy grade 95TA: 95 percent tin, 5 percent antimony. Joints shall be made with approved solder containing not more than 0.2 percent lead. I. Valves: 1. Approved Domestic manufacturers: Hammond, Kitz, Nibco, Apollo, Milwaukee, or approved equal. 2. Valves should be installed according to manufacturer’s recommendations. 3. Valves 2-1/2” inches and smaller shall be equal to Nibco T-585-70, full port ball type with bronze body, chrome plated ball and bronze threaded ends, 600 psi WOG or Nibco S- 585-70 in copper lines. PART 3 - EXECUTION 3.1 GENERAL A. All piping shall be routed to conserve building space, be coordinated with items installed by other trades and not interfere with access to or operation of the facility. B. Provide roof flashings for pipe penetrations through roof, to be installed by roofing contractor. Install roof drains as recommended by manufacturer and such that piping does not carry weight of roof drain. C. Water piping within building shall be size indicated on plans and risers. In the event no size is shown, pipe size or size required by the Plumbing Code. Piping shall be sloped toward a system drain and toward outlets, to provide for system drain-down. Install piping to prevent direct contact between ferrous and non-ferrous materials. Allow flexibility for expansion in piping. D. All water piping within building shall be installed on the interior side of building envelope insulation, except where installed underslab. Where installed in attic locations piping shall be insulated and installed low to trusses/structure with the envelope insulation installed on top of the piping. A poly vapor barrier shall be secured over the piping and under the building insulation. Where it is not physically possible to install the piping within the building thermal envelope, the piping shall be fitted with electric heat tracing for freeze protection. E. Domestic water piping system shall be tested with potable water at a pressure of 125 psig or 25 psig above design working pressure, whichever is greater for 12 hours. Test shall be conducted with plumbing inspector unless approved otherwise in writing. F. Water distribution piping shall be disinfected prior to occupancy or system start-up with a chlorine solution 50 ppm. Allow system to stand for six hours minimum; then exercise all valves to ensure treatment of all branches and components. System shall be flushed with potable water after disinfection and prior to placement into service. G. Sanitary waste and vent piping shall be tested in accordance with water and air tests as specified in the SBCCI Standard Plumbing Code, in addition to any tests required by the local plumbing official. (10 feet of head with no apparent leaks. Hold for 30 minutes minimum). Flush all gravity piping including floor drains and roof drains prior to turning over to the Owner. 3.2 PREPARATION A. All pipe shall be cut square. Ream pipe and tube ends and remove burrs. Clean the ends of pipes to remove oil, grease and oxides. Project No. 18088080 3 Section 22 11 16 Lake Lewisville WTP Dewatering Improvements Plumbing Piping B. Prepare piping connections to equipment with flanges or unions. C. All soldered piping and equipment connections shall be properly prepared in accordance with good piping practice. Apply a thin layer of flux to only the male tubing. Rotate into the fitting with one or two revolutions. D. Where PVC is connected to hubless cast iron the connection must be made with special coupling press to compensate for differences in outside diameters of the two materials. 3.3 INSTALLATION A. Domestic Water Piping: 1. Route piping in orderly manner, plumb and parallel to building structure, and maintain gradient. 2. Install piping to allow for expansion and contraction without stressing pipe, joints, or connected equipment. 3. Provide clearance for installation of insulation and access to valves and fittings. 4. Provide access where valves and fittings are not exposed. 5. Install valves with stems upright or horizontal. Provide drain valves at low points in systems. 6. Test cold water piping before being insulated, or concealed in walls or ceiling. B. Sanitary Waste and Vent Piping: 1. Horizontal soil, waste and drainage lines within building shall have a minimum uniform slope of 1/8 inch per foot on 4 inch and larger, and 1/4 inch per foot on lines 3 inch and smaller. 2. Turns in sanitary, soil, and drain piping shall be made using 45 degree elbows, wyes, quarter-, eighth-, or sixteenth bends, or other bends approved by the Plumbing Code. 3. Do not use sanitary tees or crosses except where discharging from horizontal to vertical. 4. Make changes in pipe sizes with reducing fittings and recessed reducers. Do not reduce line size in direction of flow. 5. Provide cleanouts in all horizontal turns in waste piping greater than 45 degrees. 6. Provide deep seal traps on all floor drains, and trap primers where required by code or as indicated on drawings. 7. Indirect waste lines dumping into floor or hub drains shall maintain a 2-inch air gap between the end of the waste line and the rim of the floor or hub drain. 3.4 APPLICATION A. Install unions downstream of valves and at equipment or apparatus connections. Install dielectric unions where joining dissimilar materials. B. Install ball valves for shut-off and to isolate equipment, part of systems, or vertical risers. C. Install brackets at cast iron no hub cleanouts to protect the integrity of the joint. END OF SECTION Project No. 18088080 1 Section 22 13 16 Lake Lewisville WTP Dewatering Improvements Sanitary Waste & Vent Piping SECTION 22 13 16 - SANITARY WASTE AND VENT PIPING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Pipe, tube, and fittings. 2. Specialty pipe fittings. 3. Encasement for underground metal piping. 1.2 PERFORMANCE REQUIREMENTS A. Components and installation shall be capable of withstanding the following minimum working pressure unless otherwise indicated: 1. Soil, Waste, and Vent Piping: 10-foot head of water (30 kPa). 1.3 SUBMITTALS A. Product Data: For each type of pipe and product indicated. 1.4 QUALITY ASSURANCE A. Piping materials shall bear label, stamp, or other markings of specified testing agency. B. Comply with NSF/ANSI 14, "Plastics Piping Systems Components and Related Materials," for plastic piping components. Include marking with "NSF-DWV" for plastic drain, waste, and vent piping and "NSF-SEWER" for plastic sewer piping. 1.5 PROJECT CONDITIONS A. Interruption of Existing Sanitary Waste Service: Do not interrupt service to facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary service according to requirements indicated: 1. Notify Owner no fewer than two days in advance of proposed interruption of sanitary waste service. PART 2 - PRODUCTS 2.1 PIPING MATERIALS A. Refer to drawings for where different pipe materials are to be installed. 2.2 HUB-AND-SPIGOT, CAST-IRON SOIL PIPE AND FITTINGS A. Pipe and Fittings: ASTM A74, Service classes. B. Gaskets: ASTM C564, rubber. C. Calking Materials: ASTM B29, pure lead and oakum or hemp fiber. 2.3 HUBLESS, CAST-IRON SOIL PIPE AND FITTINGS A. Pipe and Fittings: ASTM A888 or CISPI 301. Project No. 18088080 2 Section 22 13 16 Lake Lewisville WTP Dewatering Improvements Sanitary Waste & Vent Piping B. Sovent Stack Fittings: ASME B16.45 or ASSE 1043, hubless, cast-iron aerator and de-aerator drainage fittings. C. CISPI, Hubless-Piping Couplings: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. ANACO-Husky. b. Dallas Specialty & Mfg. Co. c. Fernco Inc. d. Matco-Norca, Inc. e. MIFAB, Inc. f. Mission Rubber Company; a division of MCP Industries, Inc. g. Stant. h. Tyler Pipe. 2. Standards: ASTM C1277 and CISPI 310. 3. Description: Stainless-steel corrugated shield with stainless-steel bands and tightening devices; and ASTM C564, rubber sleeve with integral, center pipe stop. 2.4 PVC PIPE AND FITTINGS A. Solid-Wall PVC Pipe: ASTM D2665, drain, waste, and vent. B. PVC Socket Fittings: ASTM D2665, made to ASTM D3311, drain, waste, and vent patterns and to fit Schedule 40 pipe. C. Adhesive Primer: ASTM F656. D. Solvent Cement: ASTM D2564. 2.5 SPECIALTY PIPE FITTINGS A. Transition Couplings: 1. General Requirements: Fitting or device for joining piping with small differences in OD's or of different materials. Include end connections same size as and compatible with pipes to be joined. 2. Fitting-Type Transition Couplings: Manufactured piping coupling or specified piping system fitting. 3. Shielded, Nonpressure Transition Couplings: a. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1) Cascade Waterworks Mfg. Co. 2) Mission Rubber Company; a division of MCP Industries, Inc. b. Standard: ASTM C 1460. c. Description: Elastomeric or rubber sleeve with full-length, corrosion-resistant outer shield and corrosion-resistant-metal tension band and tightening mechanism on each end. B. Dielectric Fittings: 1. General Requirements: Assembly of copper alloy and ferrous materials with separating nonconductive insulating material. Include end connections compatible with pipes to be joined. 2.6 ENCASEMENT FOR UNDERGROUND METAL PIPING A. Standard: ASTM A674 or AWWA C105/A 21.5. Project No. 18088080 3 Section 22 13 16 Lake Lewisville WTP Dewatering Improvements Sanitary Waste & Vent Piping B. Material: Linear low-density polyethylene film of 0.008-inch (0.20-mm) or high-density, cross- laminated polyethylene film of 0.004-inch (0.10-mm) minimum thickness. C. Form: tube. PART 3 - EXECUTION 3.1 EARTH MOVING A. Comply with requirements for excavating, trenching, and backfilling specified in Division 31. 3.2 PIPING INSTALLATION A. 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. B. Install piping in concealed locations unless otherwise indicated and except in equipment rooms and service areas. C. 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. D. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal. E. Install piping to permit valve servicing. F. Install piping at indicated slopes. G. Install piping free of sags and bends. H. Install fittings for changes in direction and branch connections. I. Install piping to allow application of insulation. J. Make changes in direction for soil and waste drainage and vent piping using appropriate branches, bends, and long-sweep bends. Sanitary tees and short-sweep 1/4 bends may be used on vertical stacks if change in direction of flow is from horizontal to vertical. Use long-turn, double Y-branch and 1/8-bend fittings if two fixtures are installed back to back or side by side with common drain pipe. Straight tees, elbows, and crosses may be used on vent lines. Do not change direction of flow more than 90 degrees. Use proper size of standard increasers and reducers if pipes of different sizes are connected. Reducing size of drainage piping in direction of flow is prohibited. K. Lay buried building drainage piping beginning at low point of each system. Install true to grades and alignment indicated, with unbroken continuity of invert. Place hub ends of piping upstream. Install required gaskets according to manufacturer's written instructions for use of lubricants, cements, and other installation requirements. Maintain swab in piping and pull past each joint as completed. L. Install soil and waste drainage and vent piping at the following minimum slopes unless otherwise indicated: Project No. 18088080 4 Section 22 13 16 Lake Lewisville WTP Dewatering Improvements Sanitary Waste & Vent Piping 1. Building Sanitary Drain: 2 percent downward in direction of flow for piping NPS 3 (DN 80) and smaller; Unless indicated otherwise in the Drawings, 1 percent downward in direction of flow for piping NPS 4 (DN 100) and larger. 2. Horizontal Sanitary Drainage Piping: 2 percent downward in direction of flow. 3. Vent Piping: 1 percent down toward vertical fixture vent or toward vent stack. M. Install cast-iron soil piping according to CISPI's "Cast Iron Soil Pipe and Fittings Handbook," Chapter IV, "Installation of Cast Iron Soil Pipe and Fittings." 1. Install encasement on underground piping according to ASTM A674 or AWWA C105/A 21.5. N. Install aboveground PVC piping according to ASTM D2665. O. Install underground PVC piping according to ASTM D2321. P. Install engineered soil and waste drainage and vent piping systems as follows: 1. Combination Waste and Vent: Comply with standards of authorities having jurisdiction. 2. Sovent Drainage System: Comply with ASSE 1043 and sovent fitting manufacturer's written installation instructions. 3. Reduced-Size Venting: Comply with standards of authorities having jurisdiction. Q. Plumbing Specialties: 1. Install cleanouts at grade and extend to where building sanitary drains connect to building sanitary sewers in sanitary drainage gravity-flow piping. Install cleanout fitting with closure plug inside the building in sanitary drainage force-main piping. R. Do not enclose, cover, or put piping into operation until it is inspected and approved by authorities having jurisdiction. S. Install sleeves for piping penetrations of walls, ceilings, and floors. T. Install sleeve seals for piping penetrations of concrete walls and slabs. U. Install escutcheons for piping penetrations of walls, ceilings, and floors. 3.3 JOINT CONSTRUCTION A. Join hub-and-spigot, cast-iron soil piping with gasket joints according to CISPI's "Cast Iron Soil Pipe and Fittings Handbook" for compression joints. B. Join hub-and-spigot, cast-iron soil piping with calked joints according to CISPI's "Cast Iron Soil Pipe and Fittings Handbook" for lead-and-oakum calked joints. C. Plastic, Nonpressure-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. PVC Piping: Join according to ASTM D2855 and ASTM D2665 Appendices. 3.4 SPECIALTY PIPE FITTING INSTALLATION A. Transition Couplings: 1. Install transition couplings at joints of piping with small differences in OD's. 2. In Drainage Piping: nonpressure transition couplings. Project No. 18088080 5 Section 22 13 16 Lake Lewisville WTP Dewatering Improvements Sanitary Waste & Vent Piping 3.5 HANGER AND SUPPORT INSTALLATION A. Comply with requirements for pipe hanger and support devices and installation specified in Section 22 05 29, PROCESS SUPPORTS AND ANCHORS. 1. Install galvanized steel pipe hangers for horizontal piping in noncorrosive environments. 2. Install individual, straight, horizontal piping runs: a. 100 Feet (30 m) and Less: MSS Type 1, adjustable, steel clevis hangers. b. Longer Than 100 Feet (30 m): MSS Type 43, adjustable roller hangers. c. Longer Than 100 Feet (30 m) if Indicated: MSS Type 49, spring cushion rolls. 3. Multiple, Straight, Horizontal Piping Runs 100 Feet (30 m) or Longer: MSS Type 44, pipe rolls. Support pipe rolls on trapeze. 4. Base of Vertical Piping: MSS Type 52, spring hangers. B. Support horizontal piping and tubing within 12 inches (300 mm) of each fitting and coupling. C. Support vertical piping and tubing at base and at each floor. D. Rod diameter may be reduced one size for double-rod hangers, with 3/8-inch (10-mm) minimum rods. E. Install hangers for cast-iron soil piping with the following maximum horizontal spacing and minimum rod diameters: 1. NPS 1-1/2 and NPS 2 (DN 40 and DN 50): 60 inches (1500 mm) with 3/8-inch (10-mm) rod. 2. NPS 3 (DN 80): 60 inches (1500 mm) with 1/2-inch (13-mm) rod. 3. NPS 4 and NPS 5 (DN 100 and DN 125): 60 inches (1500 mm) with 5/8-inch (16-mm) rod. 4. NPS 6 and NPS 8 (DN 150 and DN 200): 60 inches (1500 mm) with 3/4-inch (19-mm) rod. 5. NPS 10 and NPS 12 (DN 250 and DN 300): 60 inches (1500 mm) with 7/8-inch (22-mm) rod. 6. Spacing for 10-foot (3-m) lengths may be increased to 10 feet (3 m). Spacing for fittings is limited to 60 inches (1500 mm). F. Install supports for vertical cast-iron soil piping every 15 feet (4.5 m). G. Install hangers for PVC piping with the following maximum horizontal spacing and minimum rod diameters: 1. NPS 1-1/2 and NPS 2 (DN 40 and DN 50): 48 inches (1200 mm) with 3/8-inch (10-mm) rod. 2. NPS 3 (DN 80): 48 inches (1200 mm) with 1/2-inch (13-mm) rod. 3. NPS 4 and NPS 5 (DN 100 and DN 125): 48 inches (1200 mm) with 5/8-inch (16-mm) rod. 4. NPS 6 and NPS 8 (DN 150 and DN 200): 48 inches (1200 mm) with 3/4-inch (19-mm) rod. 5. NPS 10 and NPS 12 (DN 250 and DN 300): 48 inches (1200 mm) with 7/8-inch (22-mm) rod. H. Install supports for vertical PVC piping every 48 inches (1200 mm). I. Support piping and tubing not listed above according to MSS SP-69 and manufacturer's written instructions. Project No. 18088080 6 Section 22 13 16 Lake Lewisville WTP Dewatering Improvements Sanitary Waste & Vent Piping 3.6 CONNECTIONS A. Drawings indicate general arrangement of piping, fittings, and specialties. B. Connect soil and waste piping to exterior sanitary sewerage piping. Use transition fitting to join dissimilar piping materials. C. Connect drainage and vent piping to the following: 1. Plumbing Fixtures: Connect drainage piping in sizes indicated, but not smaller than required by plumbing code. 2. Plumbing Fixtures and Equipment: Connect atmospheric vent piping in sizes indicated, but not smaller than required by authorities having jurisdiction. 3. Plumbing Specialties: Connect drainage and vent piping in sizes indicated, but not smaller than required by plumbing code. 4. Install test tees (wall cleanouts) in conductors near floor and floor cleanouts with cover flush with floor. 5. Equipment: Connect drainage piping as indicated. Provide shutoff valve if indicated and union for each connection. Use flanges instead of unions for connections NPS 2-1/2 (DN 65) and larger. D. Where installing piping adjacent to equipment, allow space for service and maintenance of equipment. E. 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. 3.7 IDENTIFICATION A. Identify exposed sanitary waste and vent piping. Comply with requirements for identification specified in Section 22 05 53, MECHANICAL IDENTIFICATION. 3.8 FIELD QUALITY CONTROL A. During installation, notify authorities having jurisdiction at least 24 hours before inspection must be made. Perform tests specified below in presence of authorities having jurisdiction. 1. Roughing-in Inspection: Arrange for inspection of piping before concealing or closing-in after roughing-in and before setting fixtures. 2. Final Inspection: Arrange for final inspection by authorities having jurisdiction to observe tests specified below and to ensure compliance with requirements. B. Re-inspection: If authorities having jurisdiction find that piping will not pass test or inspection, make required corrections and arrange for re-inspection. C. Reports: Prepare inspection reports and have them signed by authorities having jurisdiction. D. Test sanitary drainage and vent piping according to procedures of authorities having jurisdiction or, in absence of published procedures, as follows: 1. Test for leaks and defects in new piping and parts of existing piping that have been altered, extended, or repaired. If testing is performed in segments, submit separate report for each test, complete with diagram of portion of piping tested. Project No. 18088080 7 Section 22 13 16 Lake Lewisville WTP Dewatering Improvements Sanitary Waste & Vent Piping 2. Leave uncovered and unconcealed new, altered, extended, or replaced drainage and vent piping until it has been tested and approved. Expose work that was covered or concealed before it was tested. 3. Roughing-in Plumbing Test Procedure: Test drainage and vent piping except outside leaders on completion of roughing-in. Close openings in piping system and fill with water to point of overflow, but not less than 10-foot head of water (30 kPa). From 15 minutes before inspection starts to completion of inspection, water level must not drop. Inspect joints for leaks. 4. Finished Plumbing Test Procedure: After plumbing fixtures have been set and traps filled with water, test connections and prove they are gastight and watertight. Plug vent-stack openings on roof and building drains where they leave building. Introduce air into piping system equal to pressure of 1-inch wg (250 Pa). Use U-tube or manometer inserted in trap of water closet to measure this pressure. Air pressure must remain constant without introducing additional air throughout period of inspection. Inspect plumbing fixture connections for gas and water leaks. 5. Repair leaks and defects with new materials and retest piping, or portion thereof, until satisfactory results are obtained. 6. Prepare reports for tests and required corrective action. 3.9 CLEANING AND PROTECTION A. Clean interior of piping. Remove dirt and debris as work progresses. B. Protect drains during remainder of construction period to avoid clogging with dirt and debris and to prevent damage from traffic and construction work. C. Place plugs in ends of uncompleted piping at end of day and when work stops. D. Exposed PVC Piping: Protect plumbing vents exposed to sunlight with two coats of water- based latex paint. 3.10 PIPING SCHEDULE A. Refer to drawings for pipe material requirements. END OF SECTION Project No. 18088080 1 Section 22 45 17 Lake Lewisville WTP Dewatering Improvements Emergency Eye/Face Wash and Shower Equipment SECTION 22 45 17 - EMERGENCY EYE/FACE WASH AND SHOWER EQUIPMENT PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Emergency shower and eyewash. B. Related sections: 1. Division 22 - Plumbing. 2. Section 26 05 00 - Common Work Results for Electrical. 1.2 REFERENCES A. American National Standards Institute (ANSI): 1. Z358.1 - Emergency Eyewash and Shower Equipment. 2. Z535.1 - Safety Color. B. American Society of Mechanical Engineers (ASME). C. National Electrical Manufacturers Association (NEMA). D. National Fire Protection Association (NFPA). E. Occupational Safety and Health Administration (OSHA). F. Underwriters Laboratories, Inc. (UL). 1.3 SUBMITTALS A. Shop drawings. B. Product Data: 1. Submit manufacturer's product literature information for products specified. 2. Manufacturer's Installation Instructions. C. Operation and Maintenance Data. D. Warranty. 1.4 QUALITY ASSURANCE A. Manufacturer qualifications: Show evidence that the firm has been engaged in producing such materials and products for at least 5 years and that the product submitted has a satisfactory performance record of at least 5 years. B. Installer qualifications: Installer shall have 3 years experience in installing these materials for similar projects and shall be approved by the manufacturer prior to bidding of the project. C. Regulatory requirements: 1. As applicable, equipment of this Section shall comply with requirements of public agencies of the state where the project is located including ASME, NFPA, OSHA, UL. Project No. 18088080 2 Section 22 45 17 Lake Lewisville WTP Dewatering Improvements Emergency Eye/Face Wash and Shower Equipment 1.5 DELIVERY, STORAGE, AND HANDLING A. Packing and shipping: Deliver to the job site in manufacturer's original containers. B. Delivery: After wet operations in building are completed. C. Storage and protection: 1. Store materials in original, unopened containers in compliance with manufacturer's printed instructions. 2. Keep materials dry until ready for use. 3. Keep packages of material off the ground, under cover, and away from sweating walls and other damp surfaces. 4. Protect finished surfaces from soiling and damage during handling and installation. Keep covered with a protective covering. PART 2 - PRODUCTS 2.1 EMERGENCY SHOWERS AND EYE/FACE WASHES A. General design requirements: 1. Combination unit emergency shower with eye/face wash: a. Floor mounted fixture consisting of pipe standard, showerhead assembly, and eyewash assembly. b. Provide stanchion and floor flange, with interconnecting piping. c. Provide shower/eyewash unit with integral controls to alarm the system is in use. 1). Flow switch: a). Construction: (1) NEMA Type 4. (2) Brass or Type 316 Stainless Steel. b). Type: Paddle switch or similar displacement technology. c). Alarm Contacts: Double pole, double throw contacts rated at 2.0 Amps at 120VAC configurable for either Normally Open or Normally Closed. 2. Showerhead flow: 20.0 gallons per minute flow, minimum. 3. Eye/face wash flow: 3.0 gallons per minute flow, minimum. 4. Meet or exceed all requirements of ANSI Z358.1. 5. Provide ANSI compliant identification sign and markings. B. Combination unit emergency shower and eye/face wash: 1. Manufacturers: One of the following: a. Haws, Model No. 8309. b. Guardian Equipment, Model No. G1950HFC. c. Bradley, Model No. S19-310AC. 2. Pipe standard: a. 1-1/4-inch hot-dip galvanized steel pipe, and fittings with interconnecting piping, stanchion, and 9-inch diameter floor flange. b. Corrosion protection: Provide Haws “-CRP” or Guardian Equipment “-EC” epoxy protective coating in corrosive environments. 3. Shower head: a. Material and size: ABS plastic, 10-inch diameter. b. Valve and actuator: Stay open chrome plated brass ball valve equipped with stainless steel ball and stem operated by a rigid stainless steel pull rod. 4. Eye/face wash receptor: a. Valve and actuator: Stay open chrome plated brass ball valve with stainless steel ball and stem operated by a stainless steel or epoxy coated aluminum push handle and foot treadle. Project No. 18088080 3 Section 22 45 17 Lake Lewisville WTP Dewatering Improvements Emergency Eye/Face Wash and Shower Equipment b. Spray head(s): ABS plastic or polypropylene eye/face wash type heads, with integral flip top protective dust covers releasing with water pressure. c. Receptor bowl: Stainless steel; 11 inches diameter. 5. Supply: 1-1/4 inch Industrial Piping Systems (IPS). 6. Waste: 1-1/4 inch IPS. C. Safety shower tester: 1. Manufacturers: One of the following: a. Haws, Model No. 9010 with No. 9009. b. Guardian Equipment, Model No. AP250-005. c. Bradley, Model No. S19-330ST. 2. Kit includes: a. Minimum 5-gallon plastic bucket. b. 7 foot long watertight 12-gallon translucent vinyl plastic bag for attaching over drench showerhead. 1). Bag shall have drawstring at top and be hemmed at bottom. c. Testing record card. D. Safety shower tepid water mixing valves: 1. Manufacturers: One of the following: a. Haws, Model No. 9201 Series. b. Guardian Equipment, Model No. G3800 Series. 2. General requirements: a. Provide 1 mixing valve for each safety shower unit or group of safety shower units mounted within 100 feet of each other. 3. Tepid water system to provide a minimum of 20 gallons per minute for shower and 3 gallons per minute for eye/face wash of water for a period of at least 15 minutes at a delivery temperature of 80 to 85 degrees Fahrenheit. PART 3 - EXECUTION 3.1 INSTALLATION A. Install products in accordance with manufacturers' recommendations. B. Install fixed equipment in accordance with manufacturer's instructions. C. Plumbing and mechanical work as specified in Division 22. D. Electrical connections and distribution as specified in Section 26 05 00. E. Insulate hot water piping. 3.2 PROTECTION A. Repair or replace defective equipment with new. END OF SECTION DIVISION 23 HVAC Project No. 18088080 1 Section 23 05 00 Lake Lewisville WTP Dewatering Improvements Mechanical General SECTION 23 05 00 - MECHANICAL GENERAL PART 1 - GENERAL 1.1 RELATED DOCUMENTS: A. The "General Conditions", "Supplementary Conditions", Statutory Declarations, Special Conditions and Division 01 of the specifications as written and referred to are adopted and made part of Division 23. 1.2 DESCRIPTION OF WORK: A. Provide equipment, labor, material, etc., required to make a complete working installation as shown or as specified. B. Equipment and materials used in the work shall be: 1. In accordance with the contract documents. 2. The best quality and grade for the use intended. 3. New and unused. 4. The manufacturer's latest standard or current model. C. All equipment and method shall be installed and connected in accordance with the best engineering practices and in accordance with the manufacturer's recommendations. D. Mechanical work includes, but is not limited to: 1. Make arrangements with local utility company for services as shown or specified. 2. Obtain all permits and inspections including: Building permits and health department permits. 3. Disconnect, remove and re-install mechanical services located on or crossing through contract limits, above or below grade, obstructing construction of project or conflicting with completed project or any applicable codes. 4. Modify, extend or tie-into existing mechanical services or systems. 5. Complete insulation on piping, ductwork and equipment. 6. Complete the refrigerant piping system. 7. Complete the Condensing units. 8. Complete the air handling systems and ventilating systems. 9. Complete the ductwork. 10. Complete the casing and plenums. 11. Install devices furnished by the Temperature Controls sub-contractor. 12. Testing and Balancing will be by an independent agency paid for by this contractor. 13. Provide vibration isolation devices for all rotating or reciprocating equipment and piping connected to that equipment. 14. Provide roofing including flashing, and counter flashing for roof mounted equipment; roof penetrations and supports for work in this Division, unless noted otherwise. 1.3 UTILITY CONNECTIONS: A. Arrange with local utility companies for utility service connections, taps, meters and installation. Pay all fees and charges (if any) necessary for the utility services shown on the drawings or listed in the specifications. B. It is the responsibility of the Contractor to re-confirm with the Utility Companies, prior to bidding, that locations, arrangements, line sizes, pressures, interruptions, shut downs, etc. are in accordance with their regulations and requirements. Project No. 18088080 2 Section 23 05 00 Lake Lewisville WTP Dewatering Improvements Mechanical General C. If the utility company requirements are at variance with these drawings and specifications, this Contractor shall include the utility company requirements in his work without additional cost to the Owner. D. Obtain from Utility Company any additional charges for service of type, size and location called for. Include charges in bid to be paid by Contractor to appropriate party. Provide payment of these charges so as to allow logical progression of construction and avoid delay of completion. E. Should cost above not be available prior to bid, submit with bid a letter signed by responsible Utility Company personnel stating that cost is not available. Prime Contractor shall submit letter with his bid to Owner. Cost will then be omitted from contract and become responsibility of Owner. F. Furnish with shop drawings a signed document from each utility company describing location and type of service to be supplied and requirements for service. Document shall be signed by the appropriate responsible representative of the respective utility company. 1.4 WORK NOT INCLUDED: A. Electrical wiring and conduits shown on the electrical drawings. B. Asbestos removal. 1.5 RELATED WORK SPECIFIED ELSEWHERE: A. Electrical: Division 26. 1.6 REQUIREMENTS OF REGULATORY AGENCIES: A. Obtain and pay for all permits required for the work. Comply with all ordinances pertaining to work described herein. B. Install the work under this Division in accordance with drawings and specifications and the standards and codes (latest edition) that apply to this work. In the event of a conflict, install work in accordance with the most stringent code requirements determined by Engineer. C. Arrange, pay for and complete work to pass required tests by agencies having authority over work. Deliver to Engineer Certificates of Inspection and approval issued by authorities. 1.7 QUALIFICATION OF CONTRACTOR: A. Has completed minimum two projects same size and scope in past five (5) years. B. This qualification applies to Sub-Contractors. C. Use workmen experienced in their respective trade. Submit qualifications of Superintendent for review. D. Owner reserves right to reject bid of any Contractor failing to meet these qualifications. 1.8 GENERAL JOB REQUIREMENTS: A. Drawings and Specifications: 1. Drawings and specifications are complementary. Work called for by one is binding as if called for by both. Project No. 18088080 3 Section 23 05 00 Lake Lewisville WTP Dewatering Improvements Mechanical General 2. Drawings are drawn to a small scale and are diagrammatic only. The drawings indicate size and general arrangement of equipment. 3. Do not scale drawings for exact locations. Refer to dimensional plans. Field measurements take precedence. B. Provide all necessary offsets, elbows and fittings in ductwork and piping as required to avoid conflict with work of other trades. Maintain proper headroom and clear passageways to allow adequate access and working clearances for equipment dampers, valves, etc. This shall be done at no additional cost to the Owner. C. Visit to Site/Work in other Division: 1. Examine not only the plans and specifications for this Division, but plans and specifications of the other Divisions of work and visit the site to become acquainted with existing conditions. Execution of Contract is evidence that Contractor has examined all drawings and specifications, and that all conditions which have a bearing in any way on the manner of installing the work in this Division are known. Later claims for labor and materials required due to difficulties encountered will not be recognized. D. Underground Utilities/Concealed Utilities: 1. All utilities and services, whether shown on the drawings or not, shall be suitably protected and maintained, and any damages thereto shall be promptly repaired. Owner shall be advised immediately of any damages sustained. If any extra expense is incurred due to the existence of buried utilities not shown on the drawings, or the location of which is not made known to the Contractor, the contract price shall be adjusted in accordance with the General Conditions. The Contractor shall advise the Owner three (3) days in advance of any operation which could possibly disrupt any underground utility. The Contractor shall utilize locator services to mark any underground utilities in the area he is working in, and shall make any other measure deemed necessary to avoid utility disruption. E. Definitions: 1. Concealed: Materials or systems not visible. Work installed above a ceiling, furred behind a wall or enclosed in a chase. 2. Exposed: Materials or systems that is visible. Work installed in a room without a ceiling. Work not enclosed by walls. 3. Provide: Furnish, install and make complete. 4. Install: Receive, unload, move into place, and make connections. 5. Work: Materials completely installed and connected. 6. ADC: Air Diffusion Council. 7. AGA: American Gas Association. 8. AMCA: Air Movement and Control Association. 9. ANSI: American National Standard Institute. 10. API: American Petroleum Institute. 11. ARI: American Refrigeration Institute. 12. ASHRAE: American Society of Heating, Refrigerating and Air Conditioning Engineers. 13. ASME: American Society of Mechanical Engineers. 14. ASTM: American Society of Testing Materials. 15. AWS: American Welding Society. 16. FM: Association of Factory Mutual Fire Insurance Company. 17. MSS: Manufacturer's Standard Society of the Valve and Fittings Industry, Inc. 18. NEC: National Electrical Code. 19. NEMA: National Electrical Manufacturer's Association. 20. NFPA: National Fire Protection Association. 21. NRCA: National Roofing Contractors Association. 22. NSF: National Sanitation Foundation. 23. OSHA: Occupational Safety and Health Act. Project No. 18088080 4 Section 23 05 00 Lake Lewisville WTP Dewatering Improvements Mechanical General 24. PDI: Plumbing Drainage Institute. 25. PFMA: Power Fan Manufactures Association. 26. SMACNA: Sheet Metal and Air Conditioning Contractors National Association. 27. International: Building Code, Gas Code, Mechanical Code, Plumbing Code. 28. UL: Underwriters Laboratories. F. Workmanship, Warranty and Acceptance: 1. Work under this Division shall be first class with emphasis on neatness and workmanship. 2. Install work using competent mechanics, under supervision of foreman, all duly certified by local authorities. Installation subject to Engineer's observation, final approval, and acceptance. Engineer may reject unsuitable work. 3. Furnish Engineer written warranty, stating that if workmanship and/or materials executed under this Division are proven defective within two (2) years after final acceptance, such defects and other work damaged will be repaired and/or replaced. 4. In event that project is occupied or system placed in operation in several phases at Owner's request, warranty will begin on date each system or item of equipment is accepted by Owner. G. Observations of Work and Demonstration of Operation: 1. When observations are scheduled, provide sufficient personnel to expedite removal of access doors, cover plates, manholes covers, etc. 2. Contractor to assist Engineer in demonstration of operation of new systems to satisfaction of Owner. Contractor to have manpower available for demonstration of systems where requested by Owner. H. Materials and Substitutions: 1. All materials shall be new. All materials and equipment, for which a UL Standard, an AGA approval, an AWWA standard, FM listing or ASME requirements is established, shall be so approved and labeled or stamped. 2. Wherever in these specifications products are specified by manufacturer's name, bids shall be based on the named products. Where more than one manufacturer's name is mentioned, the one first listed establishes the standard for that product. If the bidder desires to submit a product of a manufacturer other that listed first, it must be the equivalent of the one listed first. 3. The drawings are based on the use of products specified and listed first. If any revision in piping, ductwork, conduit work, foundations, anchor bolts, connections, etc., is required by other named products or approved substitutions, it shall be the Contractor's responsibility to make such revisions at no additional expense to the Owner. 4. If any bidder desires to submit products of manufacturers not listed, he may submit a request for prior approval to the Engineer no later than 10 days prior to the bid date. If the Engineer decides to accept the manufacturers, they will be listed as "Approved" by written addendum. 5. If the manufacturers are not listed as approved either by addendum or in the specifications, they will not be accepted. I. Shop and Erection Drawings: 1. Submit complete shop drawings for all materials and equipment furnished under Division 23 of specifications. Shop drawings shall be submitted on a timely basis to allow adequate lead time for review, resubmission if necessary, manufacture and delivery to allow access of material to project at correct time based on schedule established by Engineer/Contractor. On each shop drawing include the specification section that applies to that submittal. Include complete descriptive data with dimensions, operating data and weight for each item of equipment. Carefully examine shop drawings to assure compliance with drawings and specifications prior to submittal to Engineer. Shop Project No. 18088080 5 Section 23 05 00 Lake Lewisville WTP Dewatering Improvements Mechanical General drawings and submittals shall bear the stamp of approval of the Contractor as evidence that the drawings have been checked by him. Drawing submitted without this stamp of approval will not be considered and will be returned for proper resubmission. 2. Review of shop drawings does not relieve Contractor of responsibility for errors and omissions in shop drawings. Contractor’s responsible for meeting the requirements of the contract documents. 3. Contractor is responsible for dimensions and sizes of equipment. Inform Engineer in writing of equipment differing from that shown. 4. Prepare erection drawings when required by Engineer. Investigate thoroughly all conditions affecting work and indicate on drawing. Engineer will review erection drawings before work commences. J. Operating and Maintenance Manuals: 1. Provide maintenance and operating manuals bound in 8-1/2" x 11" hardback, three-post binders. Manuals shall contain written instructions for each system, shop drawings, schematic drawings, equipment catalog cuts, manufacturer's instructions, manufacturer’s warranties, and valve tag list. 2. Arrange information in the following sequence: title of job, Owner, address, date of submittal, name of Contractor, name of Engineer, index, shop drawings, operating instruction, Contractor's purchase order numbers, supplier's name and address, date of start-up of each piece of equipment and valve tag list. 3. Submit for review and record as required by 01 78 23. K. Record Drawings: 1. Contractor shall maintain at the site one (1) copy of the drawings in good order and marked to record all changes made during construction. 1.9 PROTECTION AND STORAGE: A. Provide warning lights, bracing, shoring, rails, guards and covers necessary to prevent damage or injury. B. Protect all equipment and materials, from damage by weather, entrance of water or dirt. Cap open piping, use plastic covers made for that purpose. Do not use rags or construction debris. C. Avoid damage to materials and equipment in place. Repair, or remove and replace damaged work and materials. D. Protect all surfaces from weld spatter, solder and cutting oil. E. Deliver equipment and materials to job site in original, unopened, labeled container. Store to prevent damage and injury. Store ferrous materials to prevent rusting. Store finished materials and equipment to prevent staining and discoloring. Store materials affected by condensation in warm dry areas. Provide heaters. Storage space on site and in building designated by Owner/Engineer. END OF SECTION Project No. 18088080 1 Section 23 05 17 Lake Lewisville WTP Dewatering Improvements Common Work Results for Mechanical SECTION 23 05 17 - COMMON WORK RESULTS FOR MECHANICAL PART 1 - GENERAL 1.1 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. Mechanical sleeve seals. 5. Sleeves. 6. Escutcheons. 7. Grout. 8. Equipment installation requirements common to equipment sections. 9. Painting and finishing. 10. Concrete bases. 11. Supports and anchorages. 1.2 DEFINITIONS A. Finished Spaces: Spaces other than mechanical and electrical equipment rooms, furred spaces, pipe and duct chases, 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 chases. 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. PE: Polyethylene plastic. 2. PVC: Polyvinyl chloride plastic. G. The following are industry abbreviations for rubber materials: 1. EPDM: Ethylene-propylene-diene terpolymer rubber. 2. NBR: Acrylonitrile-butadiene rubber. 1.3 SUBMITTALS A. Product Data: For the following: 1. Transition fittings. 2. Dielectric fittings. 3. Mechanical sleeve seals. 4. Escutcheons. B. Welding certificates. Project No. 18088080 2 Section 23 05 17 Lake Lewisville WTP Dewatering Improvements Common Work Results for Mechanical 1.4 QUALITY ASSURANCE A. Steel Support Welding: Qualify processes and operators according to AWS D1.1, "Structural Welding Code--Steel." B. Electrical Characteristics for mechanical Equipment: Equipment of higher electrical characteristics may be furnished provided such proposed equipment is approved in writing and connecting electrical services, circuit breakers, and conduit sizes are appropriately modified. If minimum energy ratings or efficiencies are specified, equipment shall comply with requirements. 1.5 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. 1.6 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. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection: 1. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified. 2.2 PIPE, TUBE, AND FITTINGS A. Refer to individual Division 40 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. 2.3 JOINING MATERIALS A. Refer to individual Division 33 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, nonmetallic, flat, asbestos-free, 1/8-inch 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 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. Project No. 18088080 3 Section 23 05 17 Lake Lewisville WTP Dewatering Improvements Common Work Results for Mechanical D. Solder Filler Metals: ASTM B 32, lead-free alloys. Include water-flushable flux according to ASTM B 813. 2.4 TRANSITION FITTINGS A. Plastic-to-Metal Transition Adaptors: One-piece fitting with manufacturer's SDR 11 equivalent dimensions; one end with threaded brass insert, and one solvent-cement-joint end. B. Plastic-to-Metal Transition Unions: MSS SP-107, Four-part union. Include brass end, solvent- cement-joint end, rubber O-ring, and union nut. 2.5 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. B. Insulating Material: Suitable for system fluid, pressure, and temperature. C. Dielectric Unions: Factory-fabricated, union assembly, for 250-psig minimum working pressure at 180 deg F. 1. Manufacturers: a. Capitol Manufacturing Co. b. Central Plastics Company. c. Eclipse, Inc. d. Epco Sales, Inc. e. Hart Industries, International, Inc. f. Watts Industries, Inc.; Water Products Div. g. Zurn Industries, Inc.; Wilkins Div. D. Dielectric Flanges: Factory-fabricated, companion-flange assembly, for 150- or 300-psig 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 minimum working pressure where required to suit system pressures. F. Dielectric Couplings: Galvanized-steel coupling with inert and noncorrosive, thermoplastic lining; threaded ends; and 300-psig minimum working pressure at 225 deg F. 1. Manufacturers: a. Calpico, Inc. b. Lochinvar Corp. Project No. 18088080 4 Section 23 05 17 Lake Lewisville WTP Dewatering Improvements Common Work Results for Mechanical G. Dielectric Nipples: Electroplated steel nipple with inert and noncorrosive, thermoplastic lining; plain, threaded, or grooved ends; and 300-psig minimum working pressure at 225 deg F. 1. Manufacturers: a. Perfection Corp. b. Precision Plumbing Products, Inc. c. Sioux Chief Manufacturing Co., Inc. d. Victaulic Co. of America. 2.6 MECHANICAL SLEEVE SEALS A. Description: Modular sealing element unit, designed for field assembly, to fill annular space between pipe and sleeve. 1. Manufacturers: a. PSI – Thunderline / Link-Seal® 2. Sealing Elements: EPDM or NBR interlocking links shaped to fit surface of pipe. Provide silicone (ASTM D 2000 MI GE505) for fire seal applications. Include type and number required for pipe material and size of pipe. 3. Pressure Plates: Reinforced nylon polymer. Include two for each sealing element. 4. Connecting Bolts and Nuts: Stainless steel of length required to secure pressure plates to sealing elements. Include one for each sealing element. 2.7 SLEEVES A. Galvanized-Steel Sheet: 0.0239-inch minimum thickness; round tube closed with welded longitudinal joint. B. Steel Pipe: ASTM A 53, 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. 2.8 ESCUTCHEONS A. Description: Manufactured wall and ceiling escutcheons and floor plates, with an ID to closely fit around pipe, tube, and insulation of insulated piping and an OD that completely covers opening. B. One-Piece, Deep-Pattern Type: Deep-drawn, box-shaped brass with polished chrome-plated finish. C. One-Piece, Cast-Brass Type: With set screw. 1. Finish: Polished chrome-plated D. Split-Casting, Cast-Brass Type: With concealed hinge and set screw. 1. Finish: Polished chrome-plated E. One-Piece, Floor-Plate Type: Cast-iron floor plate. F. Split-Casting, Floor-Plate Type: Cast brass with concealed hinge and set screw. Project No. 18088080 5 Section 23 05 17 Lake Lewisville WTP Dewatering Improvements Common Work Results for Mechanical 2.9 GROUT A. Description: ASTM C 1107, Grade B, nonshrink and nonmetallic, dry hydraulic-cement grout. 1. Characteristics: Post-hardening, volume-adjusting, nonstaining, noncorrosive, nongaseous, and recommended for interior and exterior applications. 2. Design Mix: 5000-psi, 28-day compressive strength. 3. Packaging: Premixed and factory packaged. PART 3 - EXECUTION 3.1 PIPING SYSTEMS - COMMON REQUIREMENTS A. Install piping according to the following requirements and Division 33 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 to allow application of insulation. K. Select system components with pressure rating equal to or greater than system operating pressure. L. Install escutcheons for penetrations of walls, ceilings, and floors according to the following: 1. New Piping: a. Piping with Fitting or Sleeve Protruding from Wall: One-piece, deep-pattern type. b. Chrome-Plated Piping: One-piece, cast-brass type with polished chrome-plated finish. c. Insulated Piping: One-piece, stamped-steel type with spring clips. d. Bare Piping at Wall and Floor Penetrations: One-piece, cast-brass type with polished chrome-plated finish. e. Bare Piping at Wall and Floor Penetrations: One-piece, stamped-steel type. f. Bare Piping at Ceiling Penetrations: One-piece cast-brass type with polished chrome-plated finish. g. Bare Piping in Equipment Rooms: One-piece, cast-brass type. h. Bare Piping at Floor Penetrations in Equipment Rooms: One-piece, floor-plate type. Project No. 18088080 6 Section 23 05 17 Lake Lewisville WTP Dewatering Improvements Common Work Results for Mechanical M. Install sleeves for pipes passing through concrete and masonry walls 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 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 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. b. Steel Sheet Sleeves: For pipes NPS 6 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 above finished floor level. Refer to Division 7 Section "Sheet Metal Flashing and Trim" 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 7 Section "Joint Sealers" for materials and installation. N. Aboveground, Exterior-Wall Pipe Penetrations: Seal penetrations using sleeves and weatherproof sealant. Select sleeve size to allow proper clear space between pipe and sleeve for. 1. Install steel pipe for sleeves smaller than 6 inches in diameter. 2. Install cast-iron "wall pipes" for sleeves 6 inches and larger in diameter. 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 annular clear space between pipe and sleeve for installing mechanical sleeve seals. 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. Verify final equipment locations for roughing-in. Q. Refer to equipment specifications in other Sections of these Specifications for roughing-in requirements. 3.2 PIPING JOINT CONSTRUCTION A. Join pipe and fittings according to the following requirements and Division 33 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 B 813, water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B 828 or CDA's "Copper Tube Handbook," using lead- free solder alloy complying with ASTM B 32. Project No. 18088080 7 Section 23 05 17 Lake Lewisville WTP Dewatering Improvements Common Work Results for Mechanical E. 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. F. Flanged Joints: Select appropriate gasket material, size, type, and thickness for service application. Install gasket concentrically positioned. Use suitable lubricants on bolt threads. 3.3 PIPING CONNECTIONS A. Make connections according to the following, unless otherwise indicated: 1. Install unions, in piping NPS 2 and smaller, adjacent to each valve and at final connection to each piece of equipment. 2. Install flanges, in piping NPS 2-1/2 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. 3.4 EQUIPMENT INSTALLATION - COMMON REQUIREMENTS A. Install equipment to allow maximum possible headroom unless specific mounting heights are not 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. 3.5 CONCRETE BASES A. Concrete Bases: Anchor equipment to concrete base according to equipment manufacturer's written instructions and according to seismic codes at Project. 1. Construct concrete bases of dimensions indicated, but not less than 4 inches larger in both directions than supported unit. 2. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated, install dowel rods on 18-inch centers around the full perimeter of the base. 3. Install epoxy-coated anchor bolts for supported equipment that extend through concrete base, and anchor into structural concrete floor. 4. Place and secure anchorage devices. Use supported equipment manufacturer's setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded. 5. Install anchor bolts to elevations required for proper attachment to supported equipment. 6. Install anchor bolts according to anchor-bolt manufacturer's written instructions. 7. Use 3000-psi 28-day compressive-strength concrete and reinforcement as specified in Division 3. Project No. 18088080 8 Section 23 05 17 Lake Lewisville WTP Dewatering Improvements Common Work Results for Mechanical 3.6 GROUTING A. Mix and install grout for mechanical equipment base bearing surfaces, pump and other equipment base plates, and anchors. B. Clean surfaces that will come into contact with grout. C. Provide forms as required for placement of grout. D. Avoid air entrapment during placement of grout. E. Place grout, completely filling equipment bases. F. Place grout on concrete bases and provide smooth bearing surface for equipment. G. Place grout around anchors. H. Cure placed grout. END OF SECTION Project No. 18088080 1 Section 23 05 29 Lake Lewisville WTP Dewatering Improvements Hangers and Supports for Mech. Piping & Equipment SECTION 23 05 29 - HANGERS AND SUPPORTS FOR MECHANICAL PIPING AND EQUIPMENT PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following hangers and supports for Mechanical system piping and equipment: 1. Steel pipe hangers and supports. 2. Trapeze pipe hangers. 1.2 DEFINITIONS A. MSS: Manufacturers Standardization Society for The Valve and Fittings Industry Inc. B. Terminology: As defined in MSS SP-90, "Guidelines on Terminology for Pipe Hangers and Supports." 1.3 SUBMITTALS A. Product Data: For the following: 1. Steel pipe hangers and supports. 1.4 QUALITY ASSURANCE A. Welding: Qualify procedures and personnel according to AWS D1.1, "Structural Welding Code-- Steel." PART 2 - PRODUCTS 2.1 STEEL PIPE HANGERS AND SUPPORTS A. Description: MSS SP-58, Types 1 through 58, factory-fabricated components. Refer to Part 3 "Hanger and Support Applications" Article for where to use specific hanger and support types. B. Galvanized, Metallic Coatings: Pre-galvanized or hot dipped. 2.2 TRAPEZE PIPE HANGERS A. Description: MSS SP-69, Type 59, shop- or field-fabricated pipe-support assembly made from structural-steel shapes with MSS SP-58 hanger rods, nuts, saddles, and U-bolts. 2.3 MISCELLANEOUS MATERIALS A. Structural Steel: ASTM A 36/A 36M, steel plates, shapes, and bars; black and galvanized. B. Grout: ASTM C 1107, factory-mixed and packaged, dry, hydraulic-cement, non-shrink and nonmetallic grout; suitable for interior and exterior applications. 1. Properties: Non-staining, noncorrosive, and nongaseous. 2. Design Mix: 5000-psi, 28-day compressive strength. PART 3 - EXECUTION 3.1 HANGER AND SUPPORT APPLICATIONS Project No. 18088080 2 Section 23 05 29 Lake Lewisville WTP Dewatering Improvements Hangers and Supports for Mech. Piping & Equipment A. Specific hanger and support requirements are specified in Sections specifying piping systems and equipment. B. Comply with MSS SP-69 for pipe hanger selections and applications that are not specified in piping system Sections. C. Use hangers and supports with galvanized, metallic coatings for piping and equipment that will not have field-applied finish. D. Use nonmetallic coatings on attachments for electrolytic protection where attachments are in direct contact with copper tubing. E. Use padded hangers for piping that is subject to scratching. F. Horizontal-Piping Hangers and Supports: Unless otherwise indicated and except as specified in piping system Sections, install the following types: 1. Adjustable, Steel Clevis Hangers (MSS Type 1): For suspension of non-insulated or insulated stationary pipes, NPS 1/2 to NPS 30. 2. Adjustable, Pipe Saddle Supports (MSS Type 38): For stanchion-type support for pipes, NPS 2-1/2 to NPS 36, if vertical adjustment is required, with steel pipe base stanchion support and cast-iron floor flange. G. Vertical-Piping Clamps: Unless otherwise indicated and except as specified in piping system Sections, install the following types: 1. Carbon or Alloy-Steel Riser Clamps (MSS Type 42): For support of pipe risers, NPS 3/4 to NPS 20, if longer ends are required for riser clamps. H. Hanger-Rod Attachments: Unless otherwise indicated and except as specified in piping system Sections, install the following types: 1. Steel Turnbuckles (MSS Type 13): For adjustment up to 6 inches for heavy loads. I. Building Attachments: Unless otherwise indicated and except as specified in piping system Sections, install the following types: 1. Top-Beam C-Clamps (MSS Type 19): For use under roof installations with bar-joist construction to attach to top flange of structural shape. 2. Side-Beam or Channel Clamps (MSS Type 20): For attaching to bottom flange of beams, channels, or angles. 3. Center-Beam Clamps (MSS Type 21): For attaching to center of bottom flange of beams. 4. C-Clamps (MSS Type 23): For structural shapes. J. Saddles and Shields: Unless otherwise indicated and except as specified in piping system Sections, install the following types: 1. Protection Shields (MSS Type 40): Of length recommended in writing by manufacturer to prevent crushing insulation. K. Comply with MSS SP-69 for trapeze pipe hanger selections and applications that are not specified in piping system Sections. L. Comply with MFMA-102 for metal framing system selections and applications that are not specified in piping system Sections. M. Use powder-actuated fasteners or mechanical-expansion anchors instead of building attachments where required in concrete construction. Project No. 18088080 3 Section 23 05 29 Lake Lewisville WTP Dewatering Improvements Hangers and Supports for Mech. Piping & Equipment 3.2 HANGER AND SUPPORT INSTALLATION A. Steel Pipe Hanger 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. Trapeze Pipe Hanger Installation: Comply with MSS SP-69 and MSS SP-89. Arrange for grouping of parallel runs of horizontal piping and support together on field-fabricated trapeze pipe hangers. 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 A 36/A 36M, steel shapes selected for loads being supported. Weld steel according to AWS D1.1. C. Metal Framing System Installation: Arrange for grouping of parallel runs of piping and support together on field-assembled metal framing systems. D. Pipe Stand Installation: 1. Pipe Stand Types except Curb-Mounting Type: Assemble components and mount on smooth roof surface. Do not penetrate roof membrane. E. Fabricate from welded-structural-steel shapes. F. 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. G. Install lateral bracing with pipe hangers and supports to prevent swaying. H. Load Distribution: Install hangers and supports so 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 B31.1 (for power piping) and ASME B31.9 (for building services piping) are not exceeded. J. Insulated Piping: Comply with the following: 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 B31.1 for power piping and ASME B31.9 for building services piping. 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. 3. Install MSS SP-58, Type 40, protective shields on cold piping with vapor barrier. Shields shall span an arc of 180 degrees. 4. Shield Dimensions for Pipe: Not less than the following: a. NPS 1/4 to NPS 3-1/2: 12 inches long and 0.048 inch thick. b. NPS 4: 12 inches long and 0.06 inch thick. 5. Insert Material: Length at least as long as protective shield. Project No. 18088080 4 Section 23 05 29 Lake Lewisville WTP Dewatering Improvements Hangers and Supports for Mech. Piping & Equipment 3.3 ADJUSTING A. Hanger Adjustments: Adjust hangers to distribute loads equally on attachments and to achieve indicated slope of pipe. B. Trim excess length of continuous-thread hanger and support rods to 1-1/2 inches. 3.4 PAINTING A. Touch 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 minimum dry film thickness of 2.0 mils. B. Touch Up: Cleaning and touchup painting of field welds, bolted connections, and abraded areas of shop paint on miscellaneous metal are specified in Division 09 painting Sections. C. Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply galvanizing-repair paint to comply with ASTM A 780. END OF SECTION Project No. 18088080 1 Section 23 05 53 Lake Lewisville WTP Dewatering Improvements Identification for HVAC Piping & Equipment SECTION 23 05 53 - IDENTIFICATION FOR HVAC PIPING AND EQUIPMENT PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Equipment labels. 2. Warning signs and labels. 3. Warning tags. 1.2 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 locations of access panels and doors. C. Install identifying devices before installing ceilings or other concealment. PART 2 - PRODUCTS 2.1 EQUIPMENT LABELS A. Metal Labels for Equipment: 1. Material and Thickness: Brass, 0.032-inch, Stainless steel, 0.025-inch, Aluminum, 0.032- inch, or anodized aluminum, 0.032-inch minimum thickness, and having predrilled or stamped holes for attachment hardware. 2. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch. 3. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering. 4. Fasteners: Stainless-steel rivets or self-tapping screws. 5. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate. B. Plastic Labels for Equipment: 1. Material and Thickness: Multilayer, multicolor, plastic labels for mechanical engraving, 1/8 inch thick, and having predrilled holes for attachment hardware. 2. Letter Color: White. 3. Background Color: Black. 4. Maximum Temperature: Able to withstand temperatures up to 160 deg F. 5. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch. 6. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering. 7. Fasteners: Stainless-steel rivets or self-tapping screws. 8. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate. C. Label Content: Include equipment's Drawing designation or unique equipment number, Drawing numbers where equipment is indicated (plans, details, and schedules). Project No. 18088080 2 Section 23 05 53 Lake Lewisville WTP Dewatering Improvements Identification for HVAC Piping & Equipment 2.2 WARNING SIGNS AND LABELS A. Material and Thickness: Multilayer, multicolor, plastic labels for mechanical engraving, 1/16 inch thick, and having predrilled holes for attachment hardware. B. Letter Color: Black. C. Background Color: Yellow. D. Maximum Temperature: Able to withstand temperatures up to 160 deg F. E. Minimum Label Size: Length and width vary for required label content, but not less than 2-1/2 by 3/4 inch. F. Minimum Letter Size: 1/4 inch for name of units if viewing distance is less than 24 inches, 1/2 inch for viewing distances up to 72 inches, and proportionately larger lettering for greater viewing distances. Include secondary lettering two-thirds to three-fourths the size of principal lettering. G. Fasteners: Stainless-steel rivets or self-tapping screws. H. Adhesive: Contact-type permanent adhesive, compatible with label and with substrate. I. Label Content: Include caution and warning information, plus emergency notification instructions. 2.3 WARNING TAGS A. Warning Tags: Preprinted or partially preprinted, accident-prevention tags, of plasticized card stock with matte finish suitable for writing. 1. Size: 3 by 5-1/4 inches minimum. 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. PART 3 - EXECUTION 3.1 PREPARATION A. Clean piping and equipment surfaces of substances that could impair bond of identification devices, including dirt, oil, grease, release agents, and incompatible primers, paints, and encapsulants. 3.2 EQUIPMENT LABEL INSTALLATION A. Install or permanently fasten labels on each major item of mechanical equipment. B. Locate equipment labels where accessible and visible. 3.3 WARNING-TAG INSTALLATION A. Write required message on, and attach warning tags to, equipment and other items where required. END OF SECTION Project No. 18088080 1 Section 23 05 93 Lake Lewisville WTP Dewatering Improvements Testing, Adjusting and Balancing SECTION 23 05 93 - TESTING, ADJUSTING, AND BALANCING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Balancing Air Systems: a. Ducted heating/cooling HVAC systems. b. Exhaust fans. 1.2 DEFINITIONS A. AABC: Associated Air Balance Council. B. NEBB: National Environmental Balancing Bureau. C. TAB: Testing, adjusting, and balancing. D. TABB: Testing, Adjusting, and Balancing Bureau. E. TAB Specialist: An entity engaged to perform TAB Work. 1.3 SUBMITTALS A. Certified TAB reports. 1.4 QUALITY ASSURANCE A. TAB Contractor Qualifications: Engage a TAB entity certified by AABC NEBB or TABB. B. TAB Report Forms: Use standard TAB contractor's forms approved by Owner. C. Instrumentation Type, Quantity, Accuracy, and Calibration: As described in ASHRAE 111, Section 5, "Instrumentation." 1.5 COORDINATION A. Perform TAB after leakage and pressure tests on air distribution systems have been satisfactorily completed. PART 2 - PRODUCTS (NOT APPLICABLE) PART 3 - EXECUTION 3.1 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. B. Examine systems for installed balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers. Verify that locations of these balancing devices are accessible. C. Examine the approved submittals for HVAC systems and equipment. Project No. 18088080 2 Section 23 05 93 Lake Lewisville WTP Dewatering Improvements Testing, Adjusting and Balancing 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. 1. 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. 2. Calculate system-effect factors to reduce performance ratings of HVAC equipment when installed under conditions different from the conditions used to rate equipment performance. To calculate system effects for air systems, use tables and charts found in AMCA 201, "Fans and Systems," or in SMACNA's "HVAC Systems - Duct Design." Compare results with the design data and installed conditions. F. Examine system and equipment installations and verify that field quality-control testing, cleaning, and adjusting specified in individual Sections have been performed. G. Examine test reports specified in individual system and equipment Sections. H. Examine HVAC equipment and filters and verify that bearings are greased, belts are aligned and tight, and equipment with functioning controls is ready for operation. I. Examine heat-transfer coils for correct piping connections and for clean and straight fins. J. Examine operating safety interlocks and controls on HVAC equipment. K. 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. 3.2 PREPARATION A. Prepare a TAB plan that includes strategies and step-by-step procedures. B. Complete system-readiness checks and prepare 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. Isolating and balancing valves are open and control valves are operational. 6. Ceilings are installed in critical areas where air-pattern adjustments are required and access to balancing devices is provided. 7. Windows and doors can be closed so indicated conditions for system operations can be met. 3.3 GENERAL PROCEDURES FOR TESTING AND BALANCING A. Perform testing and balancing procedures on each system according to the procedures contained in NEBB's "Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems" and in this Section. B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary for TAB procedures. 1. After testing and balancing, patch probe holes in ducts with same material and thickness as used to construct ducts. Project No. 18088080 3 Section 23 05 93 Lake Lewisville WTP Dewatering Improvements Testing, Adjusting and Balancing 2. Install and join new insulation that matches removed materials. Restore insulation, coverings, vapor barrier, and finish according to Division 23 Section "HVAC Insulation." C. Mark equipment and balancing devices, including damper-control positions, valve position indicators, fan-speed-control levers, and similar controls and devices, with paint or other suitable, permanent identification material to show final settings. D. Take and report testing and balancing measurements in inch-pound (IP) units. 3.4 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. Determine the best locations in main and branch ducts for accurate duct-airflow measurements. C. Check airflow patterns from the outdoor-air louvers and dampers and the return- and exhaust-air dampers through the supply-fan discharge and mixing dampers. D. Locate start-stop and disconnect switches, electrical interlocks, and motor starters. E. Verify that motor starters are equipped with properly sized thermal protection. F. Check dampers for proper position to achieve desired airflow path. G. Check for airflow blockages. H. Check condensate drains for proper connections and functioning. I. Check for proper sealing of air-handling-unit components. J. Verify that air duct system is sealed as specified in Division 23 Section 23 31 13 "Metal Ducts." 3.5 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 total airflow. a. Where sufficient space in ducts is unavailable for Pilot-tube traverse measurements, measure airflow at terminal outlets and inlets and calculate the total airflow. 2. Measure fan static pressures as follows to determine actual static pressure: a. Measure outlet static pressure as far downstream from the fan as practical 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 the 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. e. For non-ducted fans, install temporary duct at fan inlet. 3. Measure static pressure across each component that makes up an air-handling unit, rooftop unit, and other air-handling and treating equipment. a. Report the cleanliness status of filters and the time static pressures are measured. Project No. 18088080 4 Section 23 05 93 Lake Lewisville WTP Dewatering Improvements Testing, Adjusting and Balancing 4. Measure static pressures entering and leaving other devices, such as sound traps, heat- recovery equipment, and air washers, under final balanced conditions. 5. Review Record Documents to determine variations in design static pressures versus actual static pressures. Calculate actual system-effect factors. Recommend adjustments to accommodate actual conditions. 6. Obtain approval from Engineer for adjustment of fan speed higher or lower than indicated speed. Comply with requirements in Division 23 Sections for air-handling units for adjustment of fans, belts, and pulley sizes to achieve indicated air-handling-unit performance. 7. 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 mode 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 airflow of submain and branch ducts. 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. Measure static pressure at a point downstream from the balancing damper, and adjust volume dampers until the proper static pressure is achieved. 3. Re-measure 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 air 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 air outlets and inlets for each space to indicated airflows within specified tolerances of indicated values. Make adjustments using branch 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. 3.6 PROCEDURES FOR MOTORS A. Motors, 1/2 HP and Larger: Test at final balanced conditions and record the following data: 1. Manufacturer's name, model number, and serial number. 2. Motor horsepower rating. 3. Motor rpm. 4. Efficiency rating. 5. Nameplate and measured voltage, each phase. 6. Nameplate and measured amperage, each phase. 7. Starter thermal-protection-element rating. 3.7 PROCEDURES FOR CONDENSING UNITS A. Verify proper rotation of fans. B. Measure entering- and leaving-air temperatures. Project No. 18088080 5 Section 23 05 93 Lake Lewisville WTP Dewatering Improvements Testing, Adjusting and Balancing C. Record compressor electrical data. 3.8 TOLERANCES A. Set HVAC system's air flow rates within the following tolerances: 1. Supply, Return, and Exhaust Fans and Equipment with Fans: Plus or minus 5 percent. 2. Air Outlets and Inlets: Plus or minus 10 percent. 3.9 FINAL REPORT A. General: Prepare a certified written report; tabulate and divide the report into separate sections for tested systems and balanced systems. 1. Include a certification sheet at the front of the report's binder, signed and sealed by the certified testing and balancing engineer. 2. Include a list of instruments used for procedures, along with proof of calibration. B. Final Report Contents: In addition to certified field-report data, include the following: 1. Fan curves. 2. Manufacturers' test data. 3. Field test reports prepared by system and equipment installers. 4. Other information relative to equipment performance; do not include Shop Drawings and product data. C. General Report Data: In addition to form titles and entries, include the following data: 1. Title page. 2. Name and address of the TAB contractor. 3. Project name. 4. Project location. 5. Engineer's name and address. 6. Contractor's name and address. 7. Report date. 8. Signature of TAB supervisor who certifies the report. 9. Table of Contents with the total number of pages defined for each section of the report. Number each page in the report. 10. Summary of contents including the following: a. Indicated versus final performance. b. Notable characteristics of systems. c. Description of system operation sequence if it varies from the Contract Documents. 11. Nomenclature sheets for each item of equipment. 12. Data for terminal units, including manufacturer's name, type, size, and fittings. 13. Notes to explain why certain final data in the body of reports vary from indicated values. 14. Test conditions for fans performance forms including the following: a. Settings for outdoor, 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. D. Air-Handling-Unit Test Reports: For air-handling units with coils, include the following: 1. Unit Data: a. Unit identification. b. Location. c. Make and type. Project No. 18088080 6 Section 23 05 93 Lake Lewisville WTP Dewatering Improvements Testing, Adjusting and Balancing d. Model number and unit size. e. Manufacturer's serial number. f. Unit arrangement and class. g. Discharge arrangement. h. Sheave make, size in inches, and bore. i. Center-to-center dimensions of sheave, and amount of adjustments in inches. j. Number, make, and size of belts. k. Number, type, and size of filters. 2. Motor Data: a. Motor make, and frame type and size. b. Horsepower and rpm. c. Volts, phase, and hertz. d. Full-load amperage and service factor. e. Sheave make, size in inches, and bore. f. Center-to-center dimensions of sheave, and amount of adjustments in inches. 3. Test Data (Indicated and Actual Values): a. Total air flow rate in cfm. b. Total system static pressure in inches wg. c. Fan rpm. d. Discharge static pressure in inches wg. e. Filter static-pressure differential in inches wg. f. Preheat-coil static-pressure differential in inches wg. g. Cooling-coil static-pressure differential in inches wg. h. Heating-coil static-pressure differential in inches wg. i. Outdoor airflow in cfm. j. Return airflow in cfm. k. Outdoor-air damper position. l. Return-air damper position. m. Vortex damper position. E. Fan Test Reports: For supply, return, and exhaust fans, include the following: 1. Fan Data: a. System identification. b. Location. c. Make and type. d. Model number and size. e. Manufacturer's serial number. f. Arrangement and class. g. Sheave make, size in inches, and bore. h. Center-to-center dimensions of sheave, and amount of adjustments in inches. 2. Motor Data: a. Motor make, and frame type and size. b. Horsepower and rpm. c. Volts, phase, and hertz. d. Full-load amperage and service factor. e. Sheave make, size in inches, and bore. f. Center-to-center dimensions of sheave, and amount of adjustments in inches. g. Number, make, and size of belts. 3. Test Data (Indicated and Actual Values): a. Total airflow rate in cfm. b. Total system static pressure in inches wg. c. Fan rpm. d. Discharge static pressure in inches wg. e. Suction static pressure in inches wg. F. Instrument Calibration Reports: Project No. 18088080 7 Section 23 05 93 Lake Lewisville WTP Dewatering Improvements Testing, Adjusting and Balancing 1. Report Data: a. Instrument type and make. b. Serial number. c. Application. d. Dates of use. e. Dates of calibration. 3.10 INSPECTIONS A. Initial Inspection: 1. After testing and balancing are complete, operate each system and randomly check measurements to verify that the system is operating according to the final test and balance readings documented in the final report. 2. Check the following for each system: a. Measure airflow of at least 10 percent of air outlets. b. Measure room temperature at each thermostat/temperature sensor. Compare the reading to the set point. c. Verify that balancing devices are marked with final balance position. d. Note deviations from the Contract Documents in the final report. B. TAB Work will be considered defective if it does not pass inspections. If TAB Work fails, proceed as follows: 1. Recheck all measurements and make adjustments. Revise the final report and balancing device settings to include all changes; resubmit the final report and request a second final inspection. 2. If the second final inspection also fails, Owner may contract the services of another TAB contractor to complete TAB Work according to the Contract Documents and deduct the cost of the services from the original TAB contractor's final payment. C. Prepare test and inspection reports. END OF SECTION Project No. 18088080 1 Section 23 07 00 Lake Lewisville WTP Dewatering Improvements Duct Insulation SECTION 23 07 00 – DUCT INSULATION PART 1 - GENERAL 1.1 SUMMARY A. Section includes: furnishing all labor, equipment, materials and accessories, and performing all operations required, for the correct fabrication and installation of thermal or acoustic insulation applied to the following systems, piping, equipment, and ductwork. 1.2 DEFINITIONS A. Exposed piping and ductwork is that which can be seen when the building is complete without opening or removing access door panels, or ceilings tiles. This also includes all mechanical equipment rooms and pipe tunnels. B. Concealed piping and ductwork are those elements above ceilings, in chases, interstitial space and pipe spaces. Other piping and ductwork is considered to be exposed. C. Exterior piping and ductwork is that which is exposed to the weather and/or outside the building envelope. Piping and ductwork protected by overhangs, areaways, etc., exterior to the building envelope are considered exterior. D. ASJ: All service jacket, white finish facing or jacket. E. Air conditioned space: Space directly supplied with heated or cooled air. F. Cold: Equipment, ductwork or piping handling media at design temperature of 60 degrees F or below. G. FRK: Foil reinforced kraft facing. H. FSK: Foil-scrim-kraft facing. I. Hot: Ductwork handling air at design temperature above 60 degrees F; equipment or piping handling media above 105 degrees F. J. Pcf: Density, pounds per cubic foot. K. Run-out: Branch pipe connection up to one inch nominal size to a one terminal piece of equipment (fan coil, terminal box). L. Thermal conductance: Heat flow rate through materials. 1. Flat surface: BTU per hour per square foot. 2. Pipe or cylinder: BTU per hour per linear foot. 3. Thermal conductivity (k): BTU per inch thickness, per hour, per square foot, per degree Fahrenheit temperature difference. 1.3 QUALITY ASSURANCE A. Products of the manufacturers, herein, will be acceptable for use for the specific functions noted. All materials shall be compatible with the materials to which they are applied, and shall not corrode, soften or otherwise attack such materials in either the wet or dry state. Project No. 18088080 2 Section 23 07 00 Lake Lewisville WTP Dewatering Improvements Duct Insulation B. Materials shall be applied subject to their temperature limits. Any methods of application of insulation materials or finishes not specified in detail herein shall be in accordance with the particular manufacturer's published recommendations. C. Insulation shall be applied by experienced workers regularly employed for this type work. 1.4 RATING A. All insulation shall have composite surface burning characteristic rating as tested by ASTM E 84, UL 723, or NFPA 255 not exceeding: Flame Spread 25 Smoke Developed 50 B. Composite shall include insulation, jacketing and adhesive used to secure jacketing or facing. All accessory items such as PVC jacketing and fittings, adhesive, mastic, cement, tape and cloth shall have the same component rating as specified above. 1.5 STANDARDS A. ASHRAE Standard 90.1 - 2013 “Energy Standard for Buildings Except Low-Rise Residential Buildings”. B. Midwest Insulation Contractors Association “Commercial and Industrial Insulation Standards” - Third Edition. 1.6 SUBMITTALS A. Submittals shall include all materials used, including: 1. Insulation 2. Jacketing 3. Tapes 4. Hardware 5. Mastics 6. Adhesives B. Submittals shall be formatted to include a list of materials for each service C. Submittals shall use pages from Midwest Insulation Contractors Association – “Commercial and Industrial Insulation Standards” for defining how insulation materials will be applied. PART 2 - PRODUCTS 2.1 INSULATION A. Interior Ductwork (Insulation): 1. Unless otherwise noted, insulation shall be 250 deg. F rated as manufactured by Owens Corning, Manville, Knauf, or Certainteed. 2. Duct Wrap: 2 in. thick, 1.0 PCF with aluminum or FRK facing, having a maximum vapor transmission of .02 perms. Minimum installed "R" value shall be 5.6 with 25% compression. 3. Insulation Board: 2 in. thick 3 PCF with FRK facing. Minimum installed "R" value 6. 4. Commercial Duct-wrap: 2-1/2 in. thick 3 PCF semi-rigid, flexible board type with FRK facing. Minimum installed "R" value 6.0. Project No. 18088080 3 Section 23 07 00 Lake Lewisville WTP Dewatering Improvements Duct Insulation B. Exterior Ductwork (Insulation): 1. Insulation shall be rigid 2” thick polyisocyanurate. Minimum R-value = 11. a. Flame spread less than 25. b. Moisture Vapor Transmission less than 0.3 in accordance with ASTM E96. c. Compressive Strength Grade 3 in accordance with ASTM C1289. d. Water Absorption less than 1% by volume in accordance with ASTM C209. e. Service temperatures -100 degrees F to 250 degrees F. 2.2 FINISHES A. Metal jacketing, smooth .016 in. thick, type T 3003 aluminum with laminated moisture barrier. Jacketing shall be Childers, aluminum roll jacketing with Polykraft moisture barrier. Jacketing shall be embossed "No Asbestos" on a 6 inch spacing. B. Metal fitting covers shall be two-piece aluminum. Covers shall be Ell-Jac. C. Foil scrim kraft (FSK) jacket, flame retardant vapor barrier. Jacket shall be Alpha Temp 10651, all service jackets. 2.3 MISCELLANEOUS A. Adhesives: 1. Glass & Mineral Fiber - Foster 85-20 / Vimasco 795. 2. Polyurethane - Foster 81-33. 3. Polyisocyanurate - Foster CP-85. 4. Cellular Glass - Pittcote 300 / Childers CP-30. 5. Polystyrene - Foster 97-13 / Childers CP-96. B. Mastic (Weather Barrier): 1. Foster 35-00 Mastic / Vimasco. 2. Childers Vi-Cryl CP10/11. 3. Vimasco WC-5. C. Coatings: 1. Foster - Monolar Coating / Vimasco 2. Foster Sealfas 30-36 / Vimasco 3. Foster Tite-Fit 30-56 / Vimasco 4. Pittcote 300 D. Vapor Barrier Sealant: Foster Flextra 95-50 E. FSK tape 3 in. wide, equal to Nashua FSK. F. Insulation Pins: 1. Capacitor-Discharge-Weld Pins: Copper- or zinc-coated steel pin, fully annealed for capacitor-discharge welding, length to suit depth of insulation indicated. 2. Insulation-Retaining Washers: Self-locking washers formed from 0.016-inch- (0.41-mm-) thick, galvanized-steel aluminum or stainless-steel sheet, with beveled edge sized as required to hold insulation securely in place but not less than 1-1/2 inches (38 mm) in diameter. a. Protect ends with capped self-locking washers incorporating a spring steel insert to ensure permanent retention of cap in exposed locations. G. Roll on Corner bead (2 in. x 2 in., 26 ga. galvanized steel). Project No. 18088080 4 Section 23 07 00 Lake Lewisville WTP Dewatering Improvements Duct Insulation H. Fiber reinforced tape - Nashua 357, or 398. I. Insulation protection shields - Grinnell fig 167. J. Rigid insulation inserts - Hamfab. K. Reinforcing Cloth - Vimasco, Elastafab 894, conforming to ASTM D1668. L. Bands - .020 in., aluminum, 2 in. wide, embossed continuously with the legend "No Asbestos". M. Hexagonal Wire Netting - One inch mesh, 22 ga. galvanized steel. PART 3 - EXECUTION 3.1 GENERAL A. Insulation shall be applied to clean and dry surfaces after tests and approvals required by this specification have been completed. B. On cold surfaces where a vapor barrier must be maintained, insulation shall be applied with a continuous, unbroken moisture and vapor seal. All hangers, supports, anchors, or other projections that are secured to cold surfaces shall be insulated and vapor sealed to prevent condensation. C. All surface finishes shall be extended in such a manner as to protect all raw edges, ends and surfaces of insulation. D. All duct insulation shall be continuous through walls, ceiling or floor openings, or sleeves; except where fire stop or fire safeing materials are required. E. Metal shields shall be installed between hangers or supports and the piping insulation. Rigid insulation inserts shall be installed as required between the pipe and the insulation shields. Inserts shall be of equal thickness to the adjacent insulation and shall be vapor sealed as required. F. Size insulation to cover electric heat tracing on piping where it is specified. G. All clevis type pipe supports shall be sized to fit the outside diameter of the insulation. H. Insulate valves, fittings, flanges etc. with the same thickness of insulation as specified for piping. I. Install longitudinal jacketing laps to shed rainwater. J. Insulate items mounted in ductwork with the same thickness of insulation as specified for ductwork: including air measuring stations, smoke dampers, and automatic dampers. K. Repair insulation damaged by work under this contract to match existing work or replace damaged portion with insulation specified for new work. L. Standing seams and other projections in ductwork or casings shall have insulation applied so that at least 2" of insulation will cover such projections. M. Where ductwork is lined, no thermal insulation is required. N. Where unlined duct and lined duct connect, the insulation shall overlap lined section at least 6". Project No. 18088080 5 Section 23 07 00 Lake Lewisville WTP Dewatering Improvements Duct Insulation O. Piping and ductwork covered with metal or P.V.C. jacketing systems shall have the joints made to shed water. Laps shall be positioned in the bottom quadrant on horizontal pipe and ductwork. 3.2 HVAC SYSTEMS A. Concealed Ductwork: 1. Apply jacketed duct wrap to all concealed ductwork providing conditioned air, or outside air. Insulate return ductwork in non-conditioned spaces and in ceiling spaces below a roof. 2. Pull insulation snug, but do not compress insulation more than 1/4 inch. 3. Secure duct wrap insulation to ductwork using adhesive. Secure insulation on bottom on sides of horizontal ductwork and all sides of vertical ductwork with insul pins welded to duct on 12 to 18 inch centers and with clips slipped over the pins. Apply clips without compressing insulation. Make joints by lapping the facing a minimum of 2 inch and stapling with T-5 flared staples. Vapor - seal with Childers CP-30 Low Odor at all staples, clip locations and other penetrations. Seal joints with 3 inch wide FSK tape. 4. Insulation Thickness: a. Inside Thermal Envelope: i. Supply ductwork - 2 in. thick ii. Outside air ductwork - 2 in. thick iii. Return air ductwork - 2 in. thick b. Outside Thermal Envelope (Attic/Crawlspace): i. Supply ductwork - 4 in. thick - 2 layers ii. Return air ductwork - 4 in. thick - 2 layers iii. Exhaust ductwork - 2 in. thick - 1 layer iv. Outside air - 2 in. thick - 1 layer B. Exposed Interior Ductwork (Rectangular): 1. Apply insulation board with FRK facing to all exposed ductwork providing conditioned air, or outside air. Insulate return ductwork. 2. Secure insulation with insul pins (all surfaces) welded to duct on 12 to 18 in. centers and with clips slipped over pins. Seams and joints shall be vapor sealed with 3 in. wide FSK tape. Corners and edges of ductwork shall be reinforced with roll-on corner bead. 3. Seal all break and punctures with vapor barrier sealant and FSK tape. 4. Insulation Thickness: a. Inside Thermal Envelope: i. Supply ductwork - 2 in. thick ii. Outside air ductwork - 2 in. thick iii. Return air ductwork - 2 in. thick C. Exposed Interior Ductwork (Round): 1. Apply commercial semi-rigid flexible board insulation with FRK facing to all exposed ductwork providing conditioned air or outside air. 2. Secure insulation to ductwork using adhesive. Tightly butt insulation sections together. Longitudinal joint shall be lapped 2 in., stapled and taped. Tape circumferential joints with FSK tape at a 50 percent overlap. Tape entire girth at mid-point between joints. 3. Secure insulation with pins on vertical ductwork and the bottom surface of ductwork. Pins shall be spaced on 12 to 18 in. centers with clips slipped over the pins. 4. Insulation Thickness: a. Inside Thermal Envelope: i. Supply ductwork - 2-1/2 in. thick ii. Outside air ductwork - 2-1/2 in. thick iii. Return air ductwork - 2-1/2 in. thick D. Exposed Exterior Ductwork: Project No. 18088080 6 Section 23 07 00 Lake Lewisville WTP Dewatering Improvements Duct Insulation 1. Apply commercial rigid polyisocyanurate board insulation to all exposed ductwork providing conditioned air or outside air. 2. Secure insulation to ductwork using adhesive. Tightly butt insulation sections together. Longitudinal joint shall be lapped 2 in., stapled and taped. Tape circumferential joints with FSK tape at a 50 percent overlap. Tape entire girth at mid-point between joints. 3. Secure insulation with pins on vertical ductwork and the bottom surface of ductwork. Pins shall be spaced on 12 to 18 in. centers with clips slipped over the pins. 4. Insulation Thickness: a. Outside Thermal Envelope: i. Supply ductwork - 2 in. thick ii. Outside air ductwork - 2 in. thick iii. Return air ductwork - 2 in. thick E. Finishes: 1. Metal Jacketing (Aluminum): a. Insulated ductwork installed outdoors and insulated ductwork within 8 ft. of the finished floor in a mechanical room shall be covered with 0.016 in. thick aluminum. Covering shall be hemmed, and flanged. Secure with self tapping screws on eight inch centers. Do not puncture vapor barrier. END OF SECTION Project No. 18088080 1 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation SECTION 23 07 13 - MECHANICAL INSULATION PART 1 - GENERAL 1.1 SUMMARY A. Section includes insulating the following services: 1. Domestic water piping. 2. Refrigerant piping. 1.2 SUBMITTALS A. Product Data: For each type of product indicated. Include thermal conductivity, water-vapor permeance thickness, and jackets (both factory- and field-applied if any). 1.3 QUALITY ASSURANCE A. Installer Qualifications: Skilled mechanics who have successfully completed an apprenticeship program or another craft training program certified by the Department of Labor, Bureau of Apprenticeship and Training. B. Surface-Burning Characteristics: For insulation and related materials, as determined by testing identical products according to ASTM E 84, by a testing agency acceptable to authorities having jurisdiction. Factory label insulation and jacket materials and adhesive, mastic, tapes, and cement material containers, with appropriate markings of applicable testing agency. 1. Insulation Installed Indoors: Flame-spread index of 25 or less, and smoke-developed index of 50 or less. 2. Insulation Installed Outdoors: Flame-spread index of 75 or less, and smoke-developed index of 150 or less. 1.4 DELIVERY, STORAGE, AND HANDLING A. Packaging: Insulation material containers shall be marked by manufacturer with appropriate ASTM standard designation, type and grade, and maximum use temperature. 1.5 COORDINATION A. Coordinate sizes and locations of supports, hangers, and insulation. 1.6 SCHEDULING A. Schedule insulation application after pressure testing systems and, where required, after installing and testing heat tracing. Insulation application may begin on segments that have satisfactory test results. B. Complete installation and concealment of plastic materials as rapidly as possible in each area of construction. PART 2 - PRODUCTS 2.1 INSULATION MATERIALS A. Comply with requirements in "Piping Insulation Schedule." B. Products shall not contain asbestos, lead, mercury, or mercury compounds. Project No. 18088080 2 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation C. Products that come in contact with stainless steel shall have a leachable chloride content of less than 50 ppm when tested according to ASTM C 871. D. Insulation materials for use on austenitic stainless steel shall be qualified as acceptable according to ASTM C 795. E. Foam insulation materials shall not use CFC or HCFC blowing agents in the manufacturing process. F. Mineral-Fiber Blanket Insulation: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 553, Type II and ASTM C 1290. Factory-applied jacket requirements are specified in "Factory-Applied Jackets" Article. G. Mineral-Fiber Board Insulation: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 612, Type IA or Type IB. Factory-applied jacket requirements are specified in "Factory-Applied Jackets" Article. H. Mineral-Fiber, Preformed Pipe Insulation: 1. Type I, 850 Deg F Materials: Mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C 547, Type I, Grade A, with factory-applied ASJ. Factory-applied jacket requirements are specified in "Factory-Applied Jackets" Article. I. Rigid Pipe Insulation (Phenolic, Polyisocyanurate): Minimum Type II, Grade I (-70°F to +300°F). Phenolic (Type III, Grade I). Rigid foam insulation with closed cell structure. Comply with ASTM C591 and/or ASTM C1126. Must have 2% or less water absorption. Meet ASTM E84 25/50 flame and smoke development. J. Preformed Flexible Elastomeric Pipe Insulation: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTM C 534, Type I for tubular materials. 2.2 ADHESIVES A. Materials shall be compatible with insulation materials, jackets, and substrates and for bonding insulation to itself and to surfaces to be insulated unless otherwise indicated. B. Mineral-Fiber Adhesive: Comply with MIL-A-3316C, Class 2, Grade A. C. Flexible Elastomeric and Polyolefin Adhesive: Comply with MIL-A-24179A, Type II, Class I. D. ASJ Adhesive, and FSK Jacket Adhesive: Comply with MIL-A-3316C, Class 2, Grade A for bonding insulation jacket lap seams and joints. 2.3 SEALANTS A. FSK and Metal Jacket Flashing Sealants: 1. Materials shall be compatible with insulation materials, jackets, and substrates. 2. Fire- and water-resistant, flexible, elastomeric sealant. 3. Service Temperature Range: Minus 40 to plus 250 deg F. 4. Color: Aluminum. 2.4 FACTORY-APPLIED JACKETS A. Insulation system schedules indicate factory-applied jackets on various applications. When factory-applied jackets are indicated, comply with the following: Project No. 18088080 3 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation 1. ASJ for preformed mineral fiber pipe insulation: White, kraft-paper, fiberglass-reinforced scrim with aluminum-foil backing; complying with ASTM C 1136, Type I. 2.5 FIELD-APPLIED JACKETS A. Field-applied jackets shall comply with ASTM C 921, Type I, unless otherwise indicated. B. Metal Jacket: 1. Aluminum Jacket: Comply with ASTM B 209, Alloy 3003, 3005, 3105, or 5005, Temper H-14. a. Aluminum finish. b. Factory-Fabricated Fitting Covers: 1) Same material, finish, and thickness as jacket. 2) Preformed 2-piece or gore, 45- and 90-degree, short- and long-radius el- bows. 3) Tee covers. 4) Flange and union covers. 5) End caps. 6) Beveled collars. 7) Valve covers. 8) Field fabricate fitting covers only if factory-fabricated fitting covers are not available. 2.6 TAPES A. FSK Tape: Foil-face, vapor-retarder tape matching factory-applied jacket with acrylic adhesive; complying with ASTM C 1136. 1. Width: 3 inches. 2. Thickness: 6.5 mils. 3. Adhesion: 90 ounces force/inch in width. 4. Elongation: 2 percent. 5. Tensile Strength: 40 lbf/inch in width. 6. FSK Tape Disks and Squares: Precut disks or squares of FSK tape. B. Insulation Pins and Hangers: 1. Capacitor-Discharge-Weld Pins: Copper- or zinc-coated steel pin, fully annealed for capacitor-discharge welding, length to suit depth of insulation indicated. 2. Insulation-Retaining Washers: Self-locking washers formed from 0.016-inch-thick, galvanized-steel aluminum or stainless-steel sheet, with beveled edge sized as required to hold insulation securely in place but not less than 1-1/2 inches in diameter. a. Protect ends with capped self-locking washers incorporating a spring steel insert to ensure permanent retention of cap in exposed locations. C. Staples: Outward-clinching insulation staples, nominal 3/4-inch- wide, stainless steel or Monel. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine substrates and conditions for compliance with requirements for installation tolerances and other conditions affecting performance of insulation application. 1. Verify that systems to be insulated have been tested and are free of defects. 2. Verify that surfaces to be insulated are clean and dry. B. Proceed with installation only after unsatisfactory conditions have been corrected. Project No. 18088080 4 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation 3.2 PREPARATION A. Surface Preparation: Clean and dry surfaces to receive insulation. Remove materials that will adversely affect insulation application. 3.3 GENERAL INSTALLATION REQUIREMENTS A. Install insulation materials, accessories, and finishes with smooth, straight, and even surfaces; free of voids throughout the length of pipes and fittings. B. Install insulation materials, vapor barriers or retarders, jackets, and thicknesses required for each item of pipe system as specified in insulation system schedules. C. Install accessories compatible with insulation materials and suitable for the service. Install accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state. D. Install insulation with longitudinal seams at top and bottom of horizontal runs. E. Install multiple layers of insulation with longitudinal and end seams staggered. F. Keep insulation materials dry during application and finishing. G. Install insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by insulation material manufacturer. H. Install insulation with least number of joints practical. I. Where vapor barrier is indicated, seal joints, seams, and penetrations in insulation at hangers, supports, anchors, and other projections with vapor-barrier mastic. 1. Install insulation continuously through hangers and around anchor attachments. 2. For insulation application where vapor barriers are indicated, extend insulation on anchor legs from point of attachment to supported item to point of attachment to structure. Taper and seal ends at attachment to structure with vapor-barrier mastic. 3. Install insert materials and install insulation to tightly join the insert. Seal insulation to insulation inserts with adhesive or sealing compound recommended by insulation material manufacturer. J. Apply adhesives, mastics, and sealants at manufacturer's recommended coverage rate and wet and dry film thicknesses. K. Install insulation with factory-applied jackets as follows: 1. Draw jacket tight and smooth. 2. Cover circumferential joints with 3-inch-wide strips, of same material as insulation jacket. Secure strips with adhesive and outward clinching staples along both edges of strip, spaced 4 inches o.c. 3. Overlap jacket longitudinal seams at least 1-1/2 inches. Clean and dry surface to receive self-sealing lap. Staple laps with outward clinching staples along edge at 2 inches o.c. a. For below ambient services, apply vapor-barrier mastic over staples. 4. Cover joints and seams with tape, according to insulation material manufacturer's written instructions, to maintain vapor seal. 5. Where vapor barriers are indicated, apply vapor-barrier mastic on seams and joints and at ends adjacent to pipe flanges and fittings. Project No. 18088080 5 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation L. Cut insulation in a manner to avoid compressing insulation more than 75 percent of its nominal thickness. M. Finish installation with systems at operating conditions. Repair joint separations and cracking due to thermal movement. N. Repair damaged insulation facings by applying same facing material over damaged areas. Extend patches at least 4 inches beyond damaged areas. Adhere, staple, and seal patches similar to butt joints. 3.4 GENERAL PIPE INSULATION INSTALLATION A. Requirements in this article generally apply to all insulation materials except where more specific requirements are specified in various pipe insulation material installation articles. B. Insulation Installation on Fittings, Valves, Strainers, Flanges, and Unions: 1. Install insulation over fittings, valves, strainers, flanges, unions, and other specialties with continuous thermal and vapor-retarder integrity unless otherwise indicated. 2. Insulate pipe elbows using preformed fitting insulation or mitered fittings made from same material and density as adjacent pipe insulation. Each piece shall be butted tightly against adjoining piece and bonded with adhesive. Fill joints, seams, voids, and irregular surfaces with insulating cement finished to a smooth, hard, and uniform contour that is uniform with adjoining pipe insulation. 3. Insulate tee fittings with preformed fitting insulation or sectional pipe insulation of same material and thickness as used for adjacent pipe. Cut sectional pipe insulation to fit. Butt each section closely to the next and hold in place with tie wire. Bond pieces with adhesive. 4. Insulate valves using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. For valves, insulate up to and including the bonnets, valve stuffing-box studs, bolts, and nuts. Fill joints, seams, and irregular surfaces with insulating cement. 5. Insulate strainers using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. Fill joints, seams, and irregular surfaces with insulating cement. Insulate strainers so strainer basket flange or plug can be easily removed and replaced without damaging the insulation and jacket. Provide a removable reusable insulation cover. For below-ambient services, provide a design that maintains vapor barrier. 6. Insulate flanges and unions using a section of oversized preformed pipe insulation. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. 7. Cover segmented insulated surfaces with a layer of finishing cement and coat with a mastic. Install vapor-barrier mastic for below-ambient services and a breather mastic for above-ambient services. Reinforce the mastic with fabric-reinforcing mesh. Trowel the mastic to a smooth and well-shaped contour. 8. For services not specified to receive a field-applied jacket except for flexible elastomeric and polyolefin, install fitted PVC cover over elbows, tees, strainers, valves, flanges, and unions. Terminate ends with PVC end caps. Tape PVC covers to adjoining insulation facing using PVC tape. 9. Stencil or label the outside insulation jacket of each union with the word "union." Match size and color of pipe labels. Project No. 18088080 6 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation C. Insulate instrument connections for thermometers, pressure gages, pressure temperature taps, test connections, flow meters, sensors, switches, and transmitters on insulated pipes. Shape insulation at these connections by tapering it to and around the connection with insulating cement and finish with finishing cement, mastic, and flashing sealant. D. Install removable insulation covers at locations indicated. Installation shall conform to the following: 1. Make removable flange and union insulation from sectional pipe insulation of same thickness as that on adjoining pipe. Install same insulation jacket as adjoining pipe insulation. 2. When flange and union covers are made from sectional pipe insulation, extend insulation from flanges or union long at least two times the insulation thickness over adjacent pipe insulation on each side of flange or union. Secure flange cover in place with stainless- steel or aluminum bands. Select band material compatible with insulation and jacket. 3. Construct removable valve insulation covers in same manner as for flanges, except divide the two-part section on the vertical center line of valve body. 4. When covers are made from block insulation, make two halves, each consisting of mitered blocks wired to stainless-steel fabric. Secure this wire frame, with its attached insulation, to flanges with tie wire. Extend insulation at least 2 inches over adjacent pipe insulation on each side of valve. Fill space between flange or union cover and pipe insulation with insulating cement. Finish cover assembly with insulating cement applied in two coats. After first coat is dry, apply and trowel second coat to a smooth finish. 5. Unless a PVC jacket is indicated in field-applied jacket schedules, finish exposed surfaces with a metal jacket. 3.5 INSTALLATION OF FLEXIBLE ELASTOMERIC PIPE INSULATION A. Seal longitudinal seams and end joints with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated. B. Insulation Installation on Pipe Flanges: 1. Install pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice the thickness of 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 same thickness as pipe insulation. 4. Secure insulation to flanges and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated. C. Insulation Installation on Pipe Fittings and Elbows: 1. Install mitered sections of pipe insulation. 2. Secure insulation materials and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated. D. Insulation Installation on Valves and Pipe Specialties: 1. Install preformed valve covers manufactured of same material as pipe insulation when available. 2. When preformed valve covers are not available, install cut sections of pipe and sheet insulation to valve body. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation. 3. Install insulation to flanges as specified for flange insulation application. 4. Secure insulation to valves and specialties and seal seams with manufacturer's recommended adhesive to eliminate openings in insulation that allow passage of air to surface being insulated. Project No. 18088080 7 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation 3.6 INSTALLATION OF MINERAL-FIBER PIPE INSULATION A. Insulation Installation on Straight Pipes and Tubes: 1. Secure each layer of preformed pipe insulation to pipe with wire or bands and tighten bands without deforming insulation materials. 2. Where vapor barriers are indicated, seal longitudinal seams, end joints, and protrusions with vapor-barrier mastic and joint sealant. 3. For insulation with factory-applied jackets on above-ambient surfaces, secure laps with outward clinched staples at 6 inches o.c. 4. For insulation with factory-applied jackets on below-ambient surfaces, do not staple longitudinal tabs. Instead, secure tabs with additional adhesive as recommended by insulation material manufacturer and seal with vapor-barrier mastic and flashing sealant. B. Insulation Installation on Pipe Flanges: 1. Install preformed pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice the thickness of pipe insulation. 3. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with mineral-fiber blanket insulation. 4. Install jacket material with manufacturer's recommended adhesive, overlap seams at least 1 inch, and seal joints with flashing sealant. C. Insulation Installation on Pipe Fittings and Elbows: 1. Install preformed sections of same material as straight segments of pipe insulation when available. 2. When preformed insulation elbows and fittings are not available, install mitered sections of pipe insulation, to a thickness equal to adjoining pipe insulation. Secure insulation materials with wire or bands. D. Insulation Installation on Valves and Pipe Specialties: 1. Install preformed sections of same material as straight segments of pipe insulation when available. 2. When preformed sections are not available, install mitered sections of pipe insulation to valve body. 3. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation. 4. Install insulation to flanges as specified for flange insulation application. 3.7 INSTALLATION OF RIGID-FOAM PIPE INSULATION A. Insulation Installation on Straight Pipes and Tubes: 1. Secure each layer of preformed pipe insulation to pipe with wire or bands and tighten bands without deforming insulation materials. 2. Where vapor barriers are indicated, seal longitudinal seams, end joints, and protrusions with vapor-barrier mastic and joint sealant. 3. For insulation with factory-applied jackets on above-ambient surfaces, secure laps with outward clinched staples at 6 inches o.c. 4. For insulation with factory-applied jackets on below-ambient surfaces, do not staple longitudinal tabs. Instead, secure tabs with additional adhesive as recommended by insulation material manufacturer and seal with vapor-barrier mastic and flashing sealant. B. Insulation Installation on Pipe Flanges: 1. Install preformed pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice the thickness of pipe insulation. Project No. 18088080 8 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation 3. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with mineral-fiber blanket insulation. 4. Install jacket material with manufacturer's recommended adhesive, overlap seams at least 1 inch, and seal joints with flashing sealant. C. Insulation Installation on Pipe Fittings and Elbows: 1. Install preformed sections of same material as straight segments of pipe insulation when available. 2. When preformed insulation elbows and fittings are not available, install mitered sections of pipe insulation, to a thickness equal to adjoining pipe insulation. Secure insulation materials with wire or bands. D. Insulation Installation on Valves and Pipe Specialties: 1. Install preformed sections of same material as straight segments of pipe insulation when available. 2. When preformed sections are not available, install mitered sections of pipe insulation to valve body. 3. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation. 4. Install insulation to flanges as specified for flange insulation application. 3.8 FIELD-APPLIED PIPE JACKET INSTALLATION A. Where metal jackets are indicated, install with 2-inch 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 o.c. and at end joints. 3.9 FINISHES A. Flexible Elastomeric Thermal Insulation: After adhesive has fully cured, apply two coats of insulation manufacturer's recommended protective coating. B. Do not field paint aluminum or stainless-steel jackets. 3.10 PIPE INSULATION SCHEDULE A. Pipes Requiring Insulation: 1. Indoor, hot and cold domestic water piping used in office areas (above ceiling or exposed), serving sinks, lavatories, water closets, eyewashes or other general office fixtures shall be the following: a. Preformed mineral-fiber pipe insulation 1) Fluid temperature of 141°F to 200°F and nominal pipe size of 1 ¼” or less shall be 1” thick. 2) Fluid temperature of 141°F to 200°F and nominal pipe size of 1 ½” to 3” shall be 1 ½” thick. 3) Fluid temperature of 141°F to 200°F and nominal pipe size of 4” to <6” shall be 2” thick. 4) Fluid temperature of 81°F to 140°F and nominal pipe size of 1 ¼” or less shall be 1” thick. 5) Fluid temperature of 81°F to 140°F and nominal pipe size of 1 ½” to <6” shall be 1 ½” thick. 6) Fluid temperature of 40°F to 80°F and nominal pipe size of 1 ¼” or less shall be ½” thick. Project No. 18088080 9 Section 23 07 13 Lake Lewisville WTP Dewatering Improvements Mechanical Insulation 7) Fluid temperature of 40°F to 80°F and nominal pipe size of 1 ½” to <6” shall be 1” thick. b. Exposed piping shall have field applied aluminum jacket. 2. Indoor, hot and cold domestic water and water used for process applications located in non-mechanically cooled spaces exposed or concealed shall be the following: a. Rigid-foam pipe insulation (Phenolic or Polyisocyanurate) 1) Fluid temperature of 141°F to 200°F and nominal pipe size of 1 ¼” or less shall be 1” thick. 2) Fluid temperature of 141°F to 200°F and nominal pipe size of 1 ½” to 3” shall be 1 ½” thick. 3) Fluid temperature of 141°F to 200°F and nominal pipe size of 4” to <6” shall be 2” thick. 4) Fluid temperature of 81°F to 140°F and nominal pipe size of 1 ¼” or less shall be 1” thick. 5) Fluid temperature of 81°F to 140°F and nominal pipe size of 1 ½” to <6” shall be 1 ½” thick. 6) Fluid temperature of 40°F to 80°F and nominal pipe size of 1 ¼” or less shall be ½” thick. 7) Fluid temperature of 40°F to 80°F and nominal pipe size of 1 ½” to <6” shall be 1” thick. b. Exposed piping to have an aluminum jacket. 3. Outdoor, hot and cold domestic water and water used in process applications shall be the following: a. Rigid-foam pipe insulation (Phenolic or Polyisocyanurate) 1) Fluid temperature of 141°F to 200°F and nominal pipe size of 1 ¼” or less shall be 1” thick. 2) Fluid temperature of 141°F to 200°F and nominal pipe size of 1 ½” to 3” shall be 1 ½” thick. 3) Fluid temperature of 141°F to 200°F and nominal pipe size of 4” to <6” shall be 2” thick. 4) Fluid temperature of 81°F to 140°F and nominal pipe size of 1 ¼” or less shall be 1” thick. 5) Fluid temperature of 81°F to 140°F and nominal pipe size of 1 ½” to <6” shall be 1 ½” thick. 6) Fluid temperature of 40°F to 80°F and nominal pipe size of 1 ¼” or less shall be ½” thick. 7) Fluid temperature of 40°F to 80°F and nominal pipe size of 1 ½” to <6” shall be 1” thick. b. Field applied aluminum jacket. c. See Drawings and Division 26 Electrical sections for heat trace. 4. Indoor, refrigerant suction piping air shall be: a. 1 ½” preformed flexible elastomeric pipe insulation. 5. Outdoor, refrigerant suction piping air shall be: a. 1 ½” preformed flexible elastomeric pipe insulation with field applied aluminum jacket. B. Pipe insulation shall meet requirements of International Energy Code. END OF SECTION 18088080 1 Section 23 09 13 Lake Lewisville WTP Dewatering Improvements Heating, Ventilating, and Air Conditioning Controls SECTION 23 09 13 - HEATING, VENTILATING, AND AIR CONDITIONING CONTROLS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Controls for Heating, Ventilating, and Air Conditioning (HVAC) Systems: 1. Thermostats. 2. HVAC control descriptions. 3. HVAC control panels. B. Related sections: 1. Section 01 81 00 – Project Design Criteria. 2. Section 23 34 23 – Fans. 3. Section 23 74 13 – Packaged Rooftop Air Conditioning Units 4. Section 23 83 01 – Heating Units. 1.2 REFERENCES A. CSA International (CSA). B. National Electrical Manufacturers Association (NEMA). 1. 250 - Enclosures for Electrical Equipment (1,000 Volts Maximum). C. National Fire Protection Association (NFPA): 1. 90A - Standard for the Installation of Air-Conditioning and Ventilating Systems. 2. 70 - National Electrical Code (NEC). D. Underwriters' Laboratories, Inc. (UL). 1. 1479 - Fire Tests of Through-Penetration Firestops. 1.3 SYSTEM DESCRIPTION A. General requirements: 1. All electrical components shall be UL listed and meet the design and installation requirements of the NEC. 2. Complete, functional system: Provide all necessary electrical power and control systems, components, and wiring to make a complete functioning system. 3. Comply with electrical Sections for electrical power and control systems. 4. System control functions to perform as described in Products. 5. Materials: New, free from defects, and of the quality specified. 6. Common manufacturer: Provide components, component accessories, and devices, as much as possible, by the same manufacturer throughout the work. 7. Mounting: Mount control components and devices in accessible locations for maintenance and as recommended by the manufacturer; provide necessary manufacturer approved mounting and configuration hardware for mounting and operation of control components and devices. 1.4 SUBMITTALS A. Shop drawings: 1. Manufacturer's information including: a. Catalog information clearly marked to show specific products, models, and sizes being furnished. b. Component cut sheets. 18088080 2 Section 23 09 13 Lake Lewisville WTP Dewatering Improvements Heating, Ventilating, and Air Conditioning Controls 2. Control diagrams showing the interconnection of control components including wiring terminal strip diagrams. 3. Detail drawings showing control panel layout and dimensions including control panel terminal strips for wiring to outside control devices and panels. B. Operations and Maintenance Data. 1.5 QUALITY ASSURANCE A. The control system shall be designed to conform to UL and CSA standards. 1.6 DELIVERY, STORAGE, AND HANDLING A. The system control products shall be stored and handled per manufacturer's recommendations. 1.7 SITE CONDITIONS A. Elevation and ambient conditions as specified in Section 01 81 00. 1.8 WARRANTY A. Special warranties: Warranty period begins at date of Project Acceptance or first date of Beneficial Use by the OWNER: 1. 2 years: Parts and on-site labor for components, systems, and programming. PART 2 - PRODUCTS 2.1 THERMOSTATS A. General: 1. Thermostat types: Thermostat types are called out on the drawings by the letter T followed by a number; this designation refers to the specified thermostat types given in this Section; where no type is called out, provide 1 of the specified types that will match the controlled equipment requirements and provide a functioning system. 2. Manufacturers: One of the following: a. Johnson Controls, model as specified with each type. b. Honeywell, Tradeline, equivalent models. B. T-1, Type 1 Thermostat, Heating Only, Line Voltage: 1. Johnson Controls Model: a. Dry locations (no hose bibs or open water processes in room): Model A19BAC-1 in NEMA 1 enclosure. b. Wet Locations (hose bibs or open water processes in room): Model A19PRC-1 in NEMA 4X enclosure. 2. Switch action: Single pole double throw, open on rising temperature. 3. Sensing element: Coiled bulb and capillary. 4. Setpoint: 30 to 110 degrees Fahrenheit with knob adjuster and visible scale. 5. Electrical ratings: 16 amps alternating current at 120 volts, 9.2 amps alternating current at 208 volts. C. T-2, Type 2 Thermostat, Cooling Only, Line Voltage: 1. Johnson Controls Model: a. Dry locations (no hose bibs or open water processes in room): Model A19BBC-2 in NEMA 1 enclosure. 18088080 3 Section 23 09 13 Lake Lewisville WTP Dewatering Improvements Heating, Ventilating, and Air Conditioning Controls b. Wet locations (hose bibs or open water processes in room): Model A19KNC-1 in rain and dusttight enclosure. 2. Switch action: Single pole double throw, close on rising temperature. 3. Sensing element: Coiled bulb and capillary. 4. Setpoint: 30 to 110 degrees Fahrenheit with knob adjuster and visible scale. 5. Electrical ratings: 16 amps alternating current at 120 volts, 9.2 amps alternating current at 208 volts. 6. Differential range: For dry locations, 3 to 12 degrees Fahrenheit adjustable; for wet locations, 5 degrees Fahrenheit fixed. D. T-3, Type 3 Thermostat, Heating And Cooling, Line Voltage, Single Stage for MCC Room or Office Environments: 1. Johnson Controls Model: a. Dry locations (no hose bibs or open water processes in room): Model T22TFB-1 in high impact plastic enclosure. 2. Switch action: Single pole double throw, open on rising temperature in heat mode, close on rising temperature in cooling mode. 3. Sensing element: Liquid charged sensing with diaphragm and lever. 4. Setpoint: 40 to 90 degrees Fahrenheit with knob adjuster and visible scale; provide local ambient temperature indicator in degrees Fahrenheit. 5. Selector switch: Heat-Off-Cool. 6. Electrical ratings: 16 amps alternating current at 120 volts, 9.2 amps alternating current at 208 volts. E. T-4, Type 4 Thermostat, Electronic, Heating and Cooling, Low Voltage, Proportional: 1. Johnson Controls Model: a. Model TC-6500 with T-4000 - 2142 plastic enclosure. 2. Sensing element: Resistance temperature element. 3. Setpoint: 55 to 85 degrees Fahrenheit with adjuster and visible scale; provide local ambient temperature indicator in degrees Fahrenheit. 4. Electrical ratings: a. Input: 21 volts direct current. b. Output: 1 to 18 volt direct current, proportional to temperature change from setpoint; direct acting above setpoint and reverse acting below set point; 1 to 2-degree Fahrenheit deadband. 5. Cover: Provide plastic cover with thermometer and setpoint window. F. T-5, Type 5 Thermostat, Electronic Controller: 1. Johnson Controls Model: a. Model A350P with Y350R transformer, D350 display module and SETA99BC-25C sensor. 2. Electronic unit with proportional plus integral temperature control with 3 selectable integration constants plus integration off position. 3. Output: Selectable, direct or reverse acting, 0 to 10 volts direct current or 4 to 20-milliamp output signal. 4. Input power: 120-volt alternating current with transformer to supply 24-volt direct current as required. 5. Setpoint range: Minus 30 to 130 degrees Fahrenheit, adjustable by face-mounted dial. 6. Sensor: positive temperature coefficient silicon sensor with wall mounting bracket. 7. Display module: Digital, 3 digit, Fahrenheit scale, LCD display, selectable to display room temperature or setpoint temperature. 8. Mounting: Provide wall-mounting bracket for mounting modules together as 1 unit; provide interconnecting cables as necessary. 9. Field selectable heat or cool mode. 10. Module cases: High impact plastic cases. 18088080 4 Section 23 09 13 Lake Lewisville WTP Dewatering Improvements Heating, Ventilating, and Air Conditioning Controls G. T-6, Type 6 Thermostat: Electronic, with Night Setback. 2.2 HVAC CONTROL DESCRIPTIONS A. General: Provide control systems that will maintain room or area comfort under changing ambient conditions and varying use; descriptions in this Section are general in nature and do not cover every mode of operation. B. Building 77 Dewatering Facility: 1. References: a. Process area: 77 b. HVAC drawings: 77- M181. 2. Mechanical equipment: Tag Number Equipment Name Dewatering Room 77SF01 Supply Fan 77SF02 Supply Fan 77SF03 Supply Fan 77EF01 Exhaust Fan 77EF02 Exhaust Fan 77EF03 Exhaust Fan 77UH01 Electric Unit Heater 77UH02 Electric Unit Heater 77UH03 Electric Unit Heater 77UH04 Electric Unit Heater Electrical Room 77RTU01 Packaged Air Conditioning Unit 3. Controls at equipment: a. Supply Fans 77SF01, 77SF02, and 77SF03: 1). Provide disconnect switch for each supply fan. b. Exhaust Fans 77EF01, 77EF02, and 77EF03: 1). Provide disconnect switch for each exhaust fan. c. Unit Heaters 77UH01, 77UH02, 77UH03, and 77UH04: 1). Provide disconnect kit for each unit heater. d. Packaged Air Conditioning Unit 77RTU01: 1). Provide disconnect switch for packaged rooftop unit. 4. Zone controls: a. Supply Fans and Exhaust Fans: 1). 77SF01 operates based on room temperature to provide summer ventilation and is interlocked with 77EF01. 77SF01 and 77EF01 simultaneously turn on when indoor temperature meets or exceeds 85 degrees Fahrenheit (adjustable). 2). 77SF02 operates based on room temperature to provide summer ventilation and is interlocked with 77EF02. 77SF02 and 77EF02 simultaneously turn on when indoor temperature meets or exceeds 85 degrees Fahrenheit (adjustable). 18088080 5 Section 23 09 13 Lake Lewisville WTP Dewatering Improvements Heating, Ventilating, and Air Conditioning Controls 3). 77SF03 operates based on room temperature to provide summer ventilation and is interlocked with 77EF03. 77SF03 and 77EF03 simultaneously turn on when indoor temperature meets or exceeds 85 degrees Fahrenheit (adjustable). 4). Room mounted type T-2 for each exhaust fan. 5). See electrical drawings and specifications for control panel design. b. Electric Unit Heaters: 1). 77UH01, 77UH02, 77UH03, and 77UH04 operate to maintain room temperature at 50 degrees Fahrenheit (adjustable). Heater operation shall be in accordance with heater manufacturer’s recommendations. 2). Room mounted type T-1 thermostat for each heater. c. Packaged Air Conditioning Unit: 1). 77RTU01 operates automatically to meet electrical room cooling requirements. 77RTU01 shall maintain room temperature at 75 degrees Fahrenheit (adjustable). Operation shall be in accordance with heater manufacturer’s recommendations. a). 77RTU01 shall be equipped with dehumidification option (hot gas reheat) with a room mounted humidity sensor. b). 77RTU01 shall be equipped with 0-100% economizer and powered exhaust. 2). Room mounted type T-3 thermostat, or as required by manufacturer. EXECUTION 2.3 EXAMINATION A. Examine and verify that Work is in condition to receive installation specified in this Section. B. Take measurements and verify dimensions to ascertain fit of installation. C. Ascertain structural sufficiency to support installation. D. Ascertain that supports and openings are correctly located; cut new openings where required. 1. Submit details of proposed cutting and patching. 2.4 PREPARATION A. Before installation, remove dust and debris from equipment and accessories. B. During installation and until equipment is operated, protect equipment and accessories from dust and debris. 2.5 INSTALLATION A. Install as indicated on the Drawings, in accordance with NFPA 90A, and per the manufacturer’s written instructions. B. Coordinate installation of HVAC control systems with other trades. 1. Prior to installation, coordinate wiring and conduit requirements with electrical subcontractor. C. Mount remote annunciator and test station on wall near smoke detector. 1. Devices shall be easily accessible from floor level. 2. Label annunciator and test station. 18088080 6 Section 23 09 13 Lake Lewisville WTP Dewatering Improvements Heating, Ventilating, and Air Conditioning Controls D. Provide all electrical work to support smoke detector. 1. Coordinate with electrical subcontractor. E. Sensor and control station mounting: 1. Where not otherwise indicated, mount 5 feet above floor or walking level. 2. Provide insulating back plates when mounting is on an exterior wall or a wall adjoining an unconditioned space. 3. Shield outside thermostats or sensors from the sun; provide thermostats with remote bulb and compensated capillary. 4. Install locking covers where indicated on the Drawings. 2.6 FIELD QUALITY CONTROL A. Test each control system and provide written, signed, and dated test report. 1. Test individual control components and accessories to comply with the Specifications. 2. Test functions of each control system as a complete system to comply with the Specifications. B. Test each control component and system as part of HVAC system testing, adjusting, and balancing as specified in Section 23 05 93. END OF SECTION Project No. 18088080 1 Section 23 31 13 Lake Lewisville WTP Dewatering Improvements Metal Ducts SECTION 23 31 13 – METAL DUCTS PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Rectangular ducts and fittings. 2. Sheet metal materials. 3. Duct liner. 4. Sealants and gaskets. 5. Hangers and supports. B. Related Sections: 1. Section 23 05 93 - Testing, Adjusting, and Balancing 2. Section 23 33 00 - Air Duct Accessories. 1.2 PERFORMANCE REQUIREMENTS A. Delegated Duct Design: Duct construction, including sheet metal thicknesses, seam and joint construction, reinforcements, and hangers and supports, shall comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" and performance requirements and design criteria indicated in "Duct Schedule" Article. B. Flanged duct and duct fitting shall comply with SMACNA’s “HVAC Duct Construction Standards – Metal and Flexible”. C. Structural Performance: Duct hangers and supports shall withstand the effects of gravity loads and stresses within limits and under conditions described in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible". D. Airstream Surfaces: Surfaces in contact with the airstream shall comply with requirements in ASHRAE 62.1-2013. 1.3 SUBMITTALS A. Product Data: For each type of the following products: 1. Liners and adhesives. 2. Sealants and gaskets. 3. Flanged joint type. PART 2 - PRODUCTS 2.1 RECTANGULAR DUCTS AND FITTINGS A. General Fabrication Requirements: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" based on maximum static-pressure class based on fan total static pressure unless otherwise indicated. B. Rectangular ducts and fittings shall use flange style connectors with neoprene gasket material in accordance with SMACNA’s “HVAC Duct Construction Standards – Metal and Flexible”. C. Transverse Joints: Select joint types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 1-4, "Transverse (Girth) Joints," for static- Project No. 18088080 2 Section 23 31 13 Lake Lewisville WTP Dewatering Improvements Metal Ducts pressure class, applicable sealing requirements, materials involved, duct-support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible." D. Longitudinal Seams: Select seam types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 1-5, "Longitudinal Seams - Rectangular Ducts," for static-pressure class, applicable sealing requirements, materials involved, duct- support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible." E. Elbows, Transitions, Offsets, Branch Connections, and Other Duct Construction: Select types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Chapter 2, "Fittings and Other Construction," for static-pressure class, applicable sealing requirements, materials involved, duct-support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible." F. In accordance with SMACNA Manual for gauge of sheet metal, joint types, reinforcement, bracing, hangers and supports, fabrication, and installation. 1. Sheet metal thicknesses: The greater of that thickness required to in accordance with SMACNA for the design pressure specified and the following minimum thicknesses: Diameter or Largest Dimension of Rectangular Duct (Inches) Minimum Sheet Thickness, Inches (B&S Gauge) Up to 12 0.025 (22) 13 to 30 0.032 (20) Larger than 31 0.040 (18) 2.2 SHEET METAL MATERIALS A. General Material Requirements: 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. Ducts: Aluminum alloy 3003 H14 in accordance with ASTM B 209. C. Flexible connectors: As specified in Section 23 33 00. D. Turning vanes: Match duct material. E. Reinforcing: Formed or extruded aluminum angles. F. Ductwork insulation: As specified in Section 23 07 00. G. Tie Rods: Aluminum, 1/4-inch minimum diameter for lengths 36 inches or less; 3/8-inch minimum diameter for lengths longer than 36 inches. 2.3 SEALANT AND GASKETS A. General Sealant and Gasket Requirements: Surface-burning characteristics for sealants and gaskets shall be a maximum flame-spread index of 25 and a maximum smoke-developed index of 50 when tested according to UL 723; certified by an NRTL. B. Water-Based Joint and Seam Sealant: Project No. 18088080 3 Section 23 31 13 Lake Lewisville WTP Dewatering Improvements Metal Ducts 1. Application Method: Brush on. 2. Solids Content: Minimum 65 percent. 3. Shore A Hardness: Minimum 20. 4. Water resistant. 5. Mold and mildew resistant. 6. VOC: Maximum 75 g/L (less water). 7. Maximum Static-Pressure Class: 10-inch wg, positive and negative. 8. Service: Indoor or outdoor. 9. Substrate: Compatible with galvanized sheet steel (both PVC coated and bare), stainless steel, or aluminum sheets. C. Flanged Joint Sealant: Comply with ASTM C 920. 1. General: Single-component, acid-curing, silicone, elastomeric. 2. Type: S. 3. Grade: NS. 4. Class: 25. 5. Use: O. 6. For indoor applications, use sealant that has a VOC content of 250 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24). D. Flange Gaskets: Butyl rubber, neoprene, or EPDM polymer with polyisobutylene plasticizer. 2.4 HANGERS AND SUPPORTS A. Hanger Rods for Noncorrosive Environments: Cadmium-plated steel rods and nuts. B. Hanger Rods for Corrosive Environments: Electrogalvanized, rods threaded on each end (no all thread) or galvanized rods with threads painted with zinc-chromate primer after installation. C. Strap and Rod Sizes: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Table 4-1, "Rectangular Duct Hangers Minimum Size," and Table 4-2, "Minimum Hanger Sizes for Round Duct." D. Duct Attachments: Sheet metal screws, blind rivets, or self-tapping metal screws; compatible with duct materials. E. Trapeze and Riser Supports: 1. Supports for Galvanized-Steel Ducts: Galvanized-steel shapes and plates. 2. Supports for Stainless-Steel Ducts: Stainless-steel shapes and plates. 3. Supports for Aluminum Ducts: Aluminum or galvanized steel coated with zinc chromate. PART 3 - EXECUTION 3.1 DUCT INSTALLATION A. Drawing plans, schematics, and diagrams indicate general location and arrangement of duct system. Indicated duct locations, configurations, and arrangements were used to size ducts and calculate friction loss for air-handling equipment sizing and for other design considerations. Install duct systems as indicated unless deviations to layout are approved on Shop Drawings and Coordination Drawings. B. Install ducts according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" unless otherwise indicated. C. Install ducts with fewest possible joints. Project No. 18088080 4 Section 23 31 13 Lake Lewisville WTP Dewatering Improvements Metal Ducts D. Install factory- or shop-fabricated fittings for changes in direction, size, and shape and for branch connections. E. Unless otherwise indicated, install ducts vertically and horizontally, and parallel and perpendicular to building lines. F. Install ducts as high as practical, close to walls, overhead construction, columns, and other structural and permanent enclosure elements of building. G. Install ducts with a clearance of 1 inch, plus allowance for insulation thickness. H. Route ducts to avoid passing through transformer vaults and electrical equipment rooms and enclosures. I. Where ducts pass through non-fire-rated interior partitions and exterior walls and are exposed to view, cover the opening between the partition and duct or duct insulation with sheet metal flanges of same metal thickness as the duct. Overlap openings on four sides by at least 1-1/2 inches. J. Where ducts pass through fire-rated interior partitions and exterior walls, install fire dampers. Comply with requirements of the local code for fire and smoke dampers. K. Protect duct interiors from moisture, construction debris and dust, and other foreign materials. Comply with SMACNA's "Duct Cleanliness for New Construction Guidelines." 3.2 INSTALLATION OF EXPOSED DUCTWORK A. Protect ducts exposed in finished spaces from being dented, scratched, or damaged; furnish ductwork free of visual imperfections, ready for field applied painting. B. Trim duct sealants flush with metal. Create a smooth and uniform exposed bead. Do not use tape sealing system. C. Grind welds to provide smooth surface free of burrs, sharp edges, and weld splatter. When welding stainless steel with a No. 3 or 4 finish, grind the welds flush, polish the exposed welds, and treat the welds to remove discoloration caused by welding. D. Maintain consistency, symmetry, and uniformity in the arrangement and fabrication of fittings, hangers and supports, duct accessories, and air outlets. E. Repair or replace damaged sections and finished work that does not comply with these requirements. 3.3 DUCT SEALING A. Seal ducts for duct static-pressure, seal classes, and leakage classes specified in "Duct Schedule" Article according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible." B. Seal ducts to the pressure classes according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible": 1. Ductwork in conditioned spaces (including return air plenums): a. Supply air ducts: seal traverse joints and duct wall penetrations. b. Return air ducts: seal traverse joints and duct wall penetrations. c. Exhaust air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. Project No. 18088080 5 Section 23 31 13 Lake Lewisville WTP Dewatering Improvements Metal Ducts d. Outside air ducts: seal traverse joints and duct wall penetrations. 2. Ductwork in unconditioned spaces: a. Supply air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. b. Return air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. c. Exhaust air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. d. Outside air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. 3. Ductwork located outdoors: a. Supply air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. b. Return air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. c. Exhaust air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. d. Outside air ducts: seal traverse joints, longitudinal seams, and duct wall penetrations. 3.4 HANGER AND SUPPORT INSTALLATION A. Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Chapter 4, "Hangers and Supports." B. Building Attachments: Structural-steel fasteners appropriate for construction materials to which hangers are being attached. 1. Where practical, install concrete inserts before placing concrete. C. Hanger Spacing: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Table 4-1, "Rectangular Duct Hangers Minimum Size," and Table 4-2, "Minimum Hanger Sizes for Round Duct," for maximum hanger spacing; install hangers and supports within 24 inches of each elbow and within 48 inches of each branch intersection. D. Hangers Exposed to View: Threaded rod and angle or channel supports. Install swiveling attachment devices or field fabricated attachments to provide threaded rods vertical installation. E. Support vertical ducts with steel angles or channel secured to the sides of the duct with welds, bolts, sheet metal screws, or blind rivets; support at each floor and at a maximum intervals of 16 feet. F. Install upper attachments to structures. Select and size upper attachments with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used. 3.5 CONNECTIONS A. Make connections to equipment with flexible connectors. B. Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" for branch, outlet and inlet, and terminal unit connections. 3.6 DUCT CLEANING A. Clean duct systems before testing, adjusting, and balancing. B. Use service openings for entry and inspection. 1. Create new openings and install access panels appropriate for duct static-pressure class if required for cleaning access. Provide insulated panels for insulated or lined duct. Patch insulation and liner as recommended by duct liner manufacturer. Project No. 18088080 6 Section 23 31 13 Lake Lewisville WTP Dewatering Improvements Metal Ducts 2. Disconnect and reconnect flexible ducts as needed for cleaning and inspection. 3. Remove and reinstall ceiling to gain access during the cleaning process. C. Clean the following components 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, actuators, and turning vanes except in ceiling plenums and mechanical equipment rooms. 6. Supply-air ducts, dampers, actuators, and turning vanes. 7. Dedicated exhaust and ventilation components and makeup air systems. D. 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. Replace fibrous-glass duct liner that is damaged, deteriorated, or delaminated or that has friable material, mold, or fungus growth. 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. 6. Provide drainage and cleanup for wash-down procedures. 7. Antimicrobial Agents and Coatings: Apply EPA-registered antimicrobial agents if fungus is present. Apply antimicrobial agents according to manufacturer's written instructions after removal of surface deposits and debris. 3.7 START UP A. Air Balance: Comply with requirements in Section 23 05 93. 3.8 DUCT SCHEDULE A. Fabricate ducts with aluminum sheet except as otherwise indicated. B. Flanged Construction: 1. Provide flanged duct construction unless otherwise indicated. C. Elbow Configuration: 1. Rectangular Duct: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 2-2, "Rectangular Elbows." a. Radius Type RE 1 with minimum 1.5 radius-to-diameter ratio. b. Radius Type RE 3 with minimum 1.0 radius-to-diameter ratio and two vanes. c. Mitered Type RE 2 with vanes complying with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 2-3, "Vanes and Vane Runners," and Figure 2-4, "Vane Support in Elbows." Project No. 18088080 7 Section 23 31 13 Lake Lewisville WTP Dewatering Improvements Metal Ducts D. Branch Configuration: 1. Rectangular Duct: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 2-6, "Branch Connections." a. Rectangular Main to Rectangular Branch: 45-degree entry. b. Rectangular Main to Round Branch: 45-degree lead in. 2. Round and Flat Oval: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 3-4, "90 Degree Tees and Laterals," and Figure 3-5, "Conical Tees." Saddle taps are permitted in existing duct. a. 45 degree lateral. END OF SECTION Project No. 18088080 1 Section 23 33 00 Lake Lewisville WTP Dewatering Improvements Air Duct Accessories SECTION 23 33 00 – AIR DUCT ACCESSORIES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Manual volume dampers. 2. Flange connectors. 3. Turning vanes. 4. Flexible connectors. 5. Flexible ducts. 6. Duct accessory hardware. 1.2 SUBMITTALS A. Product Data: For each type of product indicated. B. Operation and Maintenance Data: For air duct accessories to include in operation and maintenance manuals. 1.3 QUALITY ASSURANCE A. Comply with NFPA 90A, "Installation of Air Conditioning and Ventilating Systems," and with NFPA 90B, "Installation of Warm Air Heating and Air Conditioning Systems." B. Comply with AMCA 500-D testing for damper rating. PART 2 - PRODUCTS 2.1 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: Comply with ASTM A 653. 1. Galvanized Coating Designation: G90. 2. Exposed-Surface Finish: Mill phosphatized. C. Stainless-Steel Sheets: Comply with ASTM A 480, Type 304, and having a No. 2 finish for concealed ducts and exposed ducts. D. Aluminum Sheets: Comply with ASTM B 209, Alloy 3003, Temper H14; with mill finish for concealed ducts and standard, 1-side bright finish for exposed ducts. E. Extruded Aluminum: Comply with ASTM B 221, Alloy 6063, Temper T6. F. Reinforcement Shapes and Plates: Galvanized-steel reinforcement where installed on galvanized sheet metal ducts; compatible materials for aluminum and stainless-steel ducts. G. Tie Rods: Galvanized steel, 1/4-inch minimum diameter for lengths 36 inches or less; 3/8-inch minimum diameter for lengths longer than 36 inches. Project No. 18088080 2 Section 23 33 00 Lake Lewisville WTP Dewatering Improvements Air Duct Accessories 2.2 MANUAL VOLUME DAMPERS A. Standard, Steel, Manual Volume Dampers: 1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: a. Air Balance Inc.; a division of Mestek, Inc. b. American Warming and Ventilating; a division of Mestek, Inc. c. Flexmaster U.S.A., Inc. d. McGill AirFlow LLC. e. METALAIRE, Inc. f. Nailor Industries Inc. g. Pottorff; a division of PCI Industries, Inc. h. Ruskin Company. i. Trox USA Inc. j. Vent Products Company, Inc. 2. Standard leakage rating. 3. Suitable for horizontal or vertical applications. 4. Frames: a. Hat-shaped, galvanized-steel channels, 0.064-inch minimum thickness. b. Mitered and welded corners. c. Flanges for attaching to walls and flangeless frames for installing in ducts. 5. Blades: a. Multiple or single blade. b. Parallel- or opposed-blade design. c. Stiffen damper blades for stability. Galvanized-steel, 0.064 inch thick. 6. Blade Axles: Galvanized steel. 7. Bearings: Oil-impregnated bronze. a. Dampers in ducts with pressure classes of 3-inch wg or less shall have axles full length of damper blades and bearings at both ends of operating shaft. 8. Tie Bars and Brackets: Galvanized steel. 2.3 FLANGE CONNECTORS A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. Ductmate Industries, Inc. 2. Nexus PDQ; Division of Shilco Holdings Inc. 3. Ward Industries, Inc.; a division of Hart & Cooley, Inc. B. Description: Factory-fabricated, slide-on transverse flange connectors, gaskets, and components. C. Material: Aluminum. D. Gage and Shape: Match connecting ductwork. 2.4 TURNING VANES A. General Requirements: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible"; Figures 4-3, "Vanes and Vane Runners," and 4-4, "Vane Support in Elbows." B. Vane Construction: Single wall for ducts up to 48 inches wide and double wall for larger dimensions. Project No. 18088080 3 Section 23 33 00 Lake Lewisville WTP Dewatering Improvements Air Duct Accessories 2.5 DUCT-MOUNTED ACCESS DOORS A. Duct-Mounted Access Doors: Fabricate access panels according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible"; Figure 7-2, "Duct Access Doors and Panels," and 7-3, "Access Doors - Round Duct." 1. Door: a. Double wall, rectangular. b. Aluminum sheet metal with insulation fill and thickness as indicated for duct pressure class. c. Vision panel. d. Hinges and Latches: 1-by-1-inch butt or piano hinge and cam latches. e. Fabricate doors airtight and suitable for duct pressure class. 2. Frame: Aluminum, with bend-over tabs and foam gaskets. 3. Number of Hinges and Locks: a. Access Doors Less Than 12 Inches Square: No hinges and two sash locks. b. Access Doors up to 18 Inches Square: Two hinges and two sash locks. c. Access Doors up to 24 by 48 Inches: Three hinges and two compression latches with outside and inside handles. d. Access Doors Larger Than 24 by 48 Inches: Four hinges and two compression latches with outside and inside handles. 2.6 FLEXIBLE CONNECTORS A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. Ductmate Industries, Inc. 2. Duro Dyne Inc. 3. Ventfabrics, Inc. 4. Ward Industries, Inc.; a division of Hart & Cooley, Inc. B. Materials: Flame-retardant or noncombustible fabrics. C. Coatings and Adhesives: Comply with UL 181, Class 1. D. Metal-Edged Connectors: Factory fabricated with a fabric strip 5-3/4 inches wide attached to 2 strips of 2-3/4-inch-wide, 0.028-inch-thick, galvanized sheet steel or 0.032-inch-thick aluminum sheets. Provide metal compatible with connected ducts. 2.7 FLEXIBLE DUCTS A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. Flexmaster U.S.A., Inc. 2. McGill AirFlow LLC. 3. Ward Industries, Inc.; a division of Hart & Cooley, Inc. B. Insulated, Flexible Duct: UL 181, Class 1, 2-ply vinyl film supported by helically wound, spring- steel wire; fibrous-glass insulation; aluminized vapor-barrier film. 1. Pressure Rating: 10-inch wg positive and 1.0-inch wg negative. 2. Maximum Air Velocity: 4000 fpm. 3. Temperature Range: Minus 10 to plus 160 deg F. 4. Insulation R-value: Comply with ASHRAE/IESNA 90.1. C. Flexible Duct Connectors: Project No. 18088080 4 Section 23 33 00 Lake Lewisville WTP Dewatering Improvements Air Duct Accessories 1. Clamps: Stainless-steel band with cadmium-plated hex screw to tighten band with a worm-gear action in sizes 3 through 18 inches, to suit duct size. 2. Non-Clamp Connectors: Adhesive plus sheet metal screws. 2.8 DUCT 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 of length to suit duct-insulation thickness. B. Adhesives: High strength, quick setting, neoprene based, waterproof, and resistant to gasoline and grease. PART 3 - EXECUTION 3.1 INSTALLATION A. Install duct accessories according to applicable details 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 at points on supply, return, and exhaust systems where branches extend from larger ducts. Where dampers are installed in ducts having duct liner, install dampers with hat channels of same depth as liner, and terminate liner with nosing at hat channel. 1. Install steel volume dampers in steel ducts. D. Set dampers to fully open position before testing, adjusting, and balancing. E. Install test holes at fan inlets and outlets and elsewhere as indicated. F. Install duct access doors on sides of ducts to allow for inspecting, adjusting, and maintaining accessories and equipment at the following locations: 1. On both sides of duct coils. 2. Upstream from filters. 3. At outdoor-air intakes and mixed-air plenums. 4. Elsewhere as indicated. G. Install access doors with swing against duct static pressure. H. Access Door Sizes: 1. One-Hand or Inspection Access: 8 by 5 inches. 2. Two-Hand Access: 12 by 6 inches. 3. Head and Hand Access: 18 by 10 inches. 4. Head and Shoulders Access: 21 by 14 inches. I. Label access doors according to Division 23 Section "Identification for HVAC Piping and Equipment" to indicate the purpose of access door. J. Install flexible connectors to connect ducts to equipment. Project No. 18088080 5 Section 23 33 00 Lake Lewisville WTP Dewatering Improvements Air Duct Accessories K. For fans developing static pressures of 5-inch wg and more, cover flexible connectors with loaded vinyl sheet held in place with metal straps. L. Connect flexible ducts to metal ducts with adhesive plus sheet metal screws. M. Install duct test holes where required for testing and balancing purposes. 3.2 FIELD QUALITY CONTROL A. Tests and Inspections: 1. Operate dampers to verify full range of movement. 2. Inspect locations of access doors and verify that purpose of access door can be performed. 3. Inspect turning vanes for proper and secure installation. END OF SECTION 18088080 1 Section 23 34 23 Lake Lewisville WTP Dewatering Improvements Fans SECTION 23 34 23 - FANS PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Type 1 – Down-blast centrifugal roof exhausters. 2. Type 4 – Sidewall propeller fans. 1.2 REFERENCES A. American Bearing Manufacturers Association (ABMA): 1. 9, Load Ratings and Fatigue Life for Ball Bearings. 2. 11, Load Ratings and Fatigue Life for Roller Bearings. B. Air Movement and Control Association International, Inc. (AMCA): 1. 210, Laboratory Methods of Testing Fans for Certified Aerodynamic Performance Rating. 2. 211, Certified Rating Program- Product Rating Manual for Fan Air Performance. 3. 300, Reverberant Room Method for Sound Testing of Fan. 4. 301, Methods for Calculating Fan Sound Ratings from Laboratory Test Data. C. American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE): 1. 52.1 - Gravimetric and Dust Spot Procedures for Testing Air-Cleaning Devices Used in General Ventilation for Removing Particle Matter. 2. 68 - Laboratory Methods of Testing to Determine Sound Power in a Duct. D. ASTM International (ASTM): 1. A 108 - Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished. 2. D 4167 - Standard Specification for Fiber Reinforced Plastic Fans and Blowers. 3. E 84 - Standard Test Method for Surface Burning Characteristics of Building Materials. E. National Electrical Code (NEC). F. National Electrical Manufacturers Association (NEMA): 1. 250 – Enclosures for Electrical Equipment (1000 V Maximum). G. National Fire Protection Association (NFPA): 1. 90A - Standard for Installation of Air Conditioning and Ventilating Systems. 2. 820 - Standard for Fire Protection in Wastewater Treatment and Collection Facilities. H. National Roofing Contractors Association (NRCA). I. Occupational Safety and Health Administration (OSHA). J. Underwriters' Laboratories, Inc. (UL). 1.3 SYSTEM DESCRIPTION A. Design requirements: 1. Provide fans that have sharply rising pressure characteristics which extend throughout the operating range and continue to rise beyond the efficiency peak. 2. Provide fans that peak as close as possible to the maximum efficiency and whose operating range is within the normal fan selection range. 18088080 2 Section 23 34 23 Lake Lewisville WTP Dewatering Improvements Fans 3. When scheduled, provide guided vibration isolator for fans, so that not more than 10 percent of the vibration amplitude of the fan and motor is transmitted to the supporting structure. 4. Design fan inner scroll and air stream surfaces to maintain smoothness for entire fan service life. 5. Seismic supports: Seismic design criteria as specified in Section 01 81 02. 6. Wind supports for exterior units: Wind design criteria as specified in Section 01 81 04. 7. Electrical components: UL listed and meeting the design and installation requirements of the NEC. 8. Motors supplied with fans: Manufacturer’s standard when type not scheduled; provide motor voltage phases and speed as scheduled; motor not to be overloaded at any point on the fan curve including belt losses. 9. Roof curbs: Designed in accordance with NRCA standards. 10. Insulation and adhesives: Meet NFPA 90A requirements for flame spread and smoke generation. 11. Belt drive systems: Adjustable for minimum within 5 percent speed change, rated for 1.5 times maximum horsepower motor available for the scheduled fan size or model. 12. Screens: Provide bird or insect screen as specified with the fan type or as listed on the Fan Schedule: 13. Bird screen: Stainless steel; 0.5-inch mesh 18 gauge. 14. Insect screen: Stainless steel mesh and frame. 15. Finishes: When not specified with fan type, coat ferrous metals as specified in Section 09 90 00. 16. Accessories: Provide accessories specified and those scheduled. 17. Provide fans with fire/smoke control system as specified under paragraph Fire/Smoke Control System Design Requirements. B. Performance requirements: 1. Performance requirements are included in the Fan Schedule. 2. Fan performance: Rated and licensed to bear the AMCA label in accordance with AMCA 210 and AMCA 211. 3. Total sound power levels in the 8 octave band range as measured in accordance with ASHRAE 68, AMCA 301, or AMCA 300 as appropriate for each fan: Not to exceed the lesser of the following or the Sones levels on the Fan Schedule. Sound Power Level, decibel levels referenced to 10-12 watts Frequency, Hz 63 125 250 500 1,000 2,000 4,000 8,000 General 100 98 94 88 84 84 78 75 4. Air filters supplied with fans: 25 to 30 percent dust spot efficiency when rated per ASHRAE Testing Standard 52.1. 5. Bearings: Rated per ABMA 9 or 11 for a L10 life rating of not less than 50,000 hours; provide greater life when specified with each fan type. C. Electrical and control system design: 1. Design and supply necessary electrical power and control systems, components, and wiring to make a complete functioning system. Design to perform the system ventilating functions with the control systems. 2. Comply with requirements as specified in Division 26. D. Fire control system design requirements: 18088080 3 Section 23 34 23 Lake Lewisville WTP Dewatering Improvements Fans 1. Provide all supply, exhaust, and odor control fans greater than or equal to 2,000 cubic feet per minute with smoke control system including the following minimum components. a. Duct or fan mounted smoke detector. b. Fan interlock to shut down fan upon smoke detection. c. Signals for fans and smoke detectors to and from local fire alarm control panel if a fire alarm control panel is part of project design. d. Provide all wire, conduit, end of line resistors, and other electrical equipment for complete functioning smoke control system. Provide in conformance with the electrical, mechanical, and instrumentation Drawings. When no electrical design for smoke control system is indicated, CONTRACTOR shall provide design and installation of the smoke control system. 1.4 SUBMITTALS A. Product Data: For each type of product indicated. Include rated capacities, operating characteristics, and furnished specialties and accessories. Also 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 thickness and finishes, including color charts. 5. Dampers, including housings, linkages, and operators. 6. Roof curbs. 1.5 QUALITY ASSURANCE A. 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. B. AMCA Compliance: Fans shall have AMCA-Certified performance ratings and shall bear the AMCA-Certified Ratings Seal. C. UL Standards: Power ventilators shall comply with UL 705. Power ventilators used for restaurant kitchen exhaust shall also comply with UL 762. 1.6 COORDINATION A. Coordinate size and location of structural-steel support members. B. Coordinate sizes and locations of roof curbs, equipment supports, and roof penetrations with actual equipment provided. C. Coordinate sizes and locations of wall openings and equipment supports with actual equipment provided. 1.7 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. Belts: One set(s) for each belt-driven unit. 2. Provide two (2) extra sets (3 total) of filters per installed fan for fans specified with filters. PART 2 - PRODUCTS 18088080 4 Section 23 34 23 Lake Lewisville WTP Dewatering Improvements Fans 2.1 TYPE 1, DOWN-BLAST CENTRIFUGAL ROOF EXHAUSTERS A. Manufacturers: One of the following or equal: 1. Greenheck, Model GB. 2. Loren Cook, Model ACE. 3. Penn Ventilator, Model Domex. B. Characteristics: 1. Roof-mounted, centrifugal, down-blast type, spun-aluminum mushroom-style weather hoods, and aluminum centrifugal fan wheels. 2. Statically and dynamically balanced. 3. Aluminum: Suitable for outdoor installation in a marine environment. 4. Fan blades or wheel material: Non-sparking type. 5. Wheel diameters: As scheduled and in accordance with standard sizes adopted by AMCA for non-overloading centrifugal fans. 6. Centrifugal backwardly inclined type with airfoil blades, maximum efficiency, and quiet regular operation C. Accessories: 1. Mounting brackets: Necessary for installation. 2. Roof curb: a. Factory fabricated of 16-gauge aluminum with wood nailer strip and gaskets. b. Capable of supporting entire unit weight. c. Suitable for installing and connecting ductwork to curb. d. In accordance with NRCA Standards. e. Extend a minimum of 8 inches above top of built up roofing, but no less than 14 inches high. f. Flashing: In accordance with NRCA Standards. 3. Bird screen: Provide bird screen if no screen is listed on the Fan Schedule. 2.2 TYPE 4, SIDEWALL PROPELLER FANS A. Manufacturers: One of the following or equal: 1. Greenheck, Model SC, or SBC. 2. Loren Cook, Model AWD or AWB. 3. Penn Ventilator, similar model. B. Characteristics: 1. Type: Wall-mounted, low noise propeller type, packaged unit. 2. Fan: Statically and dynamically balanced propeller with aluminum blades, unless noted otherwise. 3. Motor: Permanently lubricated; selected to avoid running in the service factor. C. Accessories: 1. Motor and fan side OSHA guards. 2. Wall mount collar when necessary for installation as indicated on the Drawings. 3. Dampers with damper guards when damper scheduled. 4. Weather hood when scheduled. 5. Bird screen: Provide bird screen if no screen is listed on the Fan Schedule. 6. Finish: Coat fan, housing, and accessories with polyester finish. 7. Diffusers and louvers when scheduled. 8. Mounting hardware. 2.3 MOTORS 18088080 5 Section 23 34 23 Lake Lewisville WTP Dewatering Improvements Fans A. Comply with NEMA designation, temperature rating, service factor, enclosure type, and efficiency requirements for motors specified in Division 26 Sections. 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. Controllers, Electrical Devices, and Wiring: Comply with requirements for electrical devices and connections specified in Division 26 Sections. B. Enclosure Type: Totally enclosed, fan cooled. 2.4 SOURCE QUALITY CONTROL A. Certify sound-power level ratings according to 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. B. Certify fan performance ratings, including flow rate, pressure, power, air density, speed of rotation, and efficiency by factory tests according to AMCA 210, "Laboratory Methods of Testing Fans for Aerodynamic Performance Rating." Label fans with the AMCA-Certified Ratings Seal. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine and verify that Work is in condition to receive installation specified in this Section. B. Take measurements and verify dimensions to ascertain fit of installation. C. Ascertain support and openings are correctly located. 3.2 PREPARATION A. Before installation, remove dust and debris from equipment and ducts. B. During installation and until equipment is operated, protect equipment and ducts from dust and debris by covering openings with tape or plastic. 3.3 INSTALLATION A. Observe applicable installation requirements as specified. B. Anchoring and support: 1. Provide anchoring and support for fans and appurtenances. 2. Provide anchoring to sustain seismic and wind forces as specified in Sections 01 81 02 and 01 81 04. C. Adjust alignment of ducts where necessary to resolve conflicts with architectural features or to resolve conflicts with the work of other trades. D. Install flexible connections to fans. E. Install roof curb and fan as recommended by fan manufacturer. F. For fan housings with threaded water trap drain, provide drain piped from fan housing to the nearest drain channel, floor drain, or sump. 18088080 6 Section 23 34 23 Lake Lewisville WTP Dewatering Improvements Fans G. Install fans level and plumb. H. Secure roof-mounted fans to roof curbs with stainless steel hardware. I. Install units with clearances for service and maintenance. J. Label units with permanent labels. 3.4 CONNECTIONS A. Ground equipment according to Division 26. B. Connect wiring according to Division 26. 3.5 FIELD QUALITY CONTROL A. Perform tests and inspections. 1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing. B. Tests and Inspections: 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. Adjust belt tension. 6. Adjust damper linkages for proper damper operation. 7. Verify lubrication for bearings and other moving parts. 8. Verify that manual and automatic volume control and fire and smoke dampers in connected ductwork systems are in fully open position. 9. Disable automatic temperature-control operators, energize motor and adjust fan to indicated rpm, and measure and record motor voltage and amperage. 10. Shut unit down and reconnect automatic temperature-control operators. 11. Remove and replace malfunctioning units and retest as specified above. C. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. D. Prepare test and inspection reports. 3.6 ADJUSTING A. Adjust damper linkages for proper damper operation. B. Adjust belt tension. C. Replace fan and motor pulleys as required to achieve design airflow. D. Lubricate bearings. 18088080 7 Section 23 34 23 Lake Lewisville WTP Dewatering Improvements Fans END OF SECTION Project No. 18088080 1 Section 23 37 13 Lake Lewisville WTP Dewatering Improvements Air Outlets and Inlets SECTION 23 37 13 – AIR OUTLETS AND INLETS PART 1 - GENERAL 1.1 SUMMARY A. Section includes the air distribution outlets, exhaust and return air devices, and the accessories required for complete installation. B. The work of this section is subject to the requirements of Section 23 05 00, Common Work Results for Mechanical. 1.2 CODES AND STANDARDS A. Sheet Metal and Air Conditioning Contractors National Association 1. HVAC Duct Construction Standards - Metal and Flexible B. American Society of Heating, Refrigerating and Air Conditioning Engineers 1. Fundamentals - Handbook Latest Edition 2. ANSI/ASHRAE 70-1991 Method of Testing For Rating the Performance of Air Outlets and Inlets. 3. ASHRAE 113-1990 Method of Testing For Room Air Diffusion. C. Air Conditioning and Refrigeration Institute 1. ARI 890-1994 Rating of Air Diffusers and Air Diffuser Assemblies 2. ARI 885-1990 Procedure for Estimating Occupied Space Sound Levels in the Application of Air Terminals and Air Outlets D. International Organization for Standardization (ISO) 1. ISO 5219-1984 Air Distribution and Air Diffusion -- Laboratory Aerodynamic Testing and Rating of Air Terminal Devices 2. ISO 5135-1984 Acoustics -- Determination of Sound Power Levels of Noise from Air Terminal Devices, High/Low Velocity/Pressure Assemblies, Dampers and Valves by Measurement in a Reverberation Room. 3. ISO 3741-1988 Acoustics -- Determination of Sound Power Levels of Noise Sources -- Precision Methods for Broad-Band Sources in Reverberation Rooms. 4. ISO 7244-1984 Air Distribution and Air Diffusion -- Aerodynamic Testing of Dampers and Valves. 5. ISO 7730-1994 Moderate Thermal Environments -- Determination of the PMV and PPL Indices and Specification of the Conditions for Thermal Comfort. 1.3 SUBMITTALS A. Submittals shall include manufacturers technical literature for performance (sound pressure loss, throw) pictorial literature, and schedule shall be submitted indicating the style and size of each diffuser or grille, location by room number, CFM of unit, throw, noise level, (NC rating) method of mounting and finish. 1.4 ACCEPTABLE MANUFACTURERS A. Acceptable Manufacturers shall be Titus, Price, and Tuttle & Bailey. Project No. 18088080 2 Section 23 37 13 Lake Lewisville WTP Dewatering Improvements Air Outlets and Inlets PART 2 - PRODUCTS 2.1 GENERAL A. Product performance data shall be taken from tests conducted in accordance with ISO Standard 3741, ISO Standard 5135, ISO Standard 5219, ISO Standard 5279, ISO Standard 7244, ISO Standard 7730-7794, ANSI/ASHRAE 70, and ARI-890. B. Exhaust grilles and registers including volume controllers for toilet rooms and janitors' closets, shall be constructed entirely of aluminum. Except where aluminum is specified, remainder of diffusers, grilles and registers may be constructed of steel including volume controllers. C. Unless otherwise specified on drawings, grilles and frames constructed of aluminum shall have a 60 minute anodized aluminum finish. All other grilles and diffusers shall have a white flo-coat finish suitable as a finish coat or for field painting. D. Refer to architectural drawings for the various types of ceilings, i.e., mineral tile or plaster to assure that air devices have the correct type of mounting. Refer to drawings of reflected ceiling plans for location of ceiling diffusers and grilles. E. Supplier shall also check all air distribution and return air devices for proper performance, noise and accessories. Any device exceeding noise level herein specified shall be brought to the attention of the Engineers. F. Contractor shall coordinate openings in hard ceilings, furred walls, masonry walls, and floors. G. The nominal or duct connection size of grilles (not overall dimensions) is given on plans. H. Devices are defined in the following manner in this section. Abbreviation used Device on the Drawings Supply Grilles/ Diffuser S0# Return Grilles R0# I. A third letter following these abbreviations refers to the type of device which is defined herein. 2.2 RETURN/EXHAUST GRILLES A. Unless otherwise called for on drawings and schedule the return grilles shall be the following: 1. Type A - Titus model 50F, 1/2 inch aluminum grid for. Register shall include an AG-35 opposed blade damper. Scheduled grilles take precedence. 2. Type B – Titus model 60FL, industrial style aluminum bar grilles. Scheduled grilles take precedence. 2.3 SUPPLY GRILLES A. Type A - Titus model DL - High capacity supply louver. Scheduled grilles take precedence. B. Type B – Titus model 272FL – Aeroblade double deflection supply grilles. Grilles shall include an opposed blade damper. AG35AA or equal. Scheduled grilles take precedence. Project No. 18088080 3 Section 23 37 13 Lake Lewisville WTP Dewatering Improvements Air Outlets and Inlets PART 3 - INSTALLATION A. Provide air devices as indicated on the drawings. Mount each device securely to avoid rattling and vibration. B. Devices shall be parallel to the plane of the surfaces they are mounted on. C. Continuous linear devices shall be aligned, parallel to walls, with no perceptible distortion. END OF SECTION Project No. 18088080 1 Section 23 74 13 Lake Lewisville WTP Dewatering Improvements Packaged Rooftop Air Conditioning Units SECTION 23 74 13 - PACKAGED ROOFTOP AIR CONDITIONING UNITS PART 1 - GENERAL 1.1 SUMMARY A. Section includes all work necessary for a complete installation of packaged rooftop air conditioning units. B. The work of this section is subject to the requirements of Section 23 05 00, Common Work Results for Mechanical. 1.2 SUBMITTALS A. Shop drawings shall include complete data on compressors, electric heating components electric motors, V-belt drives, coils, casing construction, vibration isolation, economizer cycle, and air filters. B. Fan data shall include: capacity, fan curve, RPM brake horsepower, fly wheel effect (WK2), class, arrangement, sound power levels for each octave band. C. Unit data shall include total and sensible cooling capacities and heating inputs and outputs. 1. Curb data. 2. Unit configuration. 1.3 QUALITY ASSURANCE A. 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. B. ASHRAE Compliance: 1. Fabricate and label refrigeration system to comply with ASHRAE 15, "Safety Standard for Refrigeration Systems." C. ASHRAE/IESNA Compliance: Applicable requirements in ASHRAE/IESNA 90.1-2013. 1.4 WARRANTY A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of packaged rooftop air-conditioning units that fail in materials or workmanship within specified warranty period. 1. Warranty Period: a. For Compressor: Five year(s) from date of Substantial Completion. b. For Parts and labor: One year(s) from date of Substantial Completion. PART 2 - PRODUCTS 2.1 GENERAL A. Packaged rooftop air conditioning units shall be completely factory assembled including compressors coils, electric heating section, refrigerant circuits, condensate drain pan, fans, motor(s), starters, filters and controls in an insulated weather resistant casing. Units shall be rated and tested in accordance with ARI standard 360. Units shall be UL listed and labeled and classified in accordance with ANSI Z21.47 and UL 465. Units shall be downflow airflow. The operating range shall be between 0 and 115 degrees. Project No. 18088080 2 Section 23 74 13 Lake Lewisville WTP Dewatering Improvements Packaged Rooftop Air Conditioning Units B. Casing: 1. Unit casing shall be constructed of zinc coated, minimum 22 gauge, ASTM A527 G90 galvanized steel. Exterior surfaces shall be cleaned, phosphatized and finished with a weather-resistant baked enamel finish. Seams shall be gasket sealed to be water tight. 2. The air handling portions of the casing shall be completely insulated with coated, fire retardant glass fiber insulation, minimum 1-1/2 inches thick. Service panels with lifting handles and air tight seal shall provide access to all sections of the unit for maintenance. The base of the unit shall be suitable for mounting on a roof curb and shall have provisions for lifting by crane. C. Compressors: 1. Compressors shall be high efficiency, sealed hermetic rotary (scroll) or reciprocating type mounted on spring vibration isolators within the unit. Compressors shall be equipped with internal overcurrent and temperature protection as well as high and low pressure protection. Each refrigerant circuit shall have independent capillary expansion devices, service pressure ports and refrigerant line filter dries. Units shall have dual compressors if available or otherwise noted. D. Coils: 1. Evaporator and condenser coils shall be seamless copper tube type with mechanically bonded aluminum fins. Coils shall be factory leak tested to 200 psig and pressure tested to 450 psig. E. R410A Refrigerant F. Fans and Blowers: 1. Evaporator fan shall be forward curved blade centrifugal type statically and dynamically balanced with adjustable V-belt drive or direct drive. High efficiency motors shall be thermally protected. Fan and motor assemblies shall be spring isolated from the rest of the unit. 2. Condenser fans shall be direct drive, vertical discharge propeller type, statically and dynamically balanced. Fan motors shall be permanently lubricated with built-in thermal overload protection. G. Operation and Safety Controls: 1. Manual reset, high pressure cutout switches. 2. Automatic reset, low pressure cutout switches. 3. Low oil pressure cutout switch. 4. Compressor winding cutout switch. 5. Excessive cycling protection. H. Filters: 1. Units shall be equipped with 2 inch thick, 30 percent efficient, pleated media type throw- away filters. I. Energy efficiency equal to or greater than prescribed by ASHRAE 90.1. J. Options and Features 1. Units shall include the following options and features. a. Hail guards. b. Comparative enthalpy economizer with powered exhaust. c. Hinged access doors. d. Supply and return smoke detectors. e. Low ambient cooling to zero degrees. f. Evaporator defrost control g. Human interface control panel. Project No. 18088080 3 Section 23 74 13 Lake Lewisville WTP Dewatering Improvements Packaged Rooftop Air Conditioning Units h. Microprocessor controls. i. Dehumidification (hot gas reheat) with space humidity sensor K. Unit shall have terminal strip for thermostat control. L. Acceptable manufacturers shall include Trane, Carrier, York, or equal. PART 3 - EXECUTION 3.1 INSTALLATION A. Install unit in accordance with manufacturers’ instructions. Unit to be installed level and plumb, and firmly anchored to structure. B. Install trapped condensate drain piping. C. Install economizer and powered exhaust modules. D. Install control wiring. E. Turn units over to Owner with a clean set of filters. 3.2 DEMONSTRATION A. Engage a factory-authorized service representative to train Owner’s maintenance personnel to adjust, operate, and maintain units. B. Test all units in both 100% recirculation and 100% economizing modes. Test units for staged cooling. Test units with lead/lag control. Assure proper operation in all modes. END OF SECTION Project No. 18088080 1 Section 23 83 01 Lake Lewisville WTP Dewatering Improvements Heating Units SECTION 23 83 01 – HEATING UNITS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: 1. Electric unit heaters corrosion resistant. 2. Thermostats for unit heater. B. Related sections: 1. Section 01 41 00 - Regulatory Requirements. 2. Section 01 81 00 - Project Design Criteria. 3. Section 01 81 02 - Seismic Design Criteria. 4. Section 01 81 04 - Wind Design Criteria. 5. Section 23 09 13 - HVAC Controls. 6. Section 23 05 93 - Testing, Adjusting, and Balancing. 7. Section 26 05 15 - Electric Motors. 1.2 REFERENCES A. Air Movement and Control Association International, Inc. (AMCA): 1. 302 - Application of Sone Ratings for Non-Ducted Air Moving Devices. B. American Gas Association (AGA). C. National Electric Code (NEC). D. National Fire Protection Association (NFPA): 1. 54 - National Fuel Gas Code. E. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (100 V Maximum). F. Underwriters’ Laboratories, Inc. (UL). G. International Fuel and Gas Code (IFGC). H. International Mechanical Code (IMC). 1.3 DEFINITIONS A. NEMA Type 3R enclosure in accordance with NEMA 250. 1.4 SYSTEM DESCRIPTION A. Design requirements: 1. Provide seismic and wind supports meeting the seismic design criteria as specified in Section 01 81 02 and wind design criteria for exterior units as specified in Section 01 81 04. 2. Electrical components: UL listed and meeting the design and installation requirements of the NEC. 3. Hot water piping, gas piping, drains, venting, and other appurtenances of unit heaters: Install in accordance with building code, mechanical code, and plumbing code as specified in Section 01 41 00, and the NFPA. Project No. 18088080 2 Section 23 83 01 Lake Lewisville WTP Dewatering Improvements Heating Units 4. Noise levels for unit heaters installed in offices, hallways, or entry areas: Not to exceed 10 Sones as measured in accordance with AMCA Publication 302. 5. Motors supplied with heating units: As specified in Section 26 05 15. B. Performance requirements are included in the Heating Unit Schedules in the drawings. C. Design and supply necessary electrical power and control systems, components, and wiring to make a complete functioning system. 1. Comply with referenced electrical Sections and design to perform system heating functions as specified in Section 23 09 13. 1.5 SUBMITTALS A. Shop drawings: 1. System layout, mechanical, electrical power, and control diagrams. 2. Materials. 3. Supports and seismic bracing calculations and details. 4. Cut sheets on primary and ancillary equipment. 5. Sound ratings of fans in Sones in accordance with AMCA Publication 302. B. Certificates: Successful testing of burners used in gas unit heaters. C. Operation and Maintenance Data. D. Warranties. 1.6 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. ASHRAE Compliance: Applicable requirements in ASHRAE 62.1-2013, Section 5 - "Systems and Equipment" and Section 7 - "Construction and Startup." C. ASHRAE/IESNA 90.1-2004 Compliance: Applicable requirements in ASHRAE/IESNA 90.1- 2013, Section 6 - "Heating, Ventilating, and Air-Conditioning." D. Provide heating units and controls that are listed by UL. 1.7 WARRANTY A. Two-year manufacturer's warranty on all components, except heating elements and coils. B. Heating elements and coils: 10-year warranty. PART 2 - PRODUCTS 2.1 ELECTRIC UNIT HEATERS CORROSION RESISTENT A. Manufacturers: One of the following. 1. Chromalox, Type HD3D. 2. QMark, Series JUH. 3. Markel, Series 5500. 4. King, KBS Series. Project No. 18088080 3 Section 23 83 01 Lake Lewisville WTP Dewatering Improvements Heating Units B. Fan type: Aluminum axial flow: 1. Provide fan guards. 2. Dynamically balance. 3. Fan designed for quiet operation. 4. Permanently lubricated ball bearings. 5. Automatic reset thermal overload protection. 6. Epoxy coated. 7. Motor: Totally enclosed, permanently lubricated ball bearing type with epoxy coating. Factory wired to Nema 4X enclosure. C. Heating element characteristics: 1. Rated capacity at entering air temperature of 65 degrees Fahrenheit. 2. Fin type, Stainless Steel Fintube, designed for maximum resistance to corrosion. 3. 3-phase designed for balanced phases. 4. Over temperature cutout with automatic reset. D. Features: 1. Built-in magnetic contactors. 2. Control transformer for 24 or 120-volt control as indicated in the Heating Unit Schedules. 3. Required mounting brackets. 4. Individually adjustable outlet louvers. 5. Cabinet formed of minimum thickness 20-gauge stainless steel type 304. 6. Controls: a. Provide thermostat as specified in this Section. b. Provide control transformer suitable for 24-volt or 120-volt control as indicated in the Heating Unit Schedules. 2.2 THERMOSTATS FOR UNIT HEATERS A. Type: Wall mounted, heat only with fan AUTO-ON selector switch when fan part of unit and separate system ON-OFF selector switch. B. Dial or lever temperature setpoint adjustment with 45 to 90 degrees Fahrenheit setpoint range. C. Setpoint and temperature indication. D. Control voltage as indicated in the attached Heating Unit Schedules. E. Bi-metallic contacts suitable for 1- or 2-stage unit heater control as specified for the heater size or as scheduled. The use of mercury within the thermostat is not acceptable. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine and verify that Work is in condition to receive installation specified in this Section. 1. Take measurements and verify dimensions to ascertain fit of installation. 2. Verify structural sufficiency to support installation. 3. Verify that chassis, shafts, and openings are correctly located. a. Otherwise cut new openings where required. 4. Confirm specified thermostat and other controls are compatible with specified equipment. B. Examine and verify structural details and sections indicated on the Drawings, ascertain adequacy, and determine possible conflicts in dimensions and clearances. Project No. 18088080 4 Section 23 83 01 Lake Lewisville WTP Dewatering Improvements Heating Units 3.2 PREPARATION A. Before installation, remove dust and debris from equipment and ducts. B. During installation and until equipment is operated, protect equipment and ducts from dust and debris by covering openings with tape or plastic. 3.3 INSTALLATION A. Anchoring and support: Install anchoring for seismic and wind forces to meet the design criteria specified in Sections 01 81 02 and 01 81 04. B. Alignment: Adjust ductwork alignment when necessary to resolve conflicts with architectural and structural features or to resolve conflicts with work of other trades. C. Install and wire heating units and thermostats in accordance with manufacturer's recommendations. 1. Provide disconnect switches at the heating units wherever indicated on the Drawings, specified in this Section, scheduled and wherever required by code. D. Adjust heater units with louvers for optimum air circulation. E. Provide gas unit heater venting in accordance with mechanical code and plumbing code as specified in Section 01 41 00 and in accordance with NFPA 54. 3.4 FIELD QUALITY CONTROL A. Test equipment and installation to verify operation is within manufacturer's standards and that noise levels do not exceed levels specified. B. Test equipment performance and balance equipment as specified in Section 23 05 93. END OF SECTION DIVISION 26 ELECTRICAL Project No. 18088080 1 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical SECTION 26 05 00 - COMMON WORK RESULTS FOR ELECTRICAL PART 1 - GENERAL 1.1 SUMMARY A. This Section specifies the basic requirements for electrical installations and includes requirements common to more than one section of Division 26. It expands and supplements the requirements specified in the General and Supplementary Conditions. B. This project consists of construction of the new building structures, associated facilities, and all related electrical systems as defined in the plans and in these specifications. C. The work includes the installation, connection and testing of new electrical equipment, including power distribution equipment, lighting equipment, underground electrical work, grounding systems, control systems, conduit and wiring, coordination of traffic flow, temporary power systems, special electrical systems and all appurtenances to construct and demonstrate proper operation of the completed electrical systems. D. The Contractor shall be responsible for the coordination of power, communication, and controls for the project. E. The electrical plans do not give exact locations, etc., and do not show all the offsets, control lines, pilot lines, and other installation details. Each contractor shall carefully lay out the work at the sites to conform to the job conditions, to conform to details of installation supplied by the manufacturers of the equipment to be installed, and thereby to provide complete operating systems. F. The electrical plans show diagrammatically the locations of the various electrical outlets and apparatus and the general method of circuiting and controlling. Exact locations of these outlets and apparatus shall be determined by reference to the general plans and to all detail drawings, etc., by measurements at the buildings, and in cooperation with other crafts, and in all cases shall be subject to the approval of the Owner and Engineer. The Engineer reserves the right to make any reasonable change in location of any outlet or apparatus before installation, without additional cost to the Owner. G. These specifications and the accompanying drawings are intended to cover systems which will not interfere with the structure of the buildings, which will fit into the several available spaces, and which will ensure complete and satisfactory systems. Each bidder shall be responsible for the proper fitting of the material and apparatus into the buildings. H. Should the particular equipment which any bidder proposes to install require other space conditions than those indicated on the Drawings, the Bidder shall arrange for such space with the Engineer before submitting the bid. Should changes become necessary on account of failure to comply with this clause, the Contractor shall make such changes at the Contractor’s expense. I. Where wire sizes, conduit and other items of construction are shown or required for a complete installation, but are not adequately identified as to size or material requirements, the materials furnished shall be in accordance with “Code” requirements as though shown in detail on the Drawings. J. All equipment shall be leveled and made plumb. Metal junction boxes, equipment enclosures and metal raceways mounted on water or earth-bearing walls shall be separated from walls not less than 1/4 inch by corrosion-resistant spacers. All electrical conduits and items of equipment shall be run or set parallel to walls, floors and other items of construction. Project No. 18088080 2 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical 1.2 STANDARDS A. The Contractor shall perform work specified in Division 26 in accordance with standards listed below. Where these specifications are more stringent, the most stringent standard shall take precedence. In case of conflict, obtain a decision from the Engineer. 1. Applicable National Fire Protection Association (NFPA) codes, including but not limited to: a. NFPA 70 – National Electrical Code. b. NFPA 70E – Standard for Electrical Safety in the Workplace. c. NFPA 72 - National Fire Alarm Code. d. NFPA 101 – Life Safety Code. e. NFPA 820 – Standard for Fire Protection in Wastewater Treatment and Collection Facilities. f. Internet Website: http://www.nfpa.org 2. Applicable Code of Federal Regulations (CFR) codes, including but not limited to: a. 29 CFR 1910 – Occupational Safety and Health Standards (OSHA). b. 29 CFR 1926 – Safety and Health Regulations for Construction. c. Internet Website: http://www.gpo.gov/fdsys 3. ANSI/IEEE C2 – National Electrical Safety Code. 4. Applicable Federal, State and Local Fire codes. 5. Applicable Federal, State and Local Energy Codes. 6. Applicable Federal, State and Local Building Codes. 7. Applicable City Electrical Code. 8. Applicable City Ordinances pertaining to electrical work. 9. Applicable Federal, State and Local – Environmental, Health and Safety Laws and Regulations. B. Contractor shall utilize the most current editions of standards, which are current at time of bid and as recognized by the Authority Having Jurisdiction for the respective standard. 1.3 SUBMITTALS A. Submittals shall comply with Section 01 33 00 SUBMITTAL PROCEDURES and the General and Supplementary Conditions. B. Submittals shall be furnished by the Contractor for the work involved in sufficient time so that no delay or changes will be caused. Fax copies are not acceptable. C. Submittals shall consist of manufacturing information, schematics, wiring diagrams, ladder logic diagrams, instrument loop diagrams, outline drawings, clearances and related information. Shop Drawings shall be so marked as to indicate the EXACT items offered. D. Submittals shall bear Contractor’s certification that the item complies in all respects with the item originally specified. It is the Contractor’s responsibility to procure the proper sizes, quantities, rearrangements, structural modifications or other modifications in order for the substituted item to comply with the established requirements. E. The Contractor shall combine each submittal set into one electronic file (pdf format). Group materials submitted by their Specification numbers, but do not submit the entire electrical within one submittal. Provide electronic bookmarks in the pdf to indicate the included equipment types and a title sheet to separate each section. F. The Contractor shall submit complete descriptions, illustrations, specification data, etc., of all materials, fittings, devices, fixtures, special systems, etc., as required by the individual sections of this Division. Project No. 18088080 3 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical G. Submittal of shop drawings, product data and samples will be accepted only when submitted by the Contractor. Data submitted from subcontractors and material suppliers directly to the Engineer will not be processed. H. All submittals shall provide the following information: 1. General Contractor. 2. Sub-Contractor. 3. Distributor and/or Supplier. 4. Sales Agency. 5. Submittals not supplying this information will be rejected. I. Shop Drawings: In addition to the above, submit shop drawings for major materials where called for and when requested by the Engineer. 1. Lockout/Tagout Program. 2. Switchboard, motor control centers, panelboards, surge arresters, and safety switches. 3. Motor starters and contactors including custom wiring diagrams for all motors. 4. Lighting fixtures and lamps including light pole foundation requirements. 5. Wire, cable and conduit. 6. Dry type transformers including weight and dimensions. 7. Wiring devices and plates. 8. Dimensioned layout of electrical room drawn to scale, with equipment location shown therein. Clearances shall be in accordance with NEC and local codes. 9. Dimensioned layout of all below grade conduit installations. 10. Grounding system and layout. 11. Lightning protection system layout. 12. Traffic control system layout and schematics. 13. Seismic protection materials and methods for all electrical equipment. 14. Mounting brackets, supports and assembly for walkway mounted equipment including instruments, lighting and control panels 1.4 QUALITY ASSURANCE A. Any electrical equipment provided under this Division shall be turned over to the Owner in operating condition. Instruction on further operation and maintenance shall be included in the operating and maintenance instructions. 1.5 PRODUCT LISTING A. Prepare listing of major electrical equipment and materials for the project. B. Provide all information requested. C. Submit this listing as a part of the submittal requirements. D. When two or more items of same material or equipment are required they shall be of the same manufacturer when available. Product manufacturer uniformity does not apply to raw materials, bulk materials, wire, conduit, fittings, sheet metal, steel bar stock, welding rods, solder, fasteners, motors for dissimilar equipment kits, and similar items used in Work, except as otherwise indicated. E. Provide products that are compatible within systems and other connected items. Project No. 18088080 4 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical 1.6 NAMEPLATE DATA A. Provide permanent operational data nameplate on each item of power operated equipment, indicating manufacturer, product name, model number, serial number, capacity, operating and power characteristics, labels of tested compliances, and similar essential data. Locate nameplates in an accessible location. 1.7 WORK SUPERVISION A. The Contractor shall designate in writing the qualified electrical supervisor who shall provide supervision to all electrical work on this project. The minimum qualifications for the electrical supervisor shall be a master electrician as defined by the statutes of the State of the work being performed. The supervisor or his appointed alternate possessing at least a master electrician license shall be on site whenever electrical work is being performed. The qualifications of the electrical supervisor shall be subject to approval of the Owner and the Engineer. B. All master and journeyman electricians shall be licensed in accordance with the statutes of the State of the work being performed. No unlicensed electrical workers shall perform work on this project. Apprentice electricians in a ratio of not more than one apprentice per journeyman electrician will be allowed if the apprentices are licensed and actively participating in an apprentice-ship program recognized and approved by the statutes of the State of the work being performed. 1.8 TELEPHONE WORK A. The Contractor shall be responsible for coordinating all telephone work with the servicing utility, Owner and Engineer. 1.9 LOCKOUT / TAGOUT PROGRAM A. The Contractor shall provide a complete copy of and electrical energy source Lockout/Tagout Program to the Owner, with copy to the Engineer. The document shall clearly identify the on-site master electricians and their contact information, including office and mobile telephone numbers. B. The Lockout/Tagout Program shall comply with Part 1910 - Occupational Safety and Health Standards (OSHA) Subpart S – Electrical, and meet the requirements of 29 CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout), including requirements listed in 1910.331 through 1910.335. C. Implementation of the Lockout/Tagout Program and all other related safety requirements are the sole responsibility of the Contractor. 1.10 SAFETY PROGRAM A. The Contractor shall implement an electrical safety program that complies with NFPA 70E and 29 CFR 1926. B. Implementation of the Electrical Safety Program, determining and providing proper Personal Protective Equipment (PPE), training and enforcing personnel to wear the prescribed PPE, conducting work area safety inspections (including correcting deficiencies), and all other related safety requirements are the sole responsibility of the Contractor. Project No. 18088080 5 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical 1.11 EQUIPMENT CONNECTIONS A. General: Provide connections for all equipment installed or modified by this contract, regardless of who furnished the equipment. B. Provide all disconnect switches required by Code whether or not shown on the plans. C. Contractor shall connect Owner-furnished equipment when specified. 1.12 GENERAL CONDITIONS A. The work under this heading is subject to the General and Supplementary Conditions, special conditions for mechanical and electrical work, and the Contractor or subcontractor will be responsible for and be governed by all requirements thereunder as though specifically repeated herein. 1.13 COORDINATION A. The Contractor shall coordinate arrangement, mounting and support of all electrical equipment: 1. To allow maximum possible headroom unless specific mounting heights are indicated. 2. To provide for ease of disconnecting the equipment with minimum interference to other installations. 3. To allow right of way for piping and conduit installed at a required slope. 4. So connecting raceways, cables and wireways will be clear of obstructions and of the working and access space of other equipment. B. The Contractor shall coordinate electrical equipment to be mounted on vendor supplied walkways with supplier. 1.14 SPECIAL NOTE A. The mechanical, structural and process plans and specifications, including the general conditions and all supplements issued thereto, information to bidders, and other pertinent documents issued by the Engineer, are a part of these specifications and the accompanying electrical plans, and shall be complied with in every respect. All the above is included herewith, and shall be examined by all bidders. Failure to comply shall not relieve the Contractor of responsibility or be used as a basis for additional compensation due to omission of mechanical, process and structural details from the electrical drawings. 1.15 CONTINUATION OF SERVICES A. The Contractor shall install any temporary lines and connections required to maintain electric services and safely remove and dispose of them when complete. The Contractor shall supply emergency power whenever any existing electrical service is without power. In general, the existing facility shall remain operational during construction. B. Planned outages shall be coordinated two weeks in advance with duration and time of start approved by the Owner. Changeover work which may be required after normal hours or weekends shall not constitute the basis for additional cost to the Owner. When an outage begins, the Contractor shall proceed directly to completion of the work without unscheduled interruptions or delays due to lack of manpower, equipment or tools. C. The Contractor shall refer to the sequence of construction and shall provide temporary connections as may be required to complete each phase of construction as may be required. The Project No. 18088080 6 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical Contractor shall submit proposed electrical service plans for each phase of construction to the Owner and Engineer for consideration. 1.16 LAYOUT A. The Contractor shall coordinate and establish all bench marks and control lines. The Contractor shall lay out all work. The lay out shall be reviewed by the Engineer and Owner prior to starting any work. 1.17 RELATED WORK SPECIFIED ELSEWHERE A. Mechanical Equipment: The Contractor shall rough-in for and make final electrical connections to all motor, panels, fixtures, and equipment furnished under other sections of the specifications, providing all material and equipment required for such final connections, except hereinbefore described. This includes, but is not limited to, control panels and other miscellaneous equipment. B. The Contractor shall refer to other sections of these specifications for all information relating to the requirements of all electrical connections to the equipment and shall furnish and install electrical items required for a complete installation, ready for operation. C. Roughing-in shall be accomplished from approved shop drawings. D. Verify final locations for rough-ins with field measurements and with the requirements of the actual equipment to be connected. E. Refer to equipment specifications in other Divisions for rough-in requirements. 1.18 LOCAL CONDITIONS A. Inspection of Sites: The bidder shall inspect the site, thoroughly acquaint himself with conditions to be met and work to be accomplished. Failure to comply with this shall not constitute grounds for any additional payments. 1.19 RECORD DOCUMENTS A. Refer to the General and Supplementary Conditions for requirements. The following paragraphs supplement the requirements of the General and Supplementary Conditions: 1. Mark Drawings to indicate revisions to conduit size and location both exterior and interior; actual equipment locations, dimensioned for column lines; concealed equipment, dimensioned to column lines; distribution and branch electrical circuitry; fuse and circuit breaker size and arrangements; support and hanger details; Change Orders; concealed control system devices. 2. The Contractor shall locate all underground and concealed work, identifying all equipment, conduit, circuit numbers, motors, feeders, breakers, switches, and starters. The Contractor will certify accuracy by endorsement. Record drawings shall be correct in every detail, such that the Owner can properly operate, maintain, and repair exposed and concealed work. 3. The Contractor shall store the Record drawings on the site. Drawings shall not be rolled. Make corrections, additions, etc., with pencil, with date and authorization of change. 4. Mark specifications to indicate approved substitutions; Change Orders; actual equipment and materials used. Project No. 18088080 7 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical 1.20 OPERATION AND MAINTENANCE DATA A. Refer to Section 01 33 00, SUBMITTAL PROCEDURES and Section 01 78 23, OPERATION AND MAINTENANCE DATA for procedures and requirements for preparation and submittal of maintenance manuals. B. In addition to the information required by Sections 01 33 00 and 01 78 23, include the following information: 1. Installation manual: Description of function, installation and calibration manuals, normal operating characteristics and limitations, performance curves, engineering data and tests, and complete nomenclature and commercial numbers of all replaceable parts. 2. Operations manual: Manufacturer’s printed operating instructions and procedures to include start-up, break-in, routine and normal operating instructions; regulation, control, stopping, shutdown, and emergency instructions; summer and winter operating instructions; and all programming and equipment settings. 3. Maintenance manual: Maintenance procedures for routine preventative maintenance and troubleshooting; disassembly, repair, and reassembly; aligning and adjusting instructions. 4. Service manual: Servicing instructions and lubrication charts and schedules, including the names and telephone numbers of personnel to contact for both routine periodic and warranty service for equipment and materials provided under this Division. 5. Final approved equipment shop drawings, clearly labeled. 6. Final test reports, clearly labeled, including motor certification tests. 7. Final certified calibration sheets for all equipment and instruments. C. After approval of the O&M Manuals, the Contractor shall provide three (3) complete electronic copies of all documentation in Adobe PDF file format using a storage media device of the Owner and Engineer’s choosing. 1.21 GUARANTEE A. The Contractor shall guarantee the work and materials for a period of one (1) year from the date of completion. If there are failures due to faulty material or workmanship, the Contractor shall correct the failure at no cost to the Owner. B. Refer to the General and Supplementary Conditions for procedures and submittal requirements for warranties. Refer to individual equipment specifications for warranty requirements. 1. Compile and assemble the warranties specified in Division 26, into a separate set of vinyl covered, three ring binders, tabulated and indexed for easy reference. C. Provide complete warranty information for each item to include product or equipment to include date of beginning of warranty or bond; duration of warranty or bond; and names, addresses, and telephone numbers and procedures for filing a claim and obtaining warranty services. D. Upon completion of the installation, the Contractor shall adjust the systems to the satisfaction of the Engineer. E. This guarantee shall include the capacity and integrated performance of the component parts of the various systems in accordance with the intent of the specifications. The Contractor shall conduct complete tests required by the Engineer to demonstrate the ability of the various systems. 1.22 CLEANING A. Refer to Section 01 77 00 CLOSEOUT PROCEDURES for general requirements for final cleaning. Project No. 18088080 8 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical B. Clean all light fixtures, lamps and lenses prior to final acceptance. Replace all inoperative lamps. C. The electrical system shall be thoroughly cleaned inside and outside, of all enclosures to remove all debris, dust, concrete splatter, plaster paint and lint. PART 2 - PRODUCTS 2.1 MATERIALS AND EQUIPMENT A. All materials and equipment used in carrying out these specifications shall be new and have UL listing, or listing by other recognized testing laboratory when such listings are available. Specifications and drawings indicate name, type, or catalog numbers of materials and equipment to be used as standards. 2.2 HEAT TRACING A. Heat trace and insulate all exposed piping, water lines, and valves less than 8” diameter and all equipment where water may collect. Where exact sizes, panels, boxes, conduit, circuitry and other items of construction are shown or required for a complete installation, but are not adequately identified as to size or material requirements, the materials furnished shall be as needed to provide freeze protection requirements as though shown in detail on the Drawings. The Contractor shall be responsible for supplying all items as required for complete heat tracing systems regardless of the level of detail shown on the Drawings. B. Contractor shall meet all National Electrical code requirements for heat tracing and particularly to Resistance Heating Elements Article 427-21, 22 and 23. PART 3 - EXECUTION 3.1 SALVAGE A. All salvage and equipment removed by the work shall remain the property of the Owner unless directed otherwise by the Owner. Material removed from the project shall be stored on the project site where and as directed. Debris shall be removed from the job site and disposed of by the Contractor. 3.2 DEMOLITION AND DISPOSAL A. All conduit, wire, and other electrical appurtenances associated with equipment removed in this project, and no longer in use, shall be removed and stored or disposed of as directed by the Owner. The Contractor shall patch and apply finish to walls, floors, and other structures from which such items are removed to match surrounding colors, textures, or other visual characteristics. 3.3 DELIVERY, STORAGE, AND HANDLING A. Deliver equipment to project properly identified with names, model numbers, types, grades, compliance labels, and similar information needed for distinct identifications; adequately packaged and protected to prevent damage during shipment, storage, and handling. B. Store equipment and materials at the site, unless off-site storage is authorized in writing. Protect stored equipment and materials from damage. C. Equipment and materials shall be stored in accordance with the manufacturer’s recommendations and instructions. Project No. 18088080 9 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical D. All equipment, including but not limited to equipment containing coils and/or electronics, shall be stored in a clean, dry, ventilated and heated building. The storage area shall be free from condensation or other injurious environmental conditions. Freedom from condensation shall be essential and shall be accomplished by the use of auxiliary heaters as required to raise the temperature to 5-degree C above the ambient temperature. The equipment shall be protected from excessive dust. E. In addition, certain electronic equipment that requires cooling based upon its specific storage temperature range shall be stored in an air-conditioned building. F. All motors shall be stored in a clean, dry, ventilated and heated building. The storage area shall be free from condensation or other injurious environmental conditions. Freedom from condensation shall be essential and shall be accomplished by the use of auxiliary heaters as required to raise the temperature to 5 degree C above the ambient temperature. The motors shall be protected from excessive dust. G. Cables and wiring shall be kept in a dry location out of the sun. H. Outdoor storage, even when protected by a tarpaulin, is unacceptable. I. Equipment may be rejected if the storage criteria are not followed. 3.4 INSTALLATION A. Coordinate electrical equipment and materials installation with other building components. B. Verify all dimensions by field measurements. C. Arrange for chases, slots, and openings in other building components to allow for electrical installations. D. The Contractor shall keep ends of conduits, including those extending through roofs, equipment and fixtures covered or closed with caps or plugs to prevent foreign material from entering during construction. E. Coordinate the installation of required supporting devices and sleeves to be set in concrete and other structural components as they are constructed. F. Sequence, coordinate, and integrate installations of electrical materials and equipment for maintaining the required operation of the facility. Give particular attention to large equipment requiring positioning prior to closing-in the building. G. Coordinate the cutting and patching of building components to accommodate the installation of electrical equipment and materials. H. Where mounting heights are not detailed or dimensioned, install electrical services and overhead equipment to provide the maximum headroom possible. I. Install electrical equipment to facilitate maintenance and repair or replacement of equipment components. As much as practical, connect equipment for ease of disconnecting, with minimum of interference with other installations. J. Coordinate the installation of electrical materials and equipment above ceilings with suspension system, mechanical equipment and systems, and structural components. Project No. 18088080 10 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical K. Coordinate connection of electrical systems with exterior underground and overhead utilities and services. Comply with requirements of governing regulations, franchised service companies, and controlling agencies. Provide required connection for each service. L. Coordinate installation of electrical equipment on vendor supplied walkways with supplier. 3.5 MATERIALS AND WORKMANSHIP A. All materials shall be new, and shall be of the latest standard design of a manufacturer regularly engaged in the manufacture of that type of equipment. Materials shall be in good condition and shall be free from dents, scratches or other damage incurred in shipment or installation. B. All equipment shall comply with the National Electrical Code, Underwriters Laboratories or other appropriate agency. C. Installation shall be made in a neat and workmanlike manner, and all materials shall be installed in accordance with the recommendations of the various manufacturers. The installation shall be subject to the approval of the Owner and Engineer. D. Incidental materials required to complete the installation as intended by these Specifications shall be of the type and quality in keeping with specified equipment. 3.6 COORDINATION A. Carefully examine specification and drawings to be thoroughly familiar with items which require electrical connections and coordination. (Electrical drawings are diagrammatic and shall not be scaled for exact sizes.) B. Notify other tradesmen of any deviations or special conditions necessary for the installation of work. Interference between work of various contractors shall be resolved prior to installation. Work installed not in compliance with specifications and drawings and without properly checking and coordinating as specified above shall, if necessary, be removed and properly reinstalled without additional cost to the Owner. Engineer to be mediating authority in all disputes arising on project. C. Equipment shall be installed in accordance with manufacturer’s recommendation. Where conflicts occur between contract documents and these recommendations, a ruling shall be requested of the Engineer for decision before proceeding with such work. 3.7 CUTTING AND PATCHING A. Repair or replace routine damage caused by cutting in performance of work under this Division. B. Correct unnecessary damage caused due to installation of electrical work, brought about through carelessness or lack of coordination. C. Holes cut through floor slabs to be sleeved or core drilled with drill designed for this purpose. All openings, sleeves, and holes in slabs to be properly sealed, fire proofed and water proofed. D. Repairs to be performed with materials which match existing materials and to be installed in accordance with appropriate sections of these specifications. E. All cutting and patching work shall be coordinated in advance with the Engineer and Owner prior to any work. Project No. 18088080 11 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical 3.8 TRENCHING, EXCAVATION, BACKFILLING, AND REPAIRS A. Provide trenching, excavation, and backfilling necessary for performance of work under this Division. 3.9 FOUNDATIONS AND PADS A. Foundations and pads required for equipment shall be provided as indicated. Proper size and location of foundations, pads and anchor bolts shall be determined under this Division. B. Provide anchors and bases for electrical equipment to withstand lateral forces and accommodate displacements. 3.10 NOISE AND VIBRATION CONTROL A. The electrical system as installed shall be free of objectionable noise or vibration. The Contractor shall isolate motors, starters, transformers, equipment, ballasts, etc., as directed or required as to ensure acceptable noise level free from objectionable vibration in all systems. 3.11 TESTS A. On completion of work, installation shall be completely operational and entirely free from ground, short circuits, and open circuits. Perform a thorough operational test in presence of the Owner and Engineer. Furnish all labor, materials and instruments for above tests. B. Furnish the Engineer, as part of closing file, a copy of such tests including identification of each circuit and readings recorded. Test information to be furnished to the Engineer includes ampere readings of all panels and major circuit breakers, isolation resistance reading of motors and transformers. C. Prior to final observation and acceptance test, all electrical systems and equipment shall be in satisfactory operating condition. Including, but not limited to the following: 1. Electrical power and distribution system. 2. Lighting systems. 3. Transformers. 4. Electric motors for all equipment. 5. Telecommunication system. 6. Emergency power system. 7. Special electrical control systems. D. After installation of the electrical system and before operating equipment, functional checking shall be conducted in accordance with the manufacturer’s recommendations, with the contract drawings and as follows: 1. Functional checking shall include inspection, testing and repair, replacement or adjustments as necessary to ensure compliance with the requirements of the specifications. Tests and inspections shall be recorded on appropriate yellow lined contract and shop drawings, standard test forms and checklists to indicate that wiring and controls are in place in accordance with requirements and to form the basis of record drawings. 2. The functional test procedures shall be signed and dated by the Contractor and presented to the Owner’s construction observation personnel prior to operating any equipment. a. Visual Inspection – The electrical system shall be examined as outlined below: 1). Parts of components missing 2). Improper assembly 3). Parts or components not functioning properly 4). Finish not as specified Project No. 18088080 12 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical 5). Materials not as specified 6). Connections not tight 7). Mounting and supports loose or unsatisfactory 8). Nameplates missing or inaccurate b. Grounding System Tests 1). Measure the resistance of the counterpoise grounding system by the rate-of- fall of potential method. Record all measurements on an approved standard test form made specifically for the purpose. The resistance of the grounding system to ground shall not exceed NFPA 70 requirements. c. Continuity Tests 1). Each wire and each wire in each cable rated 300 volts and below shall be tested for continuity. Record wire number and pass or fail on checklist for each wire. d. Dielectric Tests 1). Each power conductor rated 600 volts and above shall be tested (meggered) for dielectric strength to ground. 2). Prior to testing, all components that could be damaged should be discon- nected. After testing, the circuit shall still register a resistance value of not less than 1 megohm at 600 volts, dc. This test shall apply between all insu- lated circuits and external metal parts. Record equipment name, phase or wire number and all observed values for each wire. 3). Subsequent to wire and cable hook-ups, energize circuits and demonstrate proper functioning of all circuits. Record equipment or circuit number and pass or fail on function test checklist for each circuit. 4). The Contractor shall develop non-conforming material reports for each failure. Repair and report failures all failures to Owner and Engineer. 5). The Contractor shall replace defective parts, correct malfunctioning units, make all repairs and retest to demonstrate compliance. The Contractor shall document all actions taken on appropriate non-conforming material report. 3.12 INSPECTION FEES AND PERMITS A. Obtain and pay for all necessary permits and inspection fees required for electrical installation. 3.13 IDENTIFICATION OF EQUIPMENT A. Properly identify all electrical equipment, including but not limited to the following: 1. Switchgear, switchboards, motor control centers, and control panels. 2. Main distribution panel and individual devices within it. 3. Panelboards and individual devices within it. 4. Safety switches and disconnects. 5. Contactors and lighting control center, including all branch circuits. 6. Individually mounted circuit breakers. 7. Relays. 8. Transformers. 9. Generators and automatic transfer switches. 10. Any other type of enclosure that includes electrical equipment. 3.14 TEMPORARY LIGHTS AND POWER A. Provide a temporary electrical lighting and power distribution system of adequate size to properly serve the construction needs, including adequate feeder sizes to prevent excessive voltage drop. Temporary work to be installed in a neat and safe manner in accordance with the National Electrical Code, Article 590, and as required by OSHA or applicable local safety codes. B. Provide service and panelboards required for lighting and power outlets. Project No. 18088080 13 Section 26 05 00 Lake Lewisville WTP Dewatering Improvements Common Work Results for Electrical C. The Contractor will pay for power consumption. D. Coordinate prior to installation to determine whether single phase or three-phase temporary service is desired. END OF SECTION Project No. 18088080 1 Section 26 05 13 Lake Lewisville WTP Dewatering Improvements Medium-Voltage Cables SECTION 26 05 13 - MEDIUM-VOLTAGE CABLES PART 1 - GENERAL 1.1 SUMMARY A. This Section includes cables and related splices, terminations, and accessories for medium- voltage electrical distribution systems. 1.2 DEFINITIONS A. NETA ATS: Acceptance Testing Specification. 1.3 SUBMITTALS A. Product Data: For each type of cable indicated. Include splices and terminations for cables and cable accessories. B. Samples: 16-inch (400-mm) lengths of each type of cable indicated. C. Qualification Data: For Installer. D. Material Certificates: For each cable and accessory type, signed by manufacturers. E. Source quality-control test reports. F. Field quality-control test reports. 1.4 QUALITY ASSURANCE A. Installer: Engage a cable splicer, trained and certified by splice material manufacturer, to install, splice, and terminate medium-voltage cable. B. 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 or the National Institute for Certification in Engineering Technologies to supervise on-site testing specified in Part 3. C. Source Limitations: Obtain cables and accessories through one source from a single manufacturer. D. 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. E. Comply with IEEE C2 and NFPA 70. F. NETA documents are available at: www.netaworld.org Project No. 18088080 2 Section 26 05 13 Lake Lewisville WTP Dewatering Improvements Medium-Voltage Cables 1.5 PROJECT CONDITIONS A. Interruption of Existing Electric Service: Do not interrupt electric service to facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary electric service according to requirements indicated: 1. Notify Owner no fewer than 7 days in advance of proposed interruption of electric service. 2. Do not proceed with interruption of electric service without Owner's written permission. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: B. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Cables: a. American Insulated Wire Corp.; a Leviton Company. b. General Cable Technologies Corporation. c. Kerite Co. (The); Hubbell Incorporated. d. Okonite Company (The). e. Pirelli Cables & Systems NA. f. Rome Cable Corporation. g. Southwire Company. 2. Cable Splicing and Terminating Products and Accessories: a. G&W Electric Company. b. MPHusky. c. Raychem Corp.; Telephone Energy and Industrial Division; Tyco International Ltd. d. RTE Components; Cooper Power Systems, Inc. e. Thomas & Betts Corporation. f. 3M; Electrical Products Division. 2.2 CABLES A. Cable Type: MV105. B. Comply with UL 1072, AEIC CS 8, ICEA S-93-639, and ICEA S-97-682, ICEA S-94-649. C. Conductor: Copper. D. Conductor Stranding: Compact round, concentric lay, Class B. E. Strand Filling: Conductor interstices are filled with impermeable compound. F. Conductor Insulation: Ethylene-propylene rubber. 1. Voltage Rating: 15 kV. 2. Insulation Thickness: 133 percent insulation level. G. Shielding: Copper tape, helically applied over semiconducting insulation shield. H. Shielding and Jacket: Corrugated copper drain wires embedded in extruded, chlorinated, polyethylene jacket. I. Cable Jacket: Sunlight-resistant PVC or Chlorosulfonated polyethylene, CPE. Project No. 18088080 3 Section 26 05 13 Lake Lewisville WTP Dewatering Improvements Medium-Voltage Cables 2.3 SOLID TERMINATIONS A. Shielded-Cable Terminations: Comply with the following classes of IEEE 48. Insulation class is equivalent to that of cable. Include shield ground strap for shielded cable terminations. 1. Class 3 Terminations: Kit with stress cone and compression-type connector – outdoor rated for use in switchgear and generator housing. B. Nonshielded-Cable Terminations: Kit with compression-type connector. Include silicone-rubber tape, cold-shrink-rubber sleeve, or heat-shrink plastic-sleeve moisture seal for end of insulation whether or not supplied with kits. 2.4 SOURCE QUALITY CONTROL A. Test and inspect cables according to ICEA S-97-682 or ICEA S-94-649 before shipping. B. Test strand-filled cables for water-penetration resistance according to ICEA T-31-610, using a test pressure of 5 psig (35 kPa). PART 3 - EXECUTION 3.1 INSTALLATION A. Install cables according to IEEE 576. B. Pull Conductors: Do not exceed manufacturer's recommended maximum pulling tensions and sidewall pressure values. 1. Where necessary, use manufacturer-approved pulling compound or lubricant that will not deteriorate conductor or insulation. 2. Use pulling means, including fish tape, cable, rope, and basket-weave cable grips that will not damage cables and raceways. Do not use rope hitches for pulling attachment to cable. C. Install exposed cables parallel and perpendicular to surfaces of exposed structural members and follow surface contours where possible. D. Support cables according to Division 26 Section "Common Work Results for Electrical." E. In manholes, handholes, pull boxes, junction boxes, and cable vaults, train cables around walls by the longest route from entry to exit and support cables at intervals adequate to prevent sag. F. Seal around cables passing through fire-rated elements according to Division 07 Section "Penetration Firestopping." G. Ground shields of shielded cable at terminations, splices, and separable insulated connectors. Ground metal bodies of terminators, splices, cable and separable insulated-connector fittings, and hardware. H. Identify cables according to Division 26 Section "Identification for Electrical Systems." 3.2 FIELD QUALITY CONTROL A. Testing: Owner will engage a qualified testing and inspecting agency to perform field tests and inspections and prepare test reports. Project No. 18088080 4 Section 26 05 13 Lake Lewisville WTP Dewatering Improvements Medium-Voltage Cables B. Testing: Engage a qualified testing and inspecting agency to perform the following field tests and inspections and prepare test reports: C. Perform the following field tests and inspections and prepare test reports: 1. Perform each visual and mechanical inspection and electrical test stated in NETA ATS. Certify compliance with test parameters. 2. After installing medium-voltage cables and before electrical circuitry has been energized, test for compliance with requirements including a high potential test and record of test data for each conductor. D. Remove and replace malfunctioning units and retest as specified above. END OF SECTION Project No. 18088080 1 Section 26 05 14 Lake Lewisville WTP Dewatering Improvements Wiring Devices SECTION 26 05 14 - WIRING DEVICES PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following: 1. Receptacles with integral GFCI and associated device plates. 2. Snap switches and wall-box dimmers. 1.2 DEFINITIONS A. EMI: Electromagnetic interference. B. GFCI: Ground-fault circuit interrupter. C. Pigtail: Short lead used to connect a device to a branch-circuit conductor. D. RFI: Radio-frequency interference. E. TVSS: Transient voltage surge suppressor. 1.3 SUBMITTALS A. Product Data: for each type of product indicated. B. Shop Drawings: List of legends and description of materials and process used for pre-marking wall plates. C. Samples: One for each type of device and wall plate specified in each color specified. D. Field quality-control test reports. E. Operation and Maintenance Data: For wiring devices to include in all manufacturers’ packing label warnings and instruction manuals that include labeling conditions. 1.4 QUALITY ASSURANCE A. Source Limitations: Obtain each type of wiring device and associated wall plate through one source from a single manufacturer. Insofar as type are available, obtain all wiring devices and associated wall plates from a single manufacturer and one source. B. Electrical Components, Devices and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction and marked for intended use. C. Comply with NFPA 70. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Available Manufacturers: 1. Cooper wiring Devices; a division of Cooper Industries, Inc. (Cooper). 2. Hubbell Incorporated; Wiring Device-Kellems (Hubbell). Project No. 18088080 2 Section 26 05 14 Lake Lewisville WTP Dewatering Improvements Wiring Devices 3. Leviton Mfg. Company Inc. (Leviton). 4. Pass & Seymour/Legrand; Wiring Devices & Accessories (Pass & Seymour). 2.2 STRAIGHT BLADE RECEPTACLES A. Convenience Receptacles, 125 V, 20A: Comply with NEMA WD1, NEMA WD 6 configuration 5- 20R, and UL 498. 1. Available Products: Subject to compliance with requirements, products that may be incorporated into the work include, but are not limited to the following: a. Cooper; 5351 (single), 5352 (duplex). b. Hubbell; HBL5351 (single), CR5352 (duplex). c. Leviton; 5891 (single), 5352 (duplex). d. Pass & Seymour; 5381 (single), 5352 (duplex). 2.3 GFCI RECEPTACLES A. General Description: Straight blade, feed-through type. Comply with NEMA WD1, NEMA WD6, UL498 and UL 943, Class A and include indicator light that is lighted when device is tripped. B. Duplex GFCI Convenience Receptacles, 125 V, 20A: 1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to the following: a. Cooper; GF20. b. Pass & Seymour; 2084. 2.4 SNAP SWITCHES A. Comply with NEMA WD 1 and UL 20. B. Switches, 120/277 V, 20 A: 1. Available Products: Subject to compliance with requirements, products that may be incorporated into the work include, but are not limited to the following: a. Cooper; 2221 (single pole), 2222 (two pole), 2223 (three way), 2224 (four way). b. Hubbell; CSI221 (single pole), CSI222 (two pole), CSI223 (three way), CSI224 (four way). c. Leviton; 1221-2 (single pole), 1222-2 (two pole), 1223-2 (three way), 12224-2 (four way). d. Pass & Seymour; 20ACI (single pole), 20AC2 (two pole); 20AC3 (three way), 20AC4 (four way). C. Pilot Light Switches, 20A: 1. Available Products: Subject to compliance with requirements, products that may be incorporated into the work include, but are not limited to the following: a. Cooper; 2221PL for l20 V and 277V. b. Hubbell; HPL1221PL for 120 V and 277V. c. Leviton; 1221-PLR for 120 V, 1221-7PLR for 277V. d. Pass & Seymour; PS20ACI-PLR for 120 V. 2. Description: Single pole, with neon-lighted handle, illuminated when switch is “OFF.” 2.5 WALL PLATES A. Single and combination types to match corresponding wiring devices. 1. Plate-Securing Screws: Stainless steel or unbreakable nylon in damp areas. 2. Material: 0.035-inch-(1mm-) thick, satin-finished stainless steel. 3. Provide in-use covers for all exterior installations and interior damp locations. Project No. 18088080 3 Section 26 05 14 Lake Lewisville WTP Dewatering Improvements Wiring Devices 2.6 FINISHES A. Color: 1. Wiring Devices: As selected by Owner, unless otherwise indicated or required by NFPA 70 or device listing. PART 3 - EXECUTION 3.1 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 ensure 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. 4. Existing conductors: a. Cut back and pigtail or replace all damaged conductors. b. Straighten conductors that remain and remove corrosion and foreign matter. c. Pigtailing existing conductors is permitted provided the outlet box is large enough. D. Device Installation: 1. Replace all devices that have been in temporary use during construction or that show signs that they were installed before building finishing operations were complete. 2. Keep each wiring device in its package or otherwise protected until it is time to connect conductors. 3. Do not remove surface protection such as plastic film and smudge covers until the last possible moment. 4. Connect devices to branch circuits using pigtails that are not less than 6 inches (152 mm) in length. 5. When there is a choice, use side wiring with binding-head screw terminals. Wrap solid conductor tightly clockwise, 2/3 to 3/4 of the way around terminal screw. 6. Use a torque screwdriver when a torque is recommended or required by the manufacturer. 7. When conductors larger than No. 12 AWG are installed on 15- or 20-A circuits, splice No. 12 AWG pigtails for device connections. 8. Tighten unused terminal screws on the device. 9. When mounting into metal boxes, remove the fiber or plastic washers used to hold device mounting screws in yokes, allowing metal-to-metal contact. E. Receptacle Orientation: Project No. 18088080 4 Section 26 05 14 Lake Lewisville WTP Dewatering Improvements Wiring Devices 1. Install ground pin of vertically mounted receptacles up, and on horizontally mounted receptacles to the right. F. Device Plates: Do not use oversized or extra-deep plates. Repair wall finishes and remount outlet boxes when standard device plates do not fit flush or do not cover rough wall opening. 3.2 IDENTIFICATION A. Comply with Division 26 Section “Identification for Electrical Systems.” 1. Receptacles: Identify panelboard and circuit number from which served. Use hot, stamped or engraved machine printing with black-filled lettering on face of plate, and durable wire markers or tags inside outlet boxes. 3.3 FIELD QUALITY CONTROL A. Perform tests and inspections and prepare test reports. 1. Test Instruments: Use instruments that comply with UL 1436. 2. Test Instrument for Convenience Receptacles: digital wiring analyzer with digital readout or illuminated LED indicators of measurement. B. Tests for Convenience Receptacles: 1. Line voltage: Acceptable range is 105 to 132V. 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. C. Test straight blade for the retention force of the grounding blade according to NFPA 99. Retention force shall be not less than 4 oz. (115g). END OF SECTION Project No. 18088080 1 Section 26 05 15 Lake Lewisville WTP Dewatering Improvements Electric Motors SECTION 26 05 15 - ELECTRIC MOTORS PART 1 - GENERAL 1.1 SUMMARY A. This section describes materials, installation and testing of induction motors and applies to motors which are generally provided as part of equipment specified in other sections. The Contractor shall provide motors, accessories and appurtenances complete and operable in accordance with the individual driven equipment specifications. 1.2 SUBMITTALS A. Product Data: For each type of product indicated. B. Complete motor data shall be submitted, including: 1. Machine name and specification number of driven machine. 2. Motor manufacturer. 3. Motor type or model and dimensional drawing, including weight. 4. Horsepower nominal. 5. Guaranteed minimum full load efficiency. Also, nominal efficiencies at 1/2 and 3/4 load. 6. Full load speed. 7. Full load current at rated horsepower for application voltage. 8. Service factor, minimum 1.15. 9. Voltage, phase and frequency rating. 10. Winding insulation class. 11. Temperature rise class. 12. Frame size. 13. Enclosure. 14. NEMA design. 15. Thermal protection or over temperature protection. 16. Wiring diagram for devices such as temperature switches, space heaters and motor leak detection as applicable. 17. Bearing data, including recommendation of lubricants. 18. Inverter duty motor for all motors connected to variable frequency drive controllers. Include minimum speed at which motors may be operated. 19. Power factor at 1/2, 3/4 and full load. 20. Complete nameplate data, rating and characteristics. 21. Mounting arrangement, size and location of conduit entries, including lugs. 22. Factory test results for each motor. 1.3 QUALITY ASSURANCE A. Provide routine (short commercial) test data complying with NEMA MG 1-12.51 and MG 1- 23.46. B. Test thermally protected motors in accordance with NEMA MG 1 winding temperature and trip current tests. C. Comply with NEMA MG 1. D. Motors for applications in hazardous locations shall bear the UL label listing its use in accordance with the NEC. Project No. 18088080 2 Section 26 05 15 Lake Lewisville WTP Dewatering Improvements Electric Motors 1.4 COORDINATION A. Furnish reviewed shop drawings from motor controller manufacturer for coordination and sizing of the controller. B. Coordinate supplied motor connection box with conduits sizes indicated in the drawings. C. Coordinate motor leads and lugs with wire sizes indicated in the drawings. PART 2 - PRODUCTS 2.1 GENERAL MOTOR REQUIREMENTS A. Unless otherwise specified or specifically required by the manufacturer of the equipment to be driven, all motors shall be single speed, squirrel cage, a-c induction type motors. Electric motors shall be NEMA Design B constant speed squirrel cage induction motors having normal starting torque with low starting current except for motors controlled by variable speed operation and other special motors. In no case shall starting torque or breakdown torque be less than the value specified in ANSI/NEMA MG 1. In all cases, motors shall be suitable for the indicated starting method. B. Stator winding shall be copper. C. The maximum motor loading of each motor shall not exceed its nameplate horsepower rating (exclusive of service factor) under any operating condition. D. Motors shall be sized to start and accelerate the design loading and operate the full range of driven equipment without exceeding any of the specified design requirements. Motors that fail to meet these requirements shall be replaced at no additional cost to the Owner. E. All three phase motors shall be provided with Class F insulation, rated to operate at a maximum ambient temperature of 40 degrees C and at the altitudes where the motors will be installed and operated without exceeding Class B temperature rise limits stated in ANSI/NEMA MG1-12, 42. Single phase motors shall have Class F insulation with temperature rise not to exceed the insulation class. Motors to be operated with variable frequency drives shall be provided with insulation systems to withstand 1600 volt spikes, with dV/dt as defined in NEMA MG 1-31. F. All motors shall have a minimum service factor of 1.15. G. Motors for use in hazardous locations shall have enclosures suitable for the classification of the location. Such motors shall be UL listed and stamped. H. Motors larger than 50 HP located outdoors or in non-conditioned areas shall have 120-volt AC space heaters and temperature sensors. I. For motors controlled by variable frequency drives, the critical vibration speed of the motor/load combination shall either not fall within the operating range of the drive or such frequencies shall be blocked with the drive critical speed avoidance circuit. All motors connected to variable frequency drives shall be inverter duty rated. J. For motors controlled by variable frequency drives and larger than 50HP, provide a shaft grounding ring meeting the following requirements. Grounding ring shall be factory installed. 1. Aluminum frame and internal components. 2. Conductive microfiber brushes. 3. Maintenance free design. Project No. 18088080 3 Section 26 05 15 Lake Lewisville WTP Dewatering Improvements Electric Motors 4. Aegis Bearing Protection Ring or equal. K. Unless otherwise specified, motors shall have no-load sound power levels not to exceed the values specified in NEMA MG 1-12.53.3. L. Premium Efficiency Motors: 1. Motors with a nameplate rating of 1 horsepower and larger shall be premium efficiency type motors as determined by the testing set forth in ANSI/IEEE 112 – Standard Test Procedure for Polyphase Induction Motors and Generators, Method B. Motors shall be stamped with the efficiency on the nameplate with the caption “NEMA Nominal Efficiency.” 2. Efficiency index, nominal efficiency and minimum efficiency shall be defined in accordance with ANSI/NEMA MG1-12.59 – Efficiency Levels of Energy Efficient Polyphase Squirrel-Cage Induction Motors. All three values are required to be indicated in the submittal. 2.2 MOTOR BEARINGS A. All motors greater than 2 horsepower shall have bearings designed for 17,500 hours (belted) or 100,000 hours (coupled) L-10 life. B. Motors less than 2 horsepower shall be provided with sealed, permanently lubricated ball bearings. C. Horizontal motors over 2 horsepower shall be shielded open-type bearing installed with labyrinth sealed end bells with pipe plugs. Bearings shall be regreasable and have provisions for purging old grease. D. Vertical motors over 2 horsepower shall be provided with relubricatable ball, spherical, roller or plate type trust bearings. Lubrication shall be per manufacturer’s recommendation for smooth operation and long life of the bearing. Drains shall be provided to prevent over lubrication. 2.3 MOTOR THERMAL PROTECTION A. All single phase motors shall have integral thermal overload protection or shall be current limited. B. Winding thermostats shall be provided in accordance with NEMA MG-1. Thermostats shall be snap action, bi-metallic, temperature actuated type switches and shall be provided with a normally closed contact. Thermostats shall be precalibrated by the manufacturer and shall be series connected. 2.4 ACCESSORIES A. All vertical motors and horizontal motors 3 horsepower and larger shall have split-type conduit boxes with a gasketed moisture seal between the conduit box and motor frame. Motors less than 3 horsepower shall have the manufacturer’s standard conduit boxes. Motors other than open drip-proof shall be gasketed. B. All motors weighing 250 pounds or greater shall have suitable lifting eyes for installation and removal. C. Motor grounding lugs shall be provided and shall be suitable for terminating ground wires. Project No. 18088080 4 Section 26 05 15 Lake Lewisville WTP Dewatering Improvements Electric Motors D. All motors shall be fitted with permanent stainless steel nameplates indelibly stamped or engraved with NEMA Standard motor data. E. Refer to equipment specifications for special requirements such as space heaters or motor winding thermal protection. PART 3 - EXECUTION 3.1 STORAGE A. Protect motors from exposure to elements for which they are not designed. Install and energize temporary electrical service to motors with electrical heaters. B. Store motors in an air-conditioned, ventilated or protected environment similar to or better than the destination environment. 3.2 INSTALLATION A. Motor installation shall be performed in accordance with the motor manufacturer’s written recommendations and the written requirements of the manufacturer of the driven equipment. B. Connections, switches, controls, disconnects and other items shall be provided in accordance with the plans and specifications for each motor. C. The Contractor shall coordinate conduit sizes indicated in the drawings with the supplied motor connection box. The Contractor shall be responsible for providing larger connection boxes as may be required. 3.3 FIELD TESTING A. Perform insulation resistance tests in accordance with NEMA MG-1. Test voltage shall be 1000 VAC plus twice the rated voltage of motor. B. Inspect the physical and mechanical conditions of each motor installation including any deviations from the nameplate, drawings, specifications and manufacturer’s written guidelines. Verify expected rated voltage, phase and frequency for each motor installation. Confirm the presence of and correct application of lubrications for each motor along with proper securing and torque settings for bolted installations of each motor. C. Check for proper phase and ground connections for each motor are connected. For multi- voltage motors, verify that motors are connected properly for the supplied voltage. D. Verify that space heaters, where provided, are functional. E. Test the motor for proper rotation prior to connection to the driven equipment. Measure and record running current and evaluate the current relative to the load conditions and nameplate full-load amps. F. Simulate operating conditions for each motor to demonstrate proper operation of interlocks and control features. G. Record operating current in each phase for each motor ½ horsepower and larger. Motors exceeding motor nameplates values shall be repaired or replaced. Project No. 18088080 5 Section 26 05 15 Lake Lewisville WTP Dewatering Improvements Electric Motors H. For motors 50 horsepower and larger or when a discernible abnormal vibration is detectible, a vibration test shall be completed. Vibration shall not exceed 0.25 in./sec. For horizontal motors, the N-S and E-W vibrations shall be measured at the top and bottom of the front and rear bearing housing. For vertical motors, the N-S and E-W vibrations shall be measured at the upper and lower bearing housing. I. All testing shall be witnessed by the Engineer and Owner. 1. Motor and Motor Protection Tests for motors – In addition to other testing start and stop each motor a minimum of 3 times and perform a run test for vibration, heat, and to document motor protection. The Contractor shall document the settings of the motor overcurrent protection, overload relay and similar data on the provided form – MOTOR TEST REPORT. 2. The Contractor shall develop non-conforming material reports for each failure and repair or report failures. 3. The Contractor shall replace defective parts, correct malfunctioning units, make all repairs and retest to demonstrate compliance. The Contractor shall document action taken on appropriate non-conforming material report. 3.4 MOTOR TEST REPORT A. The following form is provided for the motor certification specified herein. Master blank forms are available on request. END OF SECTION Project No. 18088080 6 Section 26 05 15 Lake Lewisville WTP Dewatering Improvements Electric Motors MOTOR TEST REPORT Each electric motor shall be tested for proper operation. Follow manufacturer’s testing recommendations and procedures. 1. Name and Horsepower of Motor Tested: 2. Overcurrent Protection: 3. Overload Protection: 4. Visual Inspection Checklist: Momentarily Bump Motor Shaft for Proper Rotation Motor Frame Bolts Shaft Coupling Lubricants Other Comments: 5. Megger motor from wire in motor control center or control panel and record results: IA-IB_______ IB-IC_______ IC-IA_______ IA-G________ IB-G________ IC-G________ 6. Record full load voltage and current: Vab______ Van______ Ia______ Vbc______ Vbn______ Ib______ Vca______ Vcn______ Ic______ 7. Motor Nameplate FLA:______ Running Amps:______ P.F. _______ 8. Comments: Signature Required: Company: Date: Project No. 18088080 1 Section 26 05 19 Lake Lewisville WTP Dewatering Improvements Low Voltage Electrical Power Conductors & Cables SECTION 26 05 19 - LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following: 1. Building wires and cables rated 600 V and less. 2. Connectors, splices, and terminations rated 600 V and less. 3. Sleeves and sleeve seals for cables. B. Related Sections include the following: 1. Division 26 Sections 1.2 DEFINITIONS A. EPDM: Ethylene-propylene-diene monomer rubber. B. NBR: Acrylonitrile-butadiene rubber. 1.3 SUBMITTALS A. Product Data: For each type of product indicated. B. Qualification Data: For testing agency. A. Field quality-control test reports. 1.4 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 (NETA) 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 or the National Institute for Certification in Engineering Technologies to supervise on-site testing specified in Part 3. 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. 1.5 COORDINATION A. Set sleeves in cast-in-place concrete, masonry walls, and other structural components as they are constructed. PART 2 - PRODUCTS 2.1 CONDUCTORS AND CABLES A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: Project No. 18088080 2 Section 26 05 19 Lake Lewisville WTP Dewatering Improvements Low Voltage Electrical Power Conductors & Cables 1. Alcan Products Corporation; Alcan Cable Division. 2. American Insulated Wire Corp.; a Leviton Company. 3. General Cable Corporation. 4. Senator Wire & Cable Company. 5. Southwire Company. B. Copper Conductors: Comply with NEMA WC 70. No aluminum on project. C. Conductor Insulation: Comply with NEMA WC 70 for Types THHN-THWN, XHHW and RHH- RHW-USE. 2.2 CONNECTORS AND SPLICES 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. AFC Cable Systems, Inc. 2. Hubbell Power Systems, Inc. 3. O-Z/Gedney; EGS Electrical Group LLC. 4. 3M; Electrical Products Division. 5. Tyco Electronics Corp. B. Description: Factory-fabricated connectors and splices of size, ampacity rating, material, type, and class for application and service indicated. PART 3 - EXECUTION 3.1 CONDUCTOR MATERIAL APPLICATIONS A. Feeders: Copper, stranded. B. Branch Circuits: Copper. Solid for No. 10 AWG and smaller; stranded for No. 8 AWG and larger. 3.2 CONDUCTOR INSULATION AND MULTICONDUCTOR CABLE APPLICATIONS AND WIRING METHODS A. Service Entrance: Type XHHW-2, single conductors in raceway. B. Exposed Feeders: Type XHHW-2, single conductors in raceway. C. Feeders Concealed in Ceilings, Walls, Partitions, and Crawlspaces: Type XHHW-2, single conductors in raceway. D. Feeders Concealed in Concrete, below Slabs-on-Grade, and Underground: Type XHHW-2 single conductors in raceway. E. Feeders in Cable Tray: Type XHHW-2, single conductors in raceway for larger than 4/0 AWG; Otherwise Type TC tray cable. F. Exposed Branch Circuits, Including in Crawlspaces: Type THHN-THWN, single conductors in raceway. G. Branch Circuits Concealed in Ceilings, Walls, and Partitions: Type THHN-THWN, single conductors in raceway. Project No. 18088080 3 Section 26 05 19 Lake Lewisville WTP Dewatering Improvements Low Voltage Electrical Power Conductors & Cables H. Branch Circuits Concealed in Concrete, below Slabs-on-Grade, and Underground: Type XHHW-2, single conductors in raceway. I. Variable Frequency Drive Branch Circuits: Type TC-ER cable with shield, designated for VFD application. General Cable CVTC-VFD or equal. J. Cord Drops and Portable Appliance Connections: Type SO, hard service cord with stainless- steel, wire-mesh, strain relief device at terminations to suit application. K. Class 1 Control Circuits: Type THHN-THWN, in raceway. L. Class 2 Control Circuits: Type THHN-THWN, in raceway. 3.3 INSTALLATION OF CONDUCTORS AND CABLES A. Conceal cables in finished walls, ceilings, and floors, unless otherwise indicated. B. Use manufacturer-approved pulling compound or lubricant where necessary; compound used must not deteriorate conductor or insulation. Do not exceed manufacturer's recommended maximum pulling tensions and sidewall pressure values. C. Use pulling means, including fish tape, cable, rope, and basket-weave wire/cable grips that will not damage cables or raceway. D. Install exposed cables parallel and perpendicular to surfaces of exposed structural members, and follow surface contours where possible. E. Support cables according to Division 26 Section "Hangers and Supports for Electrical Systems." F. Identify and color-code conductors and cables according to Division 26 Section "Identification for Electrical Systems." 3.4 CONNECTIONS A. 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. B. Make splices and taps that are compatible with conductor material and that possess equivalent or better mechanical strength and insulation ratings than unspliced conductors. C. Wiring at Outlets: Install conductor at each outlet, with at least 6 inches of slack. D. Cable splicing, in general, will not be allowed. Where applicable, all wiring connections to be made using terminal block type connections. Wire nut use will permitted only where allowed by the Owner and Engineer. 3.5 FIELD QUALITY CONTROL A. Perform tests and inspections and prepare test reports. 1. Megger Test of individual conductors to ground after installation. 2. Visual observation of conductor at accessible locations. B. Tests and Inspections: Project No. 18088080 4 Section 26 05 19 Lake Lewisville WTP Dewatering Improvements Low Voltage Electrical Power Conductors & Cables 1. After installing conductors and cables and before electrical circuitry has been energized, test the following for compliance with requirements. a. All panel feeders. b. All motor feeders. c. All control wires for continuity. 2. Perform each visual and mechanical inspection and electrical test 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 Project No. 18088080 1 Section 26 05 26 Lake Lewisville WTP Dewatering Improvements Grounding and Bonding for Electrical Systems SECTION 26 05 26 - GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. This Section includes methods and materials for grounding systems and equipment. 1. Underground distribution grounding. 2. Common ground bonding with lightning protection system. 1.2 SUBMITTALS A. Product Data: For each type of product indicated. B. Other Informational Submittals: Plans showing dimensioned as-built locations of grounding features specified in Part 3 “Field Quality Control” Article, including the following: 1. Test wells. 2. Ground rods. 3. Ground rings. 4. Ground bus bars. 5. Grounding arrangements and connections for separately derived systems. C. Field quality-control test reports. D. Operation and Maintenance Data: For grounding to include the following in emergency, operation and maintenance manuals. 1. Instructions for periodic testing and inspection of grounding features at test wells ground rings grounding connections for separately derived systems based on ANSI/NETA MTS. a. Test shall be to determine if ground resistance or impedance values remain within specified maximums and instructions shall recommend corrective action if they do not. b. Include recommended testing intervals. 1.3 QUALITY ASSURANCE A. Electrical Components, Devices and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction and marked for intended use. B. Comply with UL 467 for grounding and bonding materials and equipment. PART 2 - PRODUCTS 2.1 CONDUCTORS A. Insulated Conductors: Copper or tinned-copper wire or cable insulated for 600 V unless otherwise required by applicable Code or authorities having jurisdiction. B. Bare copper Conductors: 1. Solid Conductors: ASTM B3 2. Stranded Conductors: ASTM B8. 3. Tinned Conductors: ASTM B 33. 4. Bonding Conductor: No. 4 AWG, stranded conductor or per NFPA 70. Project No. 18088080 2 Section 26 05 26 Lake Lewisville WTP Dewatering Improvements Grounding and Bonding for Electrical Systems 2.2 CONNECTORS A. Listed and labeled by a nationally recognized testing laboratory acceptable to authorities having jurisdiction for applications in which used, and for specific types, and combinations of conductors and other items connected. B. Bolted Connectors for Conductors and Pipes: Copper or copper alloy, bolted pressure-type, with at least two bolts. 1. Pipe connectors: Clamp type, sized for pipe. C. Welded Connectors: Exothermic-welding kits of types recommended by kit manufacturer for materials being joined and installation conditions. 2.3 GROUNDING ELECTRODES A. Ground Rods: Copper-clad steel; 3/4 inch by 10 feet. 2.4 GROUNDING BUS BARS A. Predrilled, wall-mounted, rectangular bars of hard-drawn solid copper, 1/4 by 4 inches in cross section, length as required for the application. The bus bar shall be mounted using steel brackets and UL-listed standoff insulators rated for a minimum of 2500V. PART 3 - EXECUTION 3.1 APPLICATIONS A. Conductors: Install solid conductor for No. 8 AWG and smaller, and stranded conductors for No. 6 AWG and larger, unless otherwise indicated. B. Underground Grounding Conductors: Install bare tinned-copper conductor, No. 4/0 AWG minimum. 1. Bury at least 30 inches below grade. C. Conductor Terminations and Connections: 1. Pipe and Equipment Grounding Conductor Terminations: Bolted connectors. 2. Underground Connections: Welded connectors except at test wells and as otherwise indicated. 3. Connections to Ground Rods at Test Wells: Bolted connectors. 4. Connections to Structural Steel: Bolted connectors. 3.2 GROUNDING UNDERGROUND DISTRIBUTION SYSTEM COMPONENTS A. Comply with ANSI/IEEE C2 grounding requirements. B. Grounding Manholes and Handholes: Install a driven ground rod through manhole or handhole floor, close to wall, and set rod depth so 4 inches will extend above finished floor. If necessary, install ground rod before manhole is placed and provide No. 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, nonshrink grout. C. Grounding Connections to Manhole and Handhole Components: Bond exposed-metal parts such as inserts, cable racks, pulling irons, ladders, and cable shields within each manhole or Project No. 18088080 3 Section 26 05 26 Lake Lewisville WTP Dewatering Improvements Grounding and Bonding for Electrical Systems 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 as recommended by manufacturer of splicing and termination kits. D. Pad-Mounted Equipment: Install four ground rods and ground ring around the pad. Ground pad-mounted equipment and noncurrent-carrying metal items associated with utility transformers by connecting them to underground cable and grounding electrodes. Install tinned- copper conductor not less than No. 4/0 AWG for ground ring and for taps to equipment grounding terminals. Bury ground ring not less than 6 inches from the foundation. 3.3 EQUIPMENT GROUNDING A. Install insulated equipment grounding conductors with all feeders and branch circuits. B. Install insulated equipment grounding conductors with the following items, in addition to those required by NFPA 70: 1. Feeders and branch circuits. 2. Lighting circuits. 3. Receptacle circuits. 4. Single-phase motor and appliance branch circuits. 5. Three-phase motor and appliance branch circuits. 6. Flexible raceway runs. 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. Metal Poles Supporting Outdoor Lighting fixtures: Install grounding electrode and a separate insulated equipment grounding conductor in addition to grounding conductor installed with branch-circuit conductors. 3.4 INSTALLATION A. Grounding Conductors: Route along shortest and straightest paths possible, unless otherwise indicated or required by Code. Avoid obstructing access or placing conductors where they may be subjected to strain, impact or damage. B. Common Ground Bonding with Lightning Protection System: Comply with NFPA 780 and UL 96 when interconnecting with lightning protection system. Bond electrical power system ground directly to lightning protection system through the main grounding bus bar. Use bonding conductor sized same as system grounding electrode conductor and install in conduit. C. Provide intersystem bonding of power and communication systems per NEC 250.94 requirements. D. Ground rods: Drive rods until tops are 2 inches below finished floor or final grade, unless otherwise indicated. Project No. 18088080 4 Section 26 05 26 Lake Lewisville WTP Dewatering Improvements Grounding and Bonding for Electrical Systems 1. Interconnect ground rods with grounding electrode conductor below grade and as otherwise indicated. Make connections without exposing steel or damaging coating, if any. E. Test Wells: Ground rod driven through drilled hole in bottom of handhole. Handholes are specified in Division 26 Section “Underground Ducts and Raceways for Electrical Systems,” and shall be at least 12 inches deep, with cover. 1. Test Wells: Install at least one test well for each service, unless otherwise indicated. Install at the ground rod electrically closest to service entrance. Set top of test well flush with finished grade or floor. F. Bonding Straps and Jumpers: Install in locations accessible for inspection and maintenance, except where routed through short lengths of conduit. 1. Bonding to Structure: Bond straps directly to basic structure, taking care not to penetrate any adjacent parts. 2. Bonding to Equipment Mounted on Vibration Isolation Hangers and Supports: Install so vibration is not transmitted to rigidly mounted equipment. 3. Use exothermic-welded connectors for outdoor locations, but if a disconnect-type connection is required, use a bolted clamp. G. Grounding and Bonding for Piping: 1. Metal Water Service Pipe: Install insulated copper grounding conductors, in conduit from building’s main service equipment, or grounding bus, to main metal water service entrance to building. Connect grounding conductors to main metal water service pipes, using a bolted clamp connector or by bolting a lug-type connector to a pipe flange, using one of the lug bolts of the flange. Where a dielectric main water fitting is installed, connect grounding conductor on street side of fitting. Bond metal grounding conductor conduit or sleeve to conductor at each end. 2. Water Meter Piping: Use braided-type bonding jumpers to electrically bypass water meters. Connect to pipe with a bolted connector. 3. Bond each aboveground portion of gas piping system downstream from equipment shutoff valve. H. Bonding Interior Metal Ducts: Bond metal air ducts to equipment grounding conductors of associated fans, blowers, electric heaters and air cleaners. Install bonding jumper to bond across flexible duct connections to achieve continuity. I. 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. J. Ground Ring: Install a grounding conductor, electrically connected to each building structure ground rod and to each steel column and indicated item, extending around the perimeter of building. 1. Install tinned-copper conductor not less than No. 4/0 AWG for ground ring and for taps to building steel. 2. Bury ground ring not less than 24 inches from building foundation at a depth not less than 30 inches below finished grade. K. Ufer Ground (Concrete-Encased Grounding Electrode): Fabricate according to NFPA 70, using a minimum of 20 feet of bare copper conductor not smaller than No. 4 AWG. 1. If concrete foundation is less than 20 feet long, coil excess conductor within base of foundation. 2. Bond grounding conductor to reinforcing steel in at least four locations and to anchor bolts. Extend grounding conductor below grade and connect to building grounding grid or to grounding electrode external to concrete. Project No. 18088080 5 Section 26 05 26 Lake Lewisville WTP Dewatering Improvements Grounding and Bonding for Electrical Systems 3.5 FIELD QUALITY CONTROL A. Perform the following tests and inspections and prepare test reports: 1. After installing grounding system but before permanent electrical circuits have been energized, test for compliance with requirements. 2. Test completed grounding system at each location where a maximum ground-resistance level is specified, at service disconnect enclosure grounding terminal at ground test wells. Make tests at ground rods before any conductors are connected. a. Measure ground resistance not less than two full days after last trace of precipitation and without soil being moistened by any means other than natural drainage or seepage and without chemical treatment or other artificial means of reducing natural ground resistance. b. Perform tests by fall-of-potential method according to IEEE 81. 3. Prepare dimensioned drawings locating each test well, ground rod and ground rod assembly and other grounding electrodes. Identify each by letter in alphabetical order, and key to the record of tests and observations. Include the number of rods driven 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. B. Report measured ground resistances that exceed the following values: 1. Power and Lighting Equipment or System with Capacity 500 kVA and Less: 10 ohms. 2. Power and Lighting Equipment or System with Capacity 500 to 1000 kVA: 5 ohms. 3. Power and Lighting Equipment or System with Capacity More Than 1000 kVA: 5 ohms. 4. Power Distribution Units or Panelboards Serving Electronic Equipment: 3 ohm(s). 5. Substations and Pad-Mounted Equipment: 5 ohms. 6. Manhole and Handhole Grounds: 10 ohms. C. Excessive Ground Resistance: If resistance to ground exceeds specified values, notify Engineer promptly and include recommendations to reduce ground resistance. END OF SECTION Project No. 18088080 1 Section 26 05 29 Lake Lewisville WTP Dewatering Improvements Hangers and Supports for Electrical System SECTION 26 05 29 - HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following: 1. Hangers and supports for electrical equipment and systems. 2. Construction requirements for concrete bases. 1.2 DEFINITIONS A. RMC: Rigid metal conduit. B. NECA: National Electrical Contractors Association. 1.3 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. 1.4 SUBMITTALS A. Product Data: For the following: 1. Steel slotted support systems. B. Shop Drawings: Show fabrication and installation details and include calculations for the following: 1. Trapeze hangers. Include Product Data for components. 2. Steel slotted channel systems. Include Product Data for components. 3. Equipment supports. 1.5 QUALITY ASSURANCE A. Comply with NFPA 70. 1.6 COORDINATION A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. PART 2 - PRODUCTS 2.1 SUPPORT, ANCHORAGE AND ATTACHMENT COMPONENTS A. Steel Slotted Support Systems: Comply with MFMA-4, factory-fabricated components for field assembly. 1. 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: a. Allied Tube & Conduit. b. Cooper B-Line, Inc.; a division of cooper Industries. c. ERICO International Corporation Project No. 18088080 2 Section 26 05 29 Lake Lewisville WTP Dewatering Improvements Hangers and Supports for Electrical System d. GS Metals Corp. e. Thomas & Betts Corporation. f. Unistrut; Tyco International, Ltd. g. Wesanco, Inc. 2. Metallic Coatings: Hot-dip galvanized after fabrication and applied according to MFMA-4. 3. Nonmetallic Coatings: Manufacturer’s standard PVC, polyurethane, or polyester coating applied according to MFMA-4. 4. Channel Dimensions: Selected for applicable load criteria. B. Raceway and Cable Supports: As described in NECA 1 and NECA 101. NECA publications are available at www.NECAnet.org. C. Conduit and Cable Support Devices: Steel hangers, clamps, and associated fittings, designed for types and sizes of raceway or cable to be supported. D. Support for Conductors in Vertical Conduit: Factory-fabricated assembly consisting of threaded body and insulating wedging plug or plugs for non-armored electrical conductors or cables in riser conduits. Plugs shall have number, size and shape of conductor gripping pieces as required to suit individual conductors or cables supported. E. Structural Steel for Fabricated Supports and Restraints: ASTM A 36/A 36M, steel plates, shapes and bars. F. Mounting, Anchoring and Attachment Components: Items for fastening electrical items or their supports to building surfaces include the following: 1. Powder-Actuated Fasteners: Threaded 304 stainless steel stud, for use in hardened Portland cement concrete, steel or wood, with tension, shear, and pullout capacities appropriate for supported loads and building materials where used. 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). Hilti Inc. 2). ITW Ramset/Red Head; a division of Illinois tool works, Inc. 3). MKT Fastening, LLC 4). Simpson Strong-Tie Co., Inc.; Masterset Fastening Systems Unit. 2. Mechanical-Expansion Anchors: Insert-wedge-type, stainless steel, for use in hardened Portland cement concrete with tension, shear and pullout capacities appropriate for supported loads and building materials in which used. a. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the work include, but are not limited to, the following: 1). Cooper 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. 3. Concrete Inserts: Stainless steel, slotted support system units similar to MSS Type 18; complying with MFMA-4 or MSS SP-58. 4. Clamps for Attachment to Steel Structural Elements: MSS SP-58, type suitable for attached structural element. 5. Through Bolts: Structural type, hex head, and high strength. Comply with ASTM A 325. 6. Toggle bolts: All-steel springhead type. 7. Hanger Rods: Threaded 304 stainless steel. 8. Nuts: Match threaded rod or bolt; double nut vertical hanger rods. Project No. 18088080 3 Section 26 05 29 Lake Lewisville WTP Dewatering Improvements Hangers and Supports for Electrical System 2.2 FABRICATED METAL EQUIPMENT SUPPORT ASSEMBLIES. A. Description: bolted, structural-steel shapes, shop or field fabricated to fit dimensions of supported equipment. PART 3 - EXECUTION 3.1 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. Outdoor locations: Supporting material shall be stainless steel, PVC-Coated galvanized steel, aluminum, or as described within the Drawings. C. Indoor locations: Supporting materials shall be stainless steel, PVC-Coated galvanized steel, or aluminum in damp areas, or as described within the Drawings. D. Maximum Support Spacing and Minimum Hanger Rod Size for Raceway: Space supports for RMC as required by NFPA 70. Minimum rod size shall be ¼ inch in diameter. E. Multiple Raceways or Cables: Install trapeze-type supports fabricated with 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 two-bolt conduit clamps. 3.2 SUPPORT INSTALLATION A. Comply with NECA 1 and NECA 101 for installation requirements except as specified in this Article. B. Raceway Support Methods: In addition to methods described in NECA 1, RMC 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 supported components plus 200 lbs. D. Mounting and Anchorage of Surface-Mounted Equipment and Components: Anchor and fasten electrical items and their supports to building structural elements by the following methods unless otherwise indicated by code: 1. To Wood: Fasten with lag screws or through bolts. 2. To New Concrete: Bolt to concrete inserts. 3. To Masonry: Approved toggle-type bolts on hollow masonry units and expansion anchor fasteners on solid masonry units. 4. To Existing Concrete: Expansion anchor fasteners. 5. Instead of expansion anchors, powder-actuated driven threaded studs provided with lock washers and nuts may be used in existing standard-weight concrete 4 inches thick or greater. Do not use for anchorage to lightweight-aggregate concrete or for slabs less than 4 inches thick. 6. To Steel: Welded threaded studs complying with AWS D1.1/D1.1M, with lock washers and nuts. 7. To Light Steel: Stainless steel sheet metal screws. Project No. 18088080 4 Section 26 05 29 Lake Lewisville WTP Dewatering Improvements Hangers and Supports for Electrical System 8. Items Mounted on Hollow Walls and Nonstructural Building Surfaces: Mount cabinets, panelboards, disconnect switches, control enclosures, pull and junction boxes, transformers and other devices on slotted-channel racks attached to substrate. E. Drill holes for expansion anchors in concrete at locations and to depths that avoid reinforcing bars. 3.3 INSTALLATION OF FABRICATED METAL SUPPORTS A. Cut, fit and place miscellaneous metal supports accurately in location, alignment and elevation to support and anchor electrical materials and equipment. 3.4 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 equipment. 3. Install anchor bolts according to anchor-bolt manufacturer’s written instructions. END OF SECTION Project No. 18088080 1 Section 26 05 33 Lake Lewisville WTP Dewatering Improvements Raceway and Boxes for Electrical Systems SECTION 26 05 33 - RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. This Section includes raceways, fittings, boxes, enclosures, and cabinets for electrical wiring. B. Related Sections include the following: 1. Division 26 Section “Underground Ducts and Raceways for Electrical Systems” for exterior ductbanks, manholes, and underground utility construction. 2. Division 26 Section “PVC Coated Conduit.” 1.2 DEFINITIONS A. LFMC: Liquidtight flexible metal conduit. B. LFNC: Liquidtight flexible nonmetallic conduit. C. GRS: Galvanized Rigid Steel Conduit. D. RNC: Rigid nonmetallic conduit. E. EMT: Electrical Metallic Tubing. 1.3 SUBMITTALS A. Product Data: for surface raceways, wireways and fittings, hinged-cover enclosures and cabinets. B. Custom enclosures and cabinets. C. Source quality-control test reports. 1.4 QUALITY ASSURANCE A. Electrical Components, Devices and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use. B. Comply with NFPA 70. PART 2 - PRODUCTS 2.1 METAL CONDUIT AND TUBING 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. AFC Cable Systems, Inc. 2. Alflex Inc. 3. Allied Tube & Conduit; a Tyco International Ltd. Co. 4. Anamet Electrical, Inc.; Anaconda Metal Hose. 5. Electri-Flex Co. 6. Manhattan/CDT/Cole-Flex. 7. Maverick Tube Corporation. Project No. 18088080 2 Section 26 05 33 Lake Lewisville WTP Dewatering Improvements Raceway and Boxes for Electrical Systems 8. O-Z Gedney; a unit of General Signal. 9. Wheatland Tube Company. B. Rigid Steel Conduit: ANSI C80.1. C. PVC-Coated Steel Conduit: PVC-coated. 1. Comply with NEMA RN 1. 2. Coating Thickness: 0.040 inch, minimum. 3. Comply with ETL Verified PVC-001. D. Joint Compound for Rigid Steel Conduit: Listed for use in cable connector assemblies and compounded for use to lubricate and protect threaded raceway joints from corrosion and enhance their conductivity. 2.2 NONMETALLIC CONDUIT AND TUBING 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. AFC Cable Systems, Inc. 2. Anamet Electrical, Inc.; Anaconda Metal Hose. 3. Arnco Corporation 4. CANTEX Inc. 5. CertainTeed Corp.; Pipe & Plastics Group 6. Condux International, Inc. 7. ElecSYS, Inc. 8. Electri-Flex co. 9. Lamson & Sessions; Carlon Electrical Products. 10. Manhattan/CDT/Cole-Flex. 11. RACO; a Hubbell Company 12. Thomas & Betts Corporation. B. RNC: NEMA TC2, Type EPC-40-PVC, unless otherwise indicated. C. Fittings for RNC: NEMA TC 3; match to conduit or tubing type and material. 2.3 BOXES, ENCLOSURES, AND CABINETS A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to the following: 1. Cooper Crouse-Hinds; Div. of Cooper Industries, Inc. 2. EGS/Appleton Electric. 3. Erickson Electrical Equipment Company 4. Hoffman. 5. Hubbell Incorporated; Killark Electric Manufacturing Co. Division 6. O-Z/Gedney; a unit of General Signal. 7. RACO; a Hubbell company. 8. Scott Fetzer Co.; Adalet Division. 9. Spring City Electrical Manufacturing Company. 10. Stahlin Non-Metallic Enclosures. 11. Thomas & Betts Corporation. 12. Walker Systems, Inc.; Wiremold Company (The) 13. Woodhead, Daniel Company; Woodhead Industries, Inc. subsidiary. B. Sheet Metal Outlet and Device boxes: NEMA OS 1. Project No. 18088080 3 Section 26 05 33 Lake Lewisville WTP Dewatering Improvements Raceway and Boxes for Electrical Systems C. Cast-Metal Outlet and Device boxes: NEMA FB 1, Type FD, with gasketed cover. D. Small Sheet Metal Pull and Junction boxes: NEMA OS 1. E. Cast-Metal Access, Pull and Junction boxes: NEMA FB 1. F. Hinged-Cover Enclosures: NEMA 250, Type 1, with continuous-hinge cover with flush latch for conditioned spaces only, unless otherwise indicated. G. Hinged-Cover Enclosures: NEMA 250, Type 4 Stainless steel, with continuous-hinge cover with latches for outdoor, process buildings, above and below grade structures and damp locations, unless otherwise indicated. 2.4 SLEEVES FOR RACEWAYS A. Steel Pipe Sleeves: ASTM A 53/A, 53M, Type E, Grade B, Schedule 40, galvanized steel, plain ends. B. Cast-Iron Pipe Sleeves: Cast or fabricated “wall pipe,” equivalent to ductile-iron pressure pipe, with plain ends and integral waterstop, unless otherwise indicated. C. Sleeves for Rectangular Openings: Galvanized sheet steel with minimum 0.052-or 0.138-inch thickness as indicated and of length to suit application. D. Coordinate sleeve selection and application with Engineer. 2.5 SLEEVE SEALS 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. Advance Products & systems, Inc. 2. Calpico, Inc. 3. Metraflex Co. 4. Pipeline Seal and Insulator, Inc. B. Description: Modular sealing device, designed for field assembly, to fill annular space between sleeve and cable. 1. Sealing Elements: EPDM interlocking links shaped to fit surface of cable or conduit. Include type and number required for material and size of raceway or cable. 2. Pressure Plates: Stainless steel. Include two for each sealing element. 3. Connecting Bolts and Nuts: Stainless steel of length required to secure pressure plates to sealing elements. Include one for each sealing element. PART 3 - EXECUTION 3.1 RACEWAY APPLICATION A. Outdoors: apply raceway products as specified below, unless otherwise indicated: 1. Exposed: Rigid Aluminum, PVC-Coated Rigid Steel, or as noted in the Drawings. 2. Embedded: PVC-Coated Rigid Steel. 3. Underground, Single Run: RNC, Schedule 40 in concrete encasement. 4. Underground, Grouped: RNC, Schedule 40 in concrete encasement. 5. Connection to Vibrating Equipment (Including Transformers and Hydraulic, Pneumatic, Electric Solenoid, or Motor-Driven Equipment): LFMC. B. Indoors: Project No. 18088080 4 Section 26 05 33 Lake Lewisville WTP Dewatering Improvements Raceway and Boxes for Electrical Systems 1. Exposed: Rigid Aluminum or as noted in the Drawings. 2. Concealed: Rigid Aluminum or as noted in the Drawings. 3. Connection to Vibrating Equipment (Including Transformers and Hydraulic. Pneumatic, Electric Solenoid or Motor-Driven Equipment): LFMC. 4. Damp or Wet Locations: Rigid Aluminum or as noted in the Drawings. C. Minimum Raceway Size: ¾-inch trade size; 1-inch trade size for below grade installation. D. Raceway Fittings: Compatible with raceways and suitable for use and location. 1. Rigid Metal Conduit: Use threaded rigid metal conduit fittings, unless otherwise indicated. 2. PVC Externally Coated, Rigid Steel Conduits: Use only fittings listed for use with that material. 3.2 INSTALLATION A. Comply with NECA 1 for installation requirements applicable to products specified in Part 2 except where requirements on Drawings or in this Article are stricter. B. Keep raceways at least 6 inches away from parallel runs of flues and steam or hot-water pipes. Install horizontal raceway runs above water and steam piping. C. Complete raceway installation before starting conductor installation. D. Support raceways as specified in Division 26 Section “Hangers and Supports for Electrical Systems.” E. Arrange stub-ups so curved portions of bends are not visible above the finished slab. F. Install no more than the equivalent of four 90-degree bends in any conduit run except for communications conduits, for which fewer bends are allowed. G. Raceways Embedded in Slabs: 1. Run conduit larger than 1 inch trade size, parallel or at right angles to main reinforcement. Where at right angles to reinforcement, place conduit close to slab support. 2. Arrange raceways to cross building expansion joints at right angles with expansion fittings. 3. Do not install conduits in such a manner as to compromise the structural integrity of walls, roofs, ceilings or floor. Where necessary, provide additional supporting members to support conduit runs. Below grade conduits 1 1/2” and larger shall be routed 24” below the concrete floor slabs. 4. Comply with Chapter 6 of ACI 318. 5. Change from nonmetallic conduit to PVC-Coated Rigid Steel Conduit before rising above the floor. H. Threaded Conduit Joints, Exposed to Wet, Damp, Corrosive, or Outdoor Conditions: Apply listed compound to threads of raceway and fittings before making up joints. Follow compound manufacturer’s written instructions. I. Raceway Terminations at Locations Subject to Moisture or Vibration: Use insulating bushings to protect conductors, including conductors smaller than No. 4 AWG. J. Install pull wires in empty raceways. Use polypropylene or monofilament plastic line with not less than 200-lb tensile strength. Leave at least 12 inches of slack at each end of pull wire. Project No. 18088080 5 Section 26 05 33 Lake Lewisville WTP Dewatering Improvements Raceway and Boxes for Electrical Systems K. Install raceway sealing fittings at suitable, approved and accessible locations and fill them with listed sealing compound. For concealed raceways, install each fitting in a flush steel box with a blank cover plate having a finish similar to that of adjacent plates or surfaces. Install raceway sealing fittings at the following points: 1. Where conduits pass from warm to cold locations, such as boundaries of refrigerated spaces. 2. Where otherwise required by NFPA 70. L. Expansion-Joint Fittings: Install in each run of aboveground conduit that is located where environmental temperature change may exceed 30 deg. F, and that has straight-run length that exceeds 25 feet. 1. Install expansion-joint fittings for each of the following locations, and provide type and quantity of fittings that accommodate temperature change listed for location: a. Outdoor Locations Not Exposed to Direct Sunlight: 125 deg F temperature change. b. Outdoor Locations Exposed to Direct Sunlight: 155 deg F temperature change. c. Indoor Spaces: connected with the Outdoors without Physical Separation: 125 deg F temperature change. d. Attics: 135 deg F temperature change. 2. Install fitting(s) that provide expansion and contraction for at least 0.00041 inch per foot of length of straight run per deg F of temperature change. 3. Install each expansion-joint fitting with position, mounting and piston setting selected according to manufacturer’s written instructions for conditions at specific location at the time of installation. M. Flexible conduit connections: Use maximum of 36 inches of flexible conduit for equipment subject to vibration, noise transmission, or movement, and for transformers and motors. 1. Use LFMC in damp or wet locations subject to severe physical damage. 2. Use LFMC or LFNC in damp or wet locations not subject to severe physical damage. N. Recessed Boxes in Masonry Walls: Saw-cut opening for box in center of cell of masonry block, and install box flush with surface of wall. 3.3 SLEEVE INSTALLATION FOR ELECTRICAL PENETRATIONS A. Coordinate sleeve selection and application Engineer. B. Concrete Slabs and Walls: Install sleeves for penetrations unless core-drilled holes or formed openings are used. Install sleeves during erection of slabs and walls. C. Use pipe sleeves unless penetration arrangement requires rectangular sleeved opening. D. Fire-Rated Assemblies: Install sleeves for penetrations of fire-rated floor and wall assemblies unless openings compatible with firestop system used are fabricated during construction of floor or wall. E. Cut sleeves to length for mounting flush with both surfaces of walls. F. Size pipe sleeves to provide ¼-inch annular clear space between sleeve and raceway unless sleeve seal is to be installed. G. Seal space outside of sleeves with grout for penetrations of concrete and masonry. H. Interior Penetrations of Non-Fire-Rated Walls and Floors: Seal annular space between sleeve and raceway, using joint sealant appropriate for size, depth, and location of joint. Project No. 18088080 6 Section 26 05 33 Lake Lewisville WTP Dewatering Improvements Raceway and Boxes for Electrical Systems I. Fire-Rated-Assembly Penetrations: Maintain indicated fire rating of walls, partitions, ceilings, and floors at raceway penetrations. Install sleeves and seal with fire-stop materials. J. Roof-Penetration Sleeves: Seal penetration of individual raceways with flexible, boot-type flashing units applied in coordination with roofing work. K. Aboveground, Exterior-Wall Penetrations: Seal penetrations using sleeves and mechanical sleeve seals. Select sleeve size to allow for 1-inch annular clear space between pipe and sleeve for installing mechanical sleeve seals. L. Underground, Exterior-Wall Penetrations: Install cast-iron “wall pipes” for sleeves. Size sleeves to allow for 1-inch annular clear space between raceway and sleeve for installing mechanical sleeve seals. 3.4 SLEEVE-SEAL INSTALLATION A. Install to seal underground, exterior wall penetrations. B. Use type and number of sealing elements recommended by manufacturer for raceway material and size. Position raceway in center of sleeve. Assemble mechanical sleeve seals and install in annular space between raceway and sleeve. Tighten bolts against pressure plates that cause sealing elements to expand and make watertight seal. 3.5 FIRESTOPPING A. Apply firestopping to electrical penetrations of fire-rated floor and wall assemblies to restore original fire-resistance rating of assembly. 3.6 PROTECTION A. Provide final protection and maintain conditions that ensure coatings, finishes and cabinets are without damage or deterioration at time of Substantial Completion. END OF SECTION Project No. 18088080 1 Section 26 05 43 Lake Lewisville WTP Dewatering Improvements Underground Ducts & Raceways for Electrical Systems SECTION 26 05 43 - UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following: 1. Conduit, ducts and duct accessories for concrete-encased duct banks. 2. Handholes and boxes. 1.2 DEFINITIONS A. RNC: Rigid nonmetallic conduit. B. SCTE: Society of Cable Telecommunications Engineers. 1.3 SUBMITTALS A. Product Data: For the following: 1. Accessories for manholes, handholes, boxes. B. Shop Drawings for Precast or Factory-Fabricated Underground Utility Structures: Include plans, elevations, sections, details, attachments to other work, and accessories, including the following: 1. Duct entry provisions, including locations and duct sizes. 2. Reinforcement details/ 3. Step details. 4. Grounding details. 5. Dimensioned locations of cable rack inserts, pulling-in and lifting irons, and sumps. 6. Joint details. C. Shop Drawings for Factory-Fabricated Handholes and Boxes Other Than Precast Concrete: Include dimensioned plans, sections and elevations, and fabrication and installation details, including the following: 1. Duct entry provisions, including locations and duct sizes. 2. Cover design. 3. Grounding details. 4. Dimensioned locations of cable rack inserts and pulling-in lifting irons. D. Duct-Bank Coordination Drawings: Show duct profiles and coordination with other utilities and underground structures. 1. Include plans and sections, drawn to scale, and show bends and locations of expansion fittings. E. Product Certificates: for concrete and steel used in precast concrete handholes, as required by ASTM C858. F. Source quality-control test reports. G. Field quality-control test reports. 1.4 QUALITY ASSURANCE A. Comply with ANSI C2. Project No. 18088080 2 Section 26 05 43 Lake Lewisville WTP Dewatering Improvements Underground Ducts & Raceways for Electrical Systems B. Comply with NFPA 70. 1.5 DELIVERY, STORAGE AND HANDLING A. Deliver ducts to Project site with ends capped. Store nonmetallic ducts with supports to prevent bending, warping, and deforming. B. Store precast concrete and other factory-fabricated underground utility structures at Project site as recommended by manufacturer to prevent physical damage. Arrange so identification markings are visible. C. Lift and support precast concrete units only at designated lifting or supporting points. 1.6 COORDINATION A. Coordinate layout and installation of ducts, manholes, handholes, and boxes with final arrangement of other utilities, site grading, and surface features as determined in the field. B. Coordinate elevations of ducts and duct-bank entrances into manholes, handholes and boxes with final arrangement of other utilities, site grading, and surface features as determined in the field. C. Coordinate elevations of ducts and duct-bank entrances into manholes, handholes, and boxes with final locations and profiles of ducts and duct banks as determined by coordination with other utilities, underground obstructions and surface features. Revise locations and elevations from those indicated a required to suit field conditions and to ensure that duct runs drain to manholes and handholes and as approved by Engineer. PART 2 - PRODUCTS 2.1 CONDUIT A. Rigid Steel conduit: Galvanized. Comply with ANSI C80.1. B. PVC-Coated Steel Conduit: Comply with ANSI C80. C. RNC: NEMA TC2, type EPPC-40-PVC, UL 651 , with matching fittings by same manufacturer as the conduit, complying with NEMA TC 3 and UL 514B. 2.2 PRECAST CONCRETE HANDHOLES AND BOXES 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. Oldcastle Precast Group. B. Comply with ASTM C 858 for design and manufacturing processes. C. Description: Factory-fabricated, reinforced-concrete, monolithically poured walls and bottom unless open-bottom enclosure are indicated. Frame and cover shall form top of enclosure and shall have load rating consistent with that of handhole or box. 1. Frame and Cover: Weatherproof cast-iron frame, with cast-iron cover with recessed cover hook eyes and tamper-resistant, captive, cover-securing bolts. 2. Frame and Cover: Weatherproof steel frame, with steel cover with recessed cover hook eyes and tamper-resistant, captive cover-securing bolts. Project No. 18088080 3 Section 26 05 43 Lake Lewisville WTP Dewatering Improvements Underground Ducts & Raceways for Electrical Systems 3. Frame and Cover: Weatherproof steel frame, with hinged steel access door assembly with tamper-resistant, captive, cover-securing bolts. 4. Frame and cover: Weatherproof aluminum frame with hinged aluminum access door assembly with tamper-resistant, captive, cover-securing bolts. a. Cover Hinges: concealed, with hold-open ratchet assembly. b. Cover Handle: Recessed. 5. Cover Finish: Nonskid finish shall have a minimum coefficient of friction of 0.50. 6. Cover Legend: Molded lettering, “ELECTRIC.” 7. Configuration: Units shall be designed for flush burial and have integral closed bottom, unless otherwise indicated. 8. Extensions and Slabs: Designed to mate with bottom of enclosure. Same material as enclosure. a. Extension shall provide increased depth of 12 inches. b. Slab: Same dimensions as bottom of enclosure, and arranged to provide closure. 9. Windows: Precast openings in walls, arranged to match dimensions and elevations of approaching ducts and duct banks plus an additional 12 inches vertically and horizontally to accommodate alignment variations. a. Windows shall be located no less than 6 inches from interior surfaces of walls, floors, or frames and covers of handholes, but close enough to corners to facilitate racking of cables on walls. b. Window opening shall have cast-in-place, welded wire fabric reinforcement for field cutting and bending to tie in to concrete envelopes of duct banks. c. Window openings shall be framed with at least two additional No. 4 steel reinforcing bars in concrete around each opening. 10. Duct Entrances in Handhole Walls: Cast end-bell or duct-terminating fitting in wall for each entering duct. a. Type and size shall match fittings to duct or conduit to be terminated. b. Fittings shall align with elevations of approaching ducts and be located near interior corners of handholes to facilitate racking of cable. 11. Handholes 12 inches wide by 24 inches long and larger shall have inserts for cable racks and pulling-in irons installed before concrete is poured. 2.3 HANDHOLES AND BOXES OTHER THAN PRECAST CONCRETE A. Description: comply with SCTE 77. 1. Color: Gray. 2. Configuration: Units shall be designed for flush burial and have integral closed bottom, unless otherwise indicated. 3. Cover: Weatherproof, secured by tamper-resistant locking devices and having structural load rating consistent with enclosure. 4. Cover Finish: Nonskid finish shall have a minimum coefficient of friction of 0.50. 5. Cover Legend: Molded lettering, “ELECTRIC” or as noted. 6. Duct Entrance Provisions: Duct-terminating fittings shall mate with entering ducts for secure, fixed installation in enclosure wall. 7. Handholes 12 inches wide by 24 inches long and larger shall have factory-installed inserts for cable racks and pulling-in irons. B. Polymer Concrete Handholes and Boxes with Polymer Concrete Cover: Molded of sand and aggregate, bound together with a polymer resin and reinforced with steel or fiberglass or a combination of the two. 1. 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: a. Amorcast Products Company. b. Quazite c. Carson Industries LLC. Project No. 18088080 4 Section 26 05 43 Lake Lewisville WTP Dewatering Improvements Underground Ducts & Raceways for Electrical Systems d. CDR Systems Corporation. e. NewBasis. 2.4 UTILITY STRUCTURE ACCESSORIES 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. Bilco Company (The). 2. Campbell Foundry Company. 3. Carder Concrete Products 4. Christy Concrete Products. 5. East Jordan Iron Works, Inc. 6. Elmhurst-Chicago Stone Co. 7. McKinley Iron Works, Inc. 8. Neenah Foundry Company. 9. NewBasis. 10. Oldcastle Precast Group. 11. Osburn Associates, Inc. 12. Pennsylvania Insert Corporation. 13. Riverton Concrete Products; a division of Cretex companies, Inc. 14. Strongwell Corporation; Lenoir City Divison. 15. Underground Devices, Inc. 16. Utility Concrete Products, LLC. 17. Utility Vault Co. 18. Wausau Tile, Inc. B. Duct-Sealing Compound: Nonhardening, safe for contact with human skin, not deleterious to cable insulation and workable at temperatures as low as 35 degrees F. Capable of withstanding temperature of 300 degrees F without slump and adhering to clean surfaces of plastic ducts, metallic conduits, conduit coatings, concrete, masonry, lead, cable sheaths, cable jackets, insulation materials, and common metals. C. Cover Hooks: Heavy duty, designed for lifts 60 Lb and greater. PART 3 - EXECUTION 3.1 UNDERGROUND DUCT APPLICATION A. Ducts for Electrical Feeders 600 V and Less: RNC, NEMA Type EPC-40-PVC, in red blended mix concrete-encased duct bank, unless otherwise indicated. Transition to above ground shall be PVC-coated steel conduit. 3.2 UNDERGROUND ENCLOSURE APPLICATION A. Handholes and boxes for 600 V and Less: 1. Units in Roadways and Other Deliberate Traffic Paths: Precast concrete. AASHTO HB 17, H-20 structural load rating. 2. Units in Driveway, Parking Lot, and Off-Roadway Locations, Subject to Occasional, Nondeliberate Loading by Heavy Vehicles: Precast concrete, AASHTO HB 17, H-20 structural load rating. 3.3 EARTHWORK A. Restore surface features at areas disturbed by excavation and reestablish original grades, unless otherwise indicated. Replace removed sod immediately after backfilling is completed. Project No. 18088080 5 Section 26 05 43 Lake Lewisville WTP Dewatering Improvements Underground Ducts & Raceways for Electrical Systems B. Restore areas disturbed by trenching, storing of dirt, cable laying, and other work. Restore vegetation and include necessary top soiling, fertilizing, timing, seeding, sodding, sprigging and mulching. C. Cut and patch existing pavement in the path of underground ducts and utility structures. 3.4 DUCT INSTALLATION A. Slope: Pitch ducts a minimum slope of 1:300 down toward manholes and handholes and away from buildings and equipment. Slope ducts from high point in runs between two manholes to drain in both directions. B. Curves and Bends: Use 5-degree angle couplings for small changes in direction. Use manufactured long sweep bends with a minimum radius of 36 inches, both horizontally and vertically unless otherwise indicated. All below grade elbows and bends to be galvanized. C. Joints: Use solvent-cemented joints in ducts and fittings and make watertight according to manufacturer’s written instructions. Stagger couplings so those of adjacent ducts do not lie in same plane. D. Duct Entrances to Manholes and Concrete and Polymer Concrete Handholes: Use end bells, spaced approximately 10 inches o.c. for 5-inch ducts and vary proportionately for other duct sizes. 1. Begin change from regular spacing to end-bell spacing 10- feet from the end bell without reducing duct line slope and without forming a trap in the line. 2. Grout end bells into structure walls from both sides to provide watertight entrances. E. Building Wall Penetrations: Make a transition from underground duct to PVC coated rigid steel conduit unless otherwise indicated, at least 10 feet outside the building wall without reducing duct line slope away from the building and without forming a trap in the line. Use fittings manufactured for duct-to-conduit transition. F. Emergence from Grade: Duct shall transition to PVC coated rigid steel conduit from underground elbow until emergence from grade and a minimum of 12” above finished grade. G. Sealing: Provide temporary closures at terminations of ducts that have cables pulled. Seal spare ducts at terminations. Use sealing compound and plugs to withstand at least 15-psig hydrostatic pressure. H. Pulling cord: Install 100-lbf-test nylon cord in ducts, including spares. 3.5 INSTALLATION OF CONCRETE MANHOLES, HANDHOLES AND BOXES A. Precast Concrete Handhole and Manhole Installation: 1. Comply with ASTM C 891, unless otherwise indicated. 2. Install units level and plumb and with orientation and depth coordinated with connecting ducts to minimize bends and deflections required for proper entrances. 3. Unless otherwise indicated, support units on a level 12” bed of crushed stone or gravel graded from 1-inch sieve to No. 4 sieve and compacted to same density as adjacent undisturbed earth. B. Elevations: 1. Install handholes with bottom below the frost line. 2. Handhole covers: In paved areas and trafficways, set surface flush with finished grade. Set covers of other handholes 1 inch above finished grade. Project No. 18088080 6 Section 26 05 43 Lake Lewisville WTP Dewatering Improvements Underground Ducts & Raceways for Electrical Systems 3. Where indicated, cast handhole cover frame integrally with handhole structure. C. Hardware: Install removable hardware, including pulling eyes, cable stanchions, and cable arms as required for installation and support of cables and conductors and as indicated. D. Field-Installed Bolting Anchors in Manholes and Concrete Handholes: Do not drill deeper than 3-7/8 inches for manholes and 2 inches for handholes, for anchor bolts installed in the field. Use a minimum of two anchors for each cable stanchion. 3.6 INSTALLATION OF HANDHOLES AND BOXES OTHER THAN PRECAST CONCRETE A. Install handholes and boxes level and plumb and with orientation and depth coordinated with connecting ducts to minimize bends and deflections required for proper entrances. Use box extension if required to match depths of ducts and seal joint between box and extension as recommended by the manufacturer. B. Unless otherwise indicated, support units on a level bed of crushed stone or gravel, graded from 1/2-inch sieve to No. 4 sieve and compacted to same density as adjacent undisturbed earth. C. Elevation: In paved areas and trafficways, set so cover surface will be flush with finished grade. Set covers of other handholes 1 inch above finished grade. D. Install handholes and boxes with bottom below the frost line. E. Install removable hardware, including pulling eyes, cable stanchions, cable arms, and insulators, as required for installation and support of cables and conductors and as indicated. Select arm lengths to be long enough to provide spare space for future cables, but short enough to preserve adequate working clearances in the enclosure. F. Field-cut openings for ducts and conduits according to enclosure manufacturer’s written instructions. Cut wall of enclosure with a tool designed for material to be cut. Size holes for terminating fittings to be used, and seal around penetrations after fittings are installed. G. For enclosures installed in asphalt paving and subject to occasional, nondeliberate, heavy- vehicle loading form and pour a concrete ring encircling and in contact with, enclosure and with top surface screeded to top of box cover frame. 1. Concrete: 3000 psi, 28-day strength, with a troweled finish. 2. Dimensions: 12 inches wide by 12 inches deep. 3.7 GROUNDING A. Ground underground ducts and utility structures according to Division 26 Section “Grounding and Bonding for Electrical Systems.” 3.8 FIELD QUALITY CONTROL A. Perform the following tests and inspections and prepare test reports. 1. Demonstrate capability and compliance with requirements on completion of installation of underground ducts and utility structures. 2. Pull aluminum or wood test mandrel through duct to prove joint integrity and test for out- of-round duct. Provide mandrel equal to 80 percent fill of duct. If obstructions are indicated, remove obstructions and retest. B. Correct deficiencies and retest as specified above to demonstrate compliance. Project No. 18088080 7 Section 26 05 43 Lake Lewisville WTP Dewatering Improvements Underground Ducts & Raceways for Electrical Systems 3.9 CLEANING A. Pull leather-washer-type duct cleaner, with graduated washer sizes, through full length of ducts. Follow with rubber duct swab for final cleaning and to assist in spreading lubricant throughout ducts. END OF SECTION Project No. 18088080 1 Section 26 05 48 Lake Lewisville WTP Dewatering Improvements Vibration and Seismic controls for Electrical Systems SECTION 26 05 48 - VIBRATION AND SEISMIC CONTROLS FOR ELECTRICAL SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following: 1. Isolation pads. 2. Spring isolators. 3. Restrained spring isolators. 4. Channel support systems. 5. Restraint cables. 6. Hanger rod stiffeners. 7. Anchorage bushings and washers. B. Related Sections include the following: 1. Division 26 Section "Hangers and Supports for Electrical Systems" for commonly used electrical supports and installation requirements. 1.2 DEFINITIONS A. The IBC: International Building Code. B. ICC-ES: ICC-Evaluation Service. 1.3 PERFORMANCE REQUIREMENTS A. Seismic-Restraint Loading: 1. Site Class as Defined in the IBC: D. 2. Assigned Seismic Use Group or Building Category as Defined in the IBC: III. a. Component Importance Factor: 1.5. b. Component Response Modification Factor: 2.5, 6. c. Component Amplification Factor: 1.0, 2.5. 3. Design Spectral Response Acceleration at Short Periods (0.2 Second): 53.2%. 4. Design Spectral Response Acceleration at 1.0-Second Period: 16.6%. 1.4 SUBMITTALS A. Product Data: For the following: 1. Include rated load, rated deflection, and overload capacity for each vibration isolation device. 2. Illustrate and indicate style, material, strength, fastening provision, and finish for each type and size of seismic-restraint component used. a. Tabulate types and sizes of seismic restraints, complete with report numbers and rated strength in tension and shear as evaluated by an evaluation service member of ICC-ES. b. Annotate to indicate application of each product submitted and compliance with requirements. 3. Restrained-Isolation Devices: Include ratings for horizontal, vertical, and combined loads. B. Delegated-Design Submittal: For seismic-restraint details indicated to comply with performance requirements and design criteria, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation. 1. Design Calculations: Calculate static and dynamic loading due to equipment weight and operation, seismic forces required to select vibration isolators and seismic restraints. Project No. 18088080 2 Section 26 05 48 Lake Lewisville WTP Dewatering Improvements Vibration and Seismic controls for Electrical Systems a. Coordinate design calculations with wind-load calculations required for equipment mounted outdoors. Comply with requirements in other Division 26 Sections for equipment mounted outdoors. 2. Indicate materials and dimensions and identify hardware, including attachment and anchorage devices. 3. Field-fabricated supports. 4. Seismic-Restraint Details: a. Design Analysis: To support selection and arrangement of seismic restraints. Include calculations of combined tensile and shear loads. b. Details: Indicate fabrication and arrangement. Detail attachments of restraints to the restrained items and to the structure. Show attachment locations, methods, and spacings. Identify components, list their strengths, and indicate directions and values of forces transmitted to the structure during seismic events. C. Coordination Drawings: Show coordination of seismic bracing for electrical components with other systems and equipment in the vicinity, including other supports and seismic restraints. D. Welding certificates. E. Qualification Data: For testing agency. F. Field quality-control test reports. 1.5 QUALITY ASSURANCE A. Testing Agency Qualifications: An independent agency, with the experience and capability to conduct the testing indicated, that is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29 CFR 1910.7, and that is acceptable to authorities having jurisdiction. B. Comply with seismic-restraint requirements in the IBC unless requirements in this Section are more stringent. C. Welding: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel." D. Seismic-restraint devices shall have horizontal and vertical load testing and analysis and shall bear preapproval by ICC-ES, or preapproval by another agency acceptable to authorities having jurisdiction, showing maximum seismic-restraint ratings. Ratings based on independent testing are preferred to ratings based on calculations. If preapproved ratings are not available, submittals based on independent testing are preferred. Calculations (including combining shear and tensile loads) to support seismic-restraint designs must be signed and sealed by a qualified professional engineer. E. Comply with NFPA 70. PART 2 - PRODUCTS 2.1 VIBRATION ISOLATORS 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. Ace Mountings Co., Inc. 2. Amber/Booth Company, Inc. 3. California Dynamics Corporation. 4. Isolation Technology, Inc. Project No. 18088080 3 Section 26 05 48 Lake Lewisville WTP Dewatering Improvements Vibration and Seismic controls for Electrical Systems 5. Kinetics Noise Control. 6. Mason Industries. 7. Vibration Eliminator Co., Inc. 8. Vibration Isolation. 9. Vibration Mountings & Controls, Inc. B. Pads: Arrange in single or multiple layers of sufficient stiffness for uniform loading over pad area, molded with a nonslip pattern and galvanized-steel baseplates, and factory cut to sizes that match requirements of supported equipment. 1. Resilient Material: Oil- and water-resistant neoprene. C. Spring Isolators: Freestanding, laterally stable, open-spring isolators. 1. Outside Spring Diameter: Not less than 80 percent of the compressed height of the spring at rated load. 2. Minimum Additional Travel: 50 percent of the required deflection at rated load. 3. Lateral Stiffness: More than 80 percent of rated vertical stiffness. 4. Overload Capacity: Support 200 percent of rated load, fully compressed, without deformation or failure. 5. Baseplates: Factory drilled for bolting to structure and bonded to 1/4-inch- (6-mm-) thick, rubber isolator pad attached to baseplate underside. Baseplates shall limit floor load to 500 psig (3447 kPa). 6. Top Plate and Adjustment Bolt: Threaded top plate with adjustment bolt and cap screw to fasten and level equipment. D. Restrained Spring Isolators: Freestanding, steel, open-spring isolators with seismic or limit-stop restraint. 1. Housing: Steel with resilient vertical-limit stops to prevent spring extension due to weight being removed; factory-drilled baseplate bonded to 1/4-inch- (6-mm-) thick, neoprene or rubber isolator pad attached to baseplate underside; and adjustable equipment mounting and leveling bolt that acts as blocking during installation. 2. Restraint: Seismic or limit-stop as required for equipment and authorities having jurisdiction. 3. Outside Spring Diameter: Not less than 80 percent of the compressed height of the spring at rated load. 4. Minimum Additional Travel: 50 percent of the required deflection at rated load. 5. Lateral Stiffness: More than 80 percent of rated vertical stiffness. 6. Overload Capacity: Support 200 percent of rated load, fully compressed, without deformation or failure. 2.2 SEISMIC-RESTRAINT DEVICES 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. Amber/Booth Company, Inc. 2. California Dynamics Corporation. 3. Cooper B-Line, Inc.; a division of Cooper Industries. 4. Hilti Inc. 5. Loos & Co.; Seismic Earthquake Division. 6. Mason Industries. 7. TOLCO Incorporated; a brand of NIBCO INC. 8. Unistrut; Tyco International, Ltd. B. General Requirements for Restraint Components: Rated strengths, features, and application requirements shall be as defined in reports by an evaluation service member of ICC-ES. Project No. 18088080 4 Section 26 05 48 Lake Lewisville WTP Dewatering Improvements Vibration and Seismic controls for Electrical Systems 1. Structural Safety Factor: Allowable strength in tension, shear, and pullout force of components shall be at least four times the maximum seismic forces to which they will be subjected. C. Channel Support System: MFMA-3, shop- or field-fabricated support assembly made of slotted steel channels with accessories for attachment to braced component at one end and to building structure at the other end and other matching components and with corrosion-resistant coating; and rated in tension, compression, and torsion forces. D. Restraint Cables: ASTM A 492 stainless-steel cables with end connections made of steel assemblies with thimbles, brackets, swivels, and bolts designed for restraining cable service; and with a minimum of two clamping bolts for cable engagement. E. Hanger Rod Stiffener: Steel tube or steel slotted-support-system sleeve with internally bolted connections to hanger rod. Do not weld stiffeners to rods. F. Bushings for Floor-Mounted Equipment Anchor: Neoprene bushings designed for rigid equipment mountings, and matched to type and size of anchors and studs. G. Bushing Assemblies for Wall-Mounted Equipment Anchorage: Assemblies of neoprene elements and steel sleeves designed for rigid equipment mountings, and matched to type and size of attachment devices. H. Resilient Isolation Washers and Bushings: One-piece, molded, oil- and water-resistant neoprene, with a flat washer face. I. Mechanical Anchor: Drilled-in and stud-wedge or female-wedge type in zinc-coated steel for interior applications and stainless steel for exterior applications. Select anchors with strength required for anchor and as tested according to ASTM E 488. Minimum length of eight times diameter. J. Adhesive Anchor: Drilled-in and capsule anchor system containing polyvinyl or urethane methacrylate-based resin and accelerator, or injected polymer or hybrid mortar adhesive. Provide anchor bolts and hardware with zinc-coated steel for interior applications and stainless steel for exterior applications. Select anchor bolts with strength required for anchor and as tested according to ASTM E 488. 2.3 FACTORY FINISHES A. Finish: Manufacturer's standard paint applied to factory-assembled and -tested equipment before shipping. 1. Powder coating on springs and housings. 2. All hardware shall be stainless. 3. Powder coat for metal components on isolators for interior use. 4. Color-code or otherwise mark vibration isolation and seismic-control devices to indicate capacity range. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine areas and equipment to receive seismic-control devices for compliance with requirements for installation tolerances and other conditions affecting performance. Project No. 18088080 5 Section 26 05 48 Lake Lewisville WTP Dewatering Improvements Vibration and Seismic controls for Electrical Systems B. Examine roughing-in of reinforcement and cast-in-place anchors to verify actual locations before installation. C. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 APPLICATIONS A. Multiple Raceways or Cables: Secure raceways and cables to trapeze member with clamps approved for application by an evaluation service member of ICC-ES. B. Hanger Rod Stiffeners: Install hanger rod stiffeners where indicated or scheduled on Drawings to receive them and where required to prevent buckling of hanger rods due to seismic forces. C. Strength of Support and Seismic-Restraint Assemblies: Where not indicated, select sizes of components so strength will be adequate to carry present and future static and seismic loads within specified loading limits. 3.3 SEISMIC-RESTRAINT DEVICE INSTALLATION A. Equipment and Hanger Restraints: 1. Install restrained isolators on electrical equipment. 2. Anchor bolts where clearance between anchor and adjacent surface exceeds 0.125 inch (3.2 mm). 3. Install seismic-restraint devices using methods approved by an evaluation service member of ICC-ES providing required submittals for component. B. Install bushing assemblies for mounting bolts for wall-mounted equipment, arranged to provide resilient media where equipment or equipment-mounting channels are attached to wall. C. Attachment to Structure: If specific attachment is not indicated, anchor bracing to structure at flanges of beams, at upper truss chords of bar joists, or at concrete members. D. Drilled-in Anchors: 1. Identify position of reinforcing steel and other embedded items prior to drilling holes for anchors. Do not damage existing reinforcing or embedded items during coring or drilling. Notify the structural engineer if reinforcing steel or other embedded items are encountered during drilling. Locate and avoid prestressed tendons, electrical and telecommunications conduit, and gas lines. 2. Do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved full design strength. 3. Wedge Anchors: Protect threads from damage during anchor installation. Heavy-duty sleeve anchors shall be installed with sleeve fully engaged in the structural element to which anchor is to be fastened. 4. Adhesive Anchors: Clean holes to remove loose material and drilling dust prior to installation of adhesive. Place adhesive in holes proceeding from the bottom of the hole and progressing toward the surface in such a manner as to avoid introduction of air pockets in the adhesive. 5. Set anchors to manufacturer's recommended torque, using a torque wrench. 6. Install zinc-coated steel anchors for interior and stainless-steel anchors for exterior applications. 3.4 ACCOMMODATION OF DIFFERENTIAL SEISMIC MOTION A. Install flexible connections in runs of raceways, cables, wireways, cable trays, and busways where they cross seismic joints, where adjacent sections or branches are supported by different Project No. 18088080 6 Section 26 05 48 Lake Lewisville WTP Dewatering Improvements Vibration and Seismic controls for Electrical Systems structural elements, and where they terminate with connection to equipment that is anchored to a different structural element from the one supporting them as they approach equipment. 3.5 FIELD QUALITY CONTROL A. Perform tests and inspections. B. Tests and Inspections: 1. Provide evidence of recent calibration of test equipment by a testing agency acceptable to authorities having jurisdiction. 2. Schedule test with Owner, through Engineer, before connecting anchorage device to restrained component (unless post connection testing has been approved), and with at least seven days' advance notice. 3. Obtain Engineer’s approval before transmitting test loads to structure. Provide temporary load-spreading members. 4. Test at least four of each type and size of installed anchors and fasteners.. 5. Test to 90 percent of rated proof load of device. 6. Measure isolator restraint clearance. 7. Measure isolator deflection. 8. Verify snubber minimum clearances. 9. If a device fails test, modify all installations of same type and retest until satisfactory results are achieved. C. Remove and replace malfunctioning units and retest as specified above. D. Prepare test and inspection reports. 3.6 ADJUSTING A. Adjust isolators after isolated equipment is at operating weight. B. Adjust limit stops on restrained spring isolators to mount equipment at normal operating height. After equipment installation is complete, adjust limit stops so they are out of contact during normal operation. C. Adjust active height of spring isolators. D. Adjust restraints to permit free movement of equipment within normal mode of operation. END OF SECTION Project No. 18088080 1 Section 26 05 53 Lake Lewisville WTP Dewatering Improvements Identification for Electrical Systems SECTION 26 05 53 - IDENTIFICATION FOR ELECTRICAL SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following: 1. Identification for conductors and communication and control cable. 2. Warning labels and signs. 3. Instruction signs. 4. Equipment identification labels. 5. Miscellaneous identification products. B. Related sections: 1. Section 26 05 70 – Power System Study. 1.2 SUBMITTALS A. Product Data: For each electrical identification product indicated. B. Identification Schedule: An index of nomenclature of electrical equipment and system components used in identification signs and labels. 1.3 QUALITY ASSURANCE A. Comply with ANSI A13.1 and ANSI C2. B. Comply with NFPA 70. C. Comply with NFPA 70E D. Comply with 29 CFR 1910.145. 1.4 COORDINATION A. Coordinate identification names, abbreviations, colors and other features with requirements in the Contract Documents, Shop Drawings, manufacturer’s wiring diagrams, and the Operation and Maintenance Manual, and with those required by codes, standards and 29 CFR 1910.145. Use consistent designations throughout Project. B. Coordinate installation of identifying devices with completion of covering and painting of surfaces where devices are to be applied. C. Coordinate installation of identifying devices with location of access panels and doors. PART 2 - PRODUCTS 2.1 CONDUCTOR AND COMMUNICATION – AND CONTROL-CABLE IDENTIFICATION MATERIALS. A. Color-Coding Conductor Tape: Colored, self-adhesive vinyl tape not less than 3 mils thick by 1 to 2 inches wide. B. Marker Tapes: vinyl or vinyl-cloth, self-adhesive wraparound type, with circuit identification legend machine printed by thermal transfer or equivalent process. Project No. 18088080 2 Section 26 05 53 Lake Lewisville WTP Dewatering Improvements Identification for Electrical Systems 2.2 WARNING LABEL AND SIGNS A. Comply with NFPA 70 and 29 CFR 1910.145 and NFPA 70E. B. Self-Adhesive Warning Labels: Factory printed, multicolor, pressure-sensitive adhesive labels, configured for display on front cover, door or other access to equipment unless otherwise indicated. C. Metal-Backed, Butyrate Warning Signs: Weather-resistant, nonfading, preprinted, cellulose- acetate butyrate signs with 0.0396-inch galvanized-steel backing; and with colors, legend and size required for application. ¼ inch grommets in corners for mounting. Nominal size, 10 by 14 inches. D. Sample 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.” 3. WARNING – ARC FLASH AND SHOCK HAZARD –APPROPRIATE PPE REQUIRED. 2.3 INSTRUCTION SIGNS A. Engraved, laminated acrylic or melamine plastic, minimum 1/16 inch thick for signs up to 20 sq. in. and 1/8 inch thick for larger sized. 1. Engraved legend with black letters on white face. 2. Punched or drilled for mechanical fasteners. 3. Framed with mitered acrylic molding and arranged for attachment at applicable equipment. 2.4 EQUIPMENT IDENTIFICATION LABELS A. Engraved, Laminated Acrylic or Melamine Label: Punched or drilled for screw mounting. White letters on a dark gray background. Minimum letter height shall be 3/8 inch. B. Stenciled Legend: In nonfading, waterproof, black ink or paint. Minimum letter height shall be 1 inch. 2.5 MISCELLANEOUS IDENTIFICATION PRODUCTS. A. Cable ties: fungus-inert, self-extinguishing, 1-piece, self-locking, type 6/6 nylon cable ties. 1. Minimum Width: 3/16 inch. 2. Tensile Strength: 50 lb minimum. 3. Temperature Range: Minus 40 to plus 185 degrees F. 4. Color: Black, except where used for color-coding. B. Fasteners for Labels and Signs: Self-tapping, stainless-steel screws or stainless-steel machine screws with nuts and flat and lock washers. PART 3 - EXECUTION 3.1 APPLICATION A. Outlet Boxes for Receptacles: Identify branch circuit by panel name and circuit number. Project No. 18088080 3 Section 26 05 53 Lake Lewisville WTP Dewatering Improvements Identification for Electrical Systems B. Power-Circuit Conductor Identification: of secondary conductors No. 1/0 AWG and larger in vaults, pull and junction boxes, manholes, and handholes use color-coding conductor tape. Identify source and circuit number of each set of conductors. For single conductor cables, identify phase in addition to the above. C. Branch-Circuit Conductor Identification: Where there are conductors for more than three branch circuits in same junction or pull box, use color-coding conductor tape. Identify each ungrounded conductor according to source and circuit number. D. Auxiliary Electrical Systems Conductor Identification: Identify field-installed alarm, control, signal, sound, intercommunications, voice, and data connections. 1. Identify conductors, cables and terminals in enclosures and at junctions, terminals, and pull points. Identify by system and circuit designation. 2. Use system of marker type designations that is uniform and consistent with system used by manufacturer for factory-installed connections. 3. Coordinate identification with Project Drawings, manufacturer’s wiring diagrams, and Operation and Maintenance Manual. E. Warning Labels for Indoor Cabinets, Boxes and Enclosures for Power and Lighting: comply with 29 CFR 1910.145 and apply metal-backed, butyrate warning signs. Identify system voltage with black letters on an orange background. Apply to exterior of door, cover or other access. 1. Equipment with Multiple Power or Control Sources: Apply to door or cover of equipment including, but not limited to the following: a. Power transfer switches b. Controls with external control power connections. 2. Equipment Requiring Workspace Clearance According to NFPA 70: Unless otherwise indicated, apply to door or cover of equipment but not on flush panelboards and similar equipment in finished spaces. F. Instruction Signs: 1. Operating Instructions: 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. 2. Emergency Operating Instructions: Install instruction signs with white legend on a red background with minimum 3/8 inch high letters for emergency instructions at equipment used for power transfer. G. Equipment Identification Labels: On each unit of equipment, install unique designation label that is consistent with wiring diagrams, schedules, and Operation and Maintenance Manual. Apply labels to disconnect switches and protection equipment, central or master units, control panels, control stations, terminal cabinets, and racks of each system. Systems include power, lighting, control, communication, signal, monitoring, and alarm systems unless equipment is provided with its own identification. 1. Labeling Instructions: a. Indoor Equipment: Engraved, laminated acrylic or melamine label. Unless otherwise indicated, provide a single line of text with ½-inch high letters on 1-1/2- inch high label; where 2 lines of text are required, use labels 2 inches high. b. Outdoor Equipment: Engraved, laminated acrylic or melamine label. 2. Equipment to Be Labeled: a. Panelboards, electrical cabinets and enclosures. b. Access doors and panels for concealed electrical items. c. Electrical switchgear and switchboards. d. Transformers. e. Motor-control centers. f. Disconnect switches. Project No. 18088080 4 Section 26 05 53 Lake Lewisville WTP Dewatering Improvements Identification for Electrical Systems g. Enclosed circuit breakers. h. Motor starters. i. Push-bottom stations. j. Power transfer equipment. k. Contactors. l. Remote-controlled switches and control devices. m. Power-generating units. n. Voice and data cable terminal equipment. o. Terminals, racks and patch panels for voice and data communications and for signal and control functions. 3.2 INSTALLATION A. Verify identity of each item before installing identification products. B. Location: Install identification materials and devices at locations for most convenient viewing without interference with operation and maintenance of equipment. C. Apply identification devices to surfaces that require finish after completing finish work. D. Self-Adhesive Identification Products: Clean surfaces before application, using materials and methods recommended by manufacturer of identification device. E. Attach nonadhesive signs and plastic labels with screws and auxiliary hardware appropriate to the location and substrate. F. Color-Coding for Phase and Voltage Level Identification, 600 V and Less: Use the colors listed below for ungrounded service, feeder and branch-circuit conductors. 1. Color shall be factory applied or, for sized larger than No. 6 AWG if authorities having jurisdiction permit, field applied. 2. Colors for 480/277-V Circuits: a. Phase A: Brown b. Phase B: Orange c. Phase C: Yellow 3. Field-Applied, Color-Coding Conductor Tape: Apply in half-lapped turns for a minimum distance of 6 inches from terminal points and in boxes where splices or taps are made. Apply last two turns of tape with no tension to prevent possible unwinding. Locate bands to avoid obscuring factory cable markings. END OF SECTION Project No. 18088080 1 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study SECTION 26 05 70 – POWER SYSTEM STUDY PART 1 - GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. Section includes a complete computer-based power system study including the following: short circuit analysis, equipment evaluation, protective device overcurrent coordination, and arc flash hazard analysis. 1.3 SCOPE A. Perform power system study as required by this document for all electrical equipment associated with the new facilities installed downstream of the new medium voltage transformer including new equipment and equipment provided as part of a manufacturer supplied package. The study shall originate at the new medium voltage loop transformer. 1.4 DEFINITIONS A. Existing to Remain: Existing items of construction that are not to be removed and that are not otherwise indicated to be removed, removed and salvaged, or removed and reinstalled. B. One-Line Diagram: A diagram which shows, by means of single lines and graphic symbols, the course of an electric circuit or system of circuits and the component devices or parts used therein. C. Protective Device: A device that senses when an abnormal current flow exists and then removes the affected portion from the system. D. SCCR: Short-circuit current rating. E. Service: The conductors and equipment for delivering electric energy from the serving utility to the wiring system of the premises served. 1.5 SUBMITTALS A. Product Data: For computer software program to be used for studies. B. Submit the following after the approval of system protective devices submittals. Submittals may be in digital form. 1. Power system analysis input data, including completed computer program input data sheets. 2. Complete power system study report as required by this document; signed, dated, and sealed by a qualified professional engineer. a. Submit study report for action prior to receiving final approval of the distribution equipment submittals. If formal completion of studies will cause delay in equipment manufacturing, obtain approval from Engineer for preliminary submittal of sufficient study data to ensure that the selection of devices and associated characteristics is satisfactory. b. Revised single-line diagram, reflecting field investigation results and results of power system analysis. Project No. 18088080 2 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study C. Qualification Data: For power system analysis specialist. D. Product Certificates: For power system analysis software, certifying compliance with IEEE 399, IEEE 1584, and NFPA 70E. E. Operation & Maintenance Data 1. In addition to items specified in Division 01 “Operation and Maintenance Data,” include the following: a. The following parts from the Power System Study report: 1) One-line diagram 2) Time current coordination curves 3) Arc flash hazard analysis results 1.6 QUALITY ASSURANCE A. Studies shall use computer programs that are distributed nationally and are in wide use. Software algorithms shall comply with requirements of standards and guides specified in this Section. Manual calculations are unacceptable. B. Power System Analysis Specialist Qualifications: Professional engineer in charge of performing the study and documenting recommendations, licensed in the state where Project is located. All elements of the study shall be performed under the direct supervision and control of this professional engineer. PART 2 - PRODUCTS 2.1 COMPUTER SOFTWARE A. Products: Subject to compliance with requirements, provide the following: 1. SKM; PowerTools for Windows 2. ESA International; EasyPower. B. Comply with IEEE 399, IEEE 551, IEEE 242, IEEE 1584, and NFPA 70E. C. Analytical features of computer software program shall have the capability to calculate "mandatory," "very desirable," and "desirable" features as listed in IEEE 399. D. Computer software program shall be capable of plotting and diagramming time-current- characteristic curves as part of its output. 2.2 DATA COLLECTION A. Obtain all data necessary to conduct the power system analysis. 1. Verify completeness of data supplied on the one-line diagram on Drawings. Call discrepancies to the attention of Engineer. 2. For new equipment, use characteristics submitted under the provisions of submittals for this Project. 3. For existing equipment, whether or not relocated, obtain required electrical distribution system data by field investigation and surveys, conducted by qualified technicians and engineers. B. Gather and tabulate the following input data to support power system study. Comply with recommendations in IEEE 1584 and NFPA 70E as to the amount of detail that is required to be acquired in the field. Field data gathering shall be under the direct supervision and control of the Project No. 18088080 3 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study engineer in charge of performing the study, and shall be by the engineer or its representative who holds NETA ETT Level III certification or NICET Electrical Power Testing Level III certification. 1. Product Data for overcurrent protective devices specified in other Sections and involved in overcurrent protective device coordination studies. Use equipment designation tags that are consistent with electrical distribution system diagrams, overcurrent protective device submittals, input and output data, and recommended device settings. 2. Obtain electrical power utility impedance at the service, including three phase and single phase short circuit MVA and X/R ratio. 3. Power sources and ties. 4. For transformers, include kVA, primary and secondary voltages, connection type, impedance, X/R ratio, taps measured in percent, and phase shift. 5. For reactors, provide manufacturer and model designation, voltage rating and impedance. 6. For circuit breakers and fuses, provide manufacturer and model designation. List type of breaker, type of trip and available range of settings, SCCR, current rating, and breaker settings. 7. Generator short-circuit current contribution data, including short-circuit reactance, rated kVA, rated voltage, and X/R ratio. 8. For relays, provide manufacturer and model designation, current transformer ratios, potential transformer ratios, and relay settings. 9. Busway manufacturer and model designation, current rating, impedance, lengths, and conductor material. 10. Motor horsepower and NEMA MG 1 code letter designation. 11. Low-voltage cable sizes, lengths, number, conductor material and conduit material (magnetic or nonmagnetic). 12. Medium-voltage cable sizes, lengths, conductor material, and cable construction and metallic shield performance parameters. 2.3 SYSTEM MODELING A. Provide a list of all assumptions made. The Engineer shall review and request any changes to assumptions before final approval of the model. B. Equipment names used in the modeling software shall be identical to the names used on the equipment nameplates installed in the field. C. For systems with more than one available power source (such as a generator or second utility source), separate scenarios shall be modeled for each possible operating condition. Each of the operating conditions shall be documented and modeled in the software in order to determine the worst-case arch flash hazard and short circuit values for the system components. D. All components in the model shall be based on nameplate data from the actual field device including manufacturer, type, style, ratings, actual settings, etc. Generic substitutions or assumptions shall not be allowed unless data can not be field verified. All assumptions or substitutions shall be documented in the report. E. The model shall include all electrical components of the system from the utility service (including primary relaying) down to all equipment in excess of 50V. This includes all control panels, disconnects, or other panels where voltage greater than 50V is present. Refer to requirements of arc flash analysis for evaluating hazards for equipment less than 240V. 2.4 SHORT CIRCUIT ANALYSIS A. Perform study following the general study procedures contained in IEEE 399. Project No. 18088080 4 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study B. Calculate short-circuit currents according to IEEE 551. Begin short-circuit current analysis at the service, extending down to the system overcurrent protective devices. C. Study electrical distribution system from normal and alternate power sources throughout electrical distribution system for Project. Study all cases of system-switching configurations and alternate operations that could result in maximum fault conditions. D. Actual transformer impedances shall be used if known. Design impedances shall only be used where actual impedance is unobtainable from field markings or from the manufacturer. E. The calculations shall include the ac fault-current decay from induction motors, synchronous motors, and asynchronous generators and shall apply to low- and medium-voltage, three-phase ac systems. The calculations shall also account for the fault-current dc decrement, to address the asymmetrical requirements of the interrupting equipment. 1. For grounded systems, provide a bolted line-to-ground fault-current study for areas as defined for the three-phase bolted fault short-circuit study. F. Calculate short-circuit momentary and interrupting duties for a three-phase bolted fault at each of the following: 1. Electric utility's supply termination point. 2. Incoming switchgear. 3. Low-voltage switchgear. 4. Motor-control centers. 5. Control panels. 6. Standby generators and automatic transfer switches. 7. Branch circuit panelboards. 8. Disconnect switches. 9. Other significant locations throughout the system 2.5 EQUIPMENT EVALUATION A. Provide a short circuit evaluation of all electrical equipment and protective devices. Evaluation shall compare short circuit withstand and interrupting ratings of equipment with calculated short circuit values from the study. B. The software performing the equipment evaluation shall automatically adjust results for system X/R ratios that are higher than equipment test X/R ratios. C. Equipment in the evaluation shall be marked with the following designations: 1. PASS –maximum short circuit current is less than 90% of equipment rating. 2. MARGINAL –maximum short circuit current is 90%-100% of equipment rating. 3. FAIL –maximum short circuit current is greater than 100% of equipment rating. 2.6 PROTECTIVE DEVICE COORDINATION STUDY A. Provide settings for all overcurrent protective devices to achieve the following: 1. Provide selective coordination for the electrical system. 2. Protect equipment and cables from damage during overcurrent conditions. 3. Minimize arc flash hazards. B. Graphically illustrate the settings of all overcurrent protective devices utilizing time current curves (TCCs) meeting the following requirements: 1. Display TCCs on log-log scale graphs printed in color on 8.5”x11” sized paper. Each TCC shall have a unique title and associated one-line diagram with legend identifying the portion of the system depicted in the TCC. Project No. 18088080 5 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study 2. Terminate device characteristic curves at a point reflecting maximum symmetrical or asymmetrical fault current to which the device is exposed. 3. Each device shown on a TCC shall include a datablock identifying the name of the device, manufacturer make and model, and overcurrent settings. 4. Develop TCCs for both phase and ground protective devices. 5. Plot the following listed characteristic curves, as applicable: a. Power utility’s overcurrent protective device. b. Medium voltage equipment overcurrent relays. c. Medium and low voltage fuses including manufacturer’s minimum melt, total clearing, tolerance, and damage bands. d. Low voltage equipment circuit breaker trip devices, including manufacturer’s tolerance bands. e. Transformer full load current, magnetizing inrush current, and ANSI through-fault protection curves. f. Cables and conductors damage curves. g. Ground fault protective devices. h. Motor starting characteristics and motor damage points. i. Generator short-circuit decrement curve and generator damage point. j. The largest feeder circuit breaker in each motor control center, switchboard, and panel board. 6. Provide number of TCCs as required to adequately display the selective coordination of the system. 7. Provide adequate time margins between device characteristics such that selective operation is achieved. C. For an existing system, provide the protective device settings as existing as well as recommendations for new settings if existing does not provide adequate selectivity. If settings changes are recommended, clearly identify the recommended changes in a table format. D. A table shall be developed to summarize the settings for all protective devices that contain adjustable settings. The table shall include the following: 1. Device identification. 2. For circuit breakers: manufacturer, type, style, sensor rating, long-time pickup, short-time pickup, instantaneous pickup, ground fault pickup, and associated time delay settings. 3. For protective relays: manufacturer, type, style, function pickup, current multiplier, time dial, and time delays. For multi-function units, list all devices being used. Include the CT and/or PT ratios for each function. 4. Include both existing settings and recommended changes for all protective devices with recommended settings changes. E. Transformer Primary Overcurrent Protective Devices: 1. Device shall not operate in response to the following: a. Inrush current when first energized. b. Self-cooled, full-load current or forced-air-cooled, full-load current, whichever is specified for that transformer. c. Permissible transformer overloads according to IEEE C57.96 if required by unusual loading or emergency conditions. 2. Device settings shall protect transformers according to IEEE C57.12.00, for fault currents. F. Motor Protection: 1. Select protection for low-voltage motors according to IEEE 242 and NFPA 70. 2. Select protection for motors served at voltages more than 600 V according to IEEE 620. G. Conductor Protection: Protect cables against damage from fault currents according to ICEA P- 32-382, ICEA P-45-482, and protection recommendations in IEEE 242. Demonstrate that equipment withstands the maximum short-circuit current for a time equivalent to the tripping time Project No. 18088080 6 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study of the primary relay protection or total clearing time of the fuse. To determine temperatures that damage insulation, use curves from cable manufacturers or from listed standards indicating conductor size and short-circuit current. H. Generator Protection: Select protection according to manufacturer's written recommendations and to IEEE 242. 2.7 ARC FLASH HAZARD ANALYSIS A. Comply with NFPA 70E and IEEE 1584 for hazard analysis study. B. Results from the short circuit current study and overcurrent coordination study shall be used as inputs to the arc flash hazard analysis. C. The flash protection boundary and incident energy shall be calculated at all significant locations in the electrical distribution system where work could be performed on energized parts. This includes but is not limited to switchboards, switchgear, motor control centers, panelboards, busways, and disconnect switches. D. For three-phase or single-phase equipment rated 240-V ac or less fed from transformers less than 125 kVA, refer to NFPA 70E and IEEE 1584 for determining hazard category levels. Include in the report a description of methods used to determine hazard levels for equipment in this category. E. Safe working distances shall be specified for calculated fault locations based on the calculated arc-flash boundary, considering incident energy of 1.2 cal/sq.cm. F. The incident energy calculations for multiple scenarios must be compared and the greatest incident energy must be reported for each equipment location. Calculations must be performed to represent the maximum and minimum contributions of fault current magnitude for all normal and emergency operating conditions. The minimum calculation shall assume that the utility contribution is at a minimum and shall assume no motor load. The maximum calculation shall assume a maximum contribution from the utility and shall assume motors to be operating under full load conditions. Note that maximum utility contribution is not defined as infinite bus, but rather the maximum value reported by the utility. G. Incident energy calculations shall consider the accumulation of energy over time when performing arc-flash calculations on buses with multiple sources. Iterative calculations shall take into account the changing current contributions, as the sources are interrupted or decremented with time. Fault contribution from motors and generators shall be decremented as follows: 1. Fault contribution from induction motors should not be considered beyond three to five cycles. H. Fault contribution from synchronous motors and generators should be decayed to match the actual decrement of each as closely as possible (e.g., contributions from permanent magnet generators will typically decay from 10 per unit to three per unit after 10 cycles). I. Arc-flash computation shall include both line and load side of a circuit breaker as follows: 1. When the circuit breaker is in a separate enclosure. 2. When the line terminals of the circuit breaker are separate from the work location. J. Base arc-flash calculations on actual overcurrent protective device clearing time. Cap maximum clearing time at two seconds based on IEEE 1584, Section B.1.2. Project No. 18088080 7 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study PART 3 - EXECUTION 3.1 POWER SYSTEM STUDY REPORT CONTENTS A. Executive Summary 1. Brief description of the important findings and recommendations of the study. The executive summary should not include general study information or methodology. B. Introduction 1. Describe the purpose and scope of the study and the methodology used for each analysis. 2. Provide a description of the connection of the system and the different operating scenarios analyzed. 3. List all engineering assumptions made for the study. C. Input Data 1. Provide input data for all components of the system model in tabular format, including but not limited to the following: a. Cable data including size, length, number per phase, conduit type, and conductor material b. Transformer data including winding connections, kVA rating, primary and secondary voltage ratings, %Z, and X/R ratios. c. Reactor data including voltage rating and inductance. d. Generator contribution data including kVA rating, power factor, voltage, and subtransient reactance. e. Utility contribution data including rated voltage and three phase and single-line- ground contributions with X/R ratios. D. One-Line Diagram 1. Provide one-line diagram(s) generated from the computer software package that show all electrical distribution for the system. Include as a minimum the following information on the diagram(s): a. Protective device designations and ampere ratings. b. Cable sizes and lengths. c. Transformer kilovolt ampere (kVA), voltage, and impedance ratings. d. Motor and generator designations and kVA ratings. e. Utility contribution data f. Switchgear, switchboard, motor-control center, and panelboard designations, voltage ratings, bus ampacities, and short circuit current ratings. E. Short Circuit Current Analysis 1. Output data shall include but not be limited to the following reports: a. Low-Voltage Fault Report: Three-phase and unbalanced fault calculations, showing the following for each overcurrent device location: 1) Voltage. 2) Calculated fault-current magnitude and angle. 3) Fault-point X/R ratio. 4) Equivalent impedance. b. Momentary Duty Report: Three-phase and unbalanced fault calculations, showing the following for each overcurrent device location: 1) Voltage. 2) Calculated symmetrical fault-current magnitude and angle. 3) Fault-point X/R ratio. 4) Calculated asymmetrical fault currents: a) Based on fault-point X/R ratio. b) Based on calculated symmetrical value multiplied by 1.6. c) Based on calculated symmetrical value multiplied by 2.7. Project No. 18088080 8 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study c. Interrupting Duty Report: Three-phase and unbalanced fault calculations, showing the following for each overcurrent device location: 1) Voltage. 2) Calculated symmetrical fault-current magnitude and angle. 3) Fault-point X/R ratio. 4) No AC Decrement (NACD) ratio. 5) Equivalent impedance. 6) Multiplying factors for 2-, 3-, 5-, and 8-cycle circuit breakers rated on a symmetrical basis. d. Multiplying factors for 2-, 3-, 5-, and 8-cycle circuit breakers rated on a total basis. F. Equipment Evaluation 1. The results of the short circuit equipment evaluation shall be reported in tabular format and provide the following information: a. Equipment name, voltage rating, and short circuit rating b. Calculated maximum available short circuit current at each device and bus c. Percent over/under duty and PASS/FAIL/MARGINAL designation as defined in Part 2 of this specification. d. Components that fail the equipment evaluation shall be highlighted for easy visual identification. G. Protective Device Coordination Study 1. Provide a brief summary of the findings of the study including any major selectivity problems or recommendations. 2. Provide all TCCs needed to illustrate the system including a table of contents and descriptions for all TCCs included. 3. Include a settings table to summarize the settings for all protective devices as required in Part 2 of this specification. H. Arc Flash Hazard Analysis 1. Provide a brief summary of the findings of the study including a list of any locations identified as Dangerous hazard category and recommendations for hazard category reductions. 2. Provide a table indicating the worst case scenario of all busses evaluated. Table shall include but is not limited to the following: a. Arcing fault magnitude. b. Protective device clearing time. c. Duration of arc. d. Arc flash boundary. e. Working distance. f. Incident energy. g. Hazard risk category. 3. Provide a separate table for each operating scenario. Provide the same information as required above for each table. I. Recommendations 1. Provide a section that summarizes and lists all recommendations for changes to the system as a result of the study. This includes protective device settings changes, equipment short circuit deficiency corrections, or other items as applicable. 3.2 ARC FLASH WARNING LABELS A. Provide a thermal transfer type label of high-adhesion polyester for each work location included in the analysis. Labels shall have a minimum size of 3.5”x5”. B. The labels shall include the following information taken directly from the arc flash hazard analysis: Project No. 18088080 9 Section 26 05 70 Lake Lewisville WTP Dewatering Improvements Power System Study 1. Equipment name (must match name on equipment nameplate). 2. Nominal voltage. 3. Flash protection boundary. 4. Hazard risk category. 5. Incident energy. 6. Available short circuit current. 7. Working distance. 8. Glove class. 9. Engineering report number, revision number, and issue date. C. Labels shall be machine printed, with no field-applied markings. D. Labels to be applied on outdoor equipment shall have a weatherproof coating for protection from deterioration or fading due to rain and UV exposure. 3.3 LABELING A. Apply one arc flash label for each of the following locations: 1. Panelboards 2. Disconnects 3. Motor control centers 4. Switchboards 5. Switchgear 6. Control panels 7. Any equipment likely to require servicing while energized B. Installation of arc flash warning labels shall be done under the direct supervision and control of the power system study specialist. 3.4 ADJUSTING A. Make minor modifications to equipment as required to accomplish compliance with power system study. 3.5 DEMONSTRATION A. Train Owner's operating and maintenance personnel in the use of study results. B. Train Owner’s operating and maintenance personnel in the potential arc flash hazards associated with working on energized equipment and the significance of arc flash warning labels. END OF SECTION Project No. 18088080 1 Section 26 09 43 Lake Lewisville WTP Dewatering Improvements Fiber Optic Network SECTION 26 09 43 - FIBER OPTIC NETWORK PART 1 - GENERAL 1.1 SUMMARY A. Related Sections: 1. General Instrumentation and Control. B. Definitions, Symbols, Definitions, and Abbreviations: All symbols, definitions and engineering unit abbreviations utilized shall conform to IEEE 100-84, S50.1 and S51.1, where applicable. C. System Description 1.2 PATENTS A. If the manufacturer is required or desires to use any design, device, material, or process covered by letter, patent, or copyright, the manufacturer shall provide for such use by suitable legal agreement with the patentee or owner, and the prices bid hereunder shall, without exception, indemnify and save the Owner and Engineer from any and all claims for infringement by reason of the use of any such patented design, device, material, or process, or any trademark or copyright used in connection with any equipment to be furnished hereunder. 1.3 SUBMITTALS A. Product Data: Installation Details 1. The Contractor shall submit to the Engineer, for approval, Shop Drawings of the equipment to be installed to meet the Specifications. The Drawings shall be supported by notes or written directions as required to fully define the installation. 2. The submission shall be made as soon as feasible after award of the Contract and, in any event, shall be submitted and approval obtained before installation of the equipment. The Contractor shall furnish the Engineer with six (6) copies of the submission. 3. The information required on the Shop Drawings shall include, but is not necessarily limited to, the following: a. Full and complete Specifications covering the equipment proposed to be furnished. b. Detail Drawings showing plan, network connections and elevation dimensions of the equipment proposed to be furnished. c. Guarantees of performance of the equipment proposed to be furnished. d. Nearest location of factory maintenance and service facilities that will be available to service the equipment offered. 1.4 DELIVERY, STORAGE, AND HANDLING A. Storage and Protection: Delivery, storage, and handling shall be in accordance with manufacturer’s recommendation and other sections herein. PART 2 - PRODUCTS 2.1 FIBER OPTIC CONNECTORS A. All fiber optic connectors shall be type SFP. All connectors on equipment and cables shall be fully compatible. B. Number cables and connect each cable to its numbered port on the indicated switch. Project No. 18088080 2 Section 26 09 43 Lake Lewisville WTP Dewatering Improvements Fiber Optic Network 2.2 12-STRAND ALL ENVIRONMENT MULTI-MODE FIBER OPTIC CABLE A. Fiber optic cable shall be industrial grade, extended performance. The cable shall consist of 12 fibers with 62.5-micron core and 125-micron cladding and shall be suitable for multimode operation at 850 and 1300 nanometers. Acceptable losses for multimode fiber lengths with connector pairs at each end shall not be greater than 3.75 dB/km at 850 nm and 1.5dB/kM at 1300nm. Cable shall be rated for installation in harsh environments such as direct burial, aerial lashing, and conduit and pathways that are subject to wide temperature variations. Cable shall be plenum rated. Cable shall comply with ANSI/TIA/EIA-568-B including all addendums for fiber optic cable performance specifications. B. The cable shall be suitable for the installation as certified by the fiber optic interface manufacturer and proven by test results. Fiber optic cable shall be supplied in continuous lengths between patch panels. Cable shall be as manufactured by Phoenix Digital or Optical Cable Corporation or Siecor or Lucent or Berk-Tek or equal. 2.3 FIBER OPTIC PATCH PANEL / TERMINATION PANEL A. Refer to specification 26 90 30 – Computer System and Network. 2.4 FIBER OPTIC PATCH CORDS A. Fiber optic patch cords shall be duplex SFP to SFP cords with two tight buffered 62.5/125 multi- mode strands. Patch cords must comply with ANSI/EIA/TIA standards. Provide Ortronics or Lucent or Amp or Molex Premise or NORDX/CDT or Panduit or Siemon or equal. PART 3 - EXECUTION 3.1 INSTALLATION A. Provide and install fiber optic cable, connectors, transceivers and converters, network cable, connectors, hubs and network switches to interconnect the PLCs. Fiber optic materials and equipment shall be installed, tested and terminated by experienced fiber optic system personnel. B. Cable shall be carefully installed and professionally terminated. Submit credentials and a sample of fiber termination technician. All terminations shall be compatible with the terminal and communicating equipment. Fiber optic cable shall be installed in underground concrete encased conduit. Network cable shall be installed in interior locations in conduit. C. Fiber Optic splices are not desired or permitted except in unavoidable circumstances. In the event of fiber optic cable damage exterior splices shall be made in handholes at no additional cost to the Owner and at the contractor's risk. The losses due to the splice shall not exceed 0.2dB per mechanical splice. No more than 1 set of splices shall be allowed in a run. The Contractor shall protect exposed ends of cable during construction. Network cable shall not be spliced. D. All required splicing materials shall be included with the fiber optic cable and shall meet the requirements of the terminal and communicating devices, transceivers and media converters and the fiber optical cable manufacturer's specifications. E. Fiber Optic Cable with connectors on each fiber strand shall be coiled in each Control Panel with 5 feet minimum slack ready for immediate use. Project No. 18088080 3 Section 26 09 43 Lake Lewisville WTP Dewatering Improvements Fiber Optic Network F. Cable Testing: The fiber optic cable shall be tested at the factory and at the job site before and after installation. Provide docket of shipment report with attenuation test results to the engineer prior to installation. These tests shall be signed, dated and immediately transmitted to the Engineer. Category 5 cable shall be third party verified to TIA/EIA 568-A Category 5. G. OTDR Tests: This test shall utilize an OTDR test instrument with signature trace printout capability and shall document the end-to-end attenuation for fiber, connectors and mechanical splices (if any). H. Site acceptance test: While cable is still on the reel as delivered to the site, prior to installation submit printed, signed and dated results of on-site, on-reel OTDR attenuation test of each fiber strand. Verify Category 5 cable performance with 100MHz test set. I. Post installation test: Following installation of fiber cable and termination of all strands submit results of on-site attenuation test of each terminated fiber strand. Tests shall be performed with an OTDR test instrument with printout capability. Test each terminated Category 5 cable with 100MHz test set. J. All cable with attenuation results lower than acceptable limits shall be removed and replaced at no additional cost to the Owner. K. Fiber optic and network devices installation: Modems and connecting cables shall be preconfigured at the factory for the application. No modem field settings, programming or adapters shall be required L. Fiber Optic Cable Installation: Fiber optic cable installation and termination shall be accomplished by technicians skilled and experienced in the type work indicated. Experience shall include 5 years of installation experience with proper training in use of the tools and equipment recommended by the fiber optic cable manufacturer for installation and termination in an approved manner. The installer shall have test equipment available to demonstrate that the completed installation complies with the specified bandwidth and transmission parameters. A licensed electrical or specialty controls contractor in the state of the project shall perform this work. 3.2 DEMONSTRATION A. System Demonstration and Final Acceptance Test: 1. The Contractor shall conduct a 10 day Final Acceptance test of the completed installation. The test shall start after the Engineer has received marked record (as-built) drawings from the Contractor and when directed by the Owner/Engineer. 2. The system shall operate with 100 percent reliability during the test period. Failure of hardware shall require repair or remedy of the defect to the satisfaction of the Engineer within a two hour period. If the problem cannot be repaired in this time, the test shall be aborted and restarted after the problem is corrected and when directed by the Owner/Engineer. Restarting and satisfactory completion of the test shall be conducted at no additional cost to the Owner. 3. The Contractor shall complete the Operations and Maintenance Manuals including all updated documentation of programmable devices to the satisfaction of the Engineer. 4. The Contractor will be allowed two attempts at successfully completing the Final Acceptance Test. After that time, the Contractor will become responsible to reimburse the Owner for liquidated damages. B. Service: Manufacturers shall provide as part of the equipment cost sufficient days of service by a factory-trained service engineer specifically trained on the type equipment herein specified to assist the Contractor during installation and start-up. The service time shall be sufficient to Project No. 18088080 4 Section 26 09 43 Lake Lewisville WTP Dewatering Improvements Fiber Optic Network place the units in satisfactory service and instruct the Owner's personnel in proper operation and maintenance of the equipment. C. Maintenance Instruction: Operating and maintenance instructions, along with a separate parts list, shall be furnished in three (3) copies to the Owner. Operating instructions shall also incorporate a functional description of the system, including the system schematics which reflect "as-built" modifications. Maintenance requirements particular to the system shall be clearly defined, along with calibration and test procedures. D. Warranty: All equipment and workmanship furnished under this contract shall be guaranteed to be free of defects in materials and workmanship for a period of one (1) year from and after the date of final acceptance of the work by the Owner, and any such defects which appear within the stipulated guaranty period shall be repaired, replaced or made good without charge. This guarantee shall include the capacity and integrated performance of the component's parts. END OF SECTION Project No. 18088080 1 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers SECTION 26 12 19 – MEDIUM VOLTAGE TRANSFORMERS PART 1 - GENERAL 1.1 SUMMARY A. Section includes pad-mounted, liquid-filled, medium-voltage distribution transformers, with primary and secondary bushings within or without air-terminal enclosures. 1.2 DEFINITIONS A. BIL: Basic Impulse Insulation Level. B. Bushing: An insulating structure including a central conductor, or providing a central passage for a conductor, with provision for mounting on a barrier, conducting or otherwise, for the purpose of insulating the conductor from the barrier and conducting current from one side of the barrier to the other. C. Bushing Elbow: An insulated device used to connect insulated conductors to separable insulated connectors on dead-front, pad-mounted transformers and to provide a fully insulated connection. This is also called an "elbow connector." D. Bushing Insert: That component of a separable insulated connector that is inserted into a bushing well to complete a dead-front, load break or nonload break, separable insulated connector (bushing). E. Bushing Well: A component of a separable insulated connector, either permanently welded or clamped to an enclosure wall or barrier, having a cavity that receives a replaceable component (bushing insert) to complete the separable insulated connector (bushing). F. Elbow Connector: See "bushing elbow" above. 1.3 SUBMITTALS A. Product Data: For each type of product. 1. Include rated capacities, operating characteristics, and furnished specialties and accessories. B. Shop Drawings: For pad-mounted, liquid-filled, medium-voltage transformers. 1. Include plans and elevations showing major components and features. a. Include a plan view and cross section of equipment base, showing clearances, required workspace, and locations of penetrations for grounding and conduits. 2. Include details of equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. 3. Include single-line diagram. 4. Include list of materials. 5. Include nameplate data. 6. Manufacturer's published time-current curves of the transformer high-voltage fuses, with transformer damage curve, inrush curve, and thru fault current indicated. C. Coordination Drawings: 1. Underground primary and secondary conduit stub-up locations. 2. Dimensioned concrete base, outline of transformer, and required clearances. 3. Ground rod and grounding cable locations. Project No. 18088080 2 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers D. Qualification Data: For testing agency. E. Seismic Qualification Certificates: For transformer assembly, accessories, and components, from manufacturer. 1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation. 2. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity, and locate and describe mounting and anchorage provisions. 3. Detailed description of equipment anchorage devices on which the certification is based and their installation requirements. F. Product Certificates: For transformers, signed by product manufacturer. G. Source quality-control reports. H. Field quality-control reports. I. Operation and Maintenance Data: For transformer and accessories to include in emergency, operation, and maintenance manuals. 1.4 QUALITY ASSURANCE A. Testing Agency Qualifications: Member company of NETA or an NRTL. 1. Testing Agency's Field Supervisor: Certified by NETA to supervise on-site testing. B. Comply with IEEE C2. C. Comply with ANSI C57.12.10, ANSI C57.12.28, IEEE C57.12.70, and IEEE C57.12.80. D. Comply with NFPA 70. 1.5 DELIVERY, STORAGE, AND HANDLING A. Store transformers protected from weather so condensation will not form on or in units. Provide temporary heating according to manufacturer’s written instructions. PART 2 - PRODUCTS 2.1 SYSTEM DESCRIPTION A. 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. B. Comply with IEEE C2. C. Comply with IEEE C57.12.00. 2.2 PERFORMANCE REQUIREMENTS A. Windings Material: Copper. B. Winding Connections: The connection of windings and terminal markings shall comply with IEEE C57.12.70. C. Efficiency: Comply with 10 CFR 431, Subpart K. Project No. 18088080 3 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers D. Insulation: Transformer kVA rating shall be as follows: The average winding temperature rise above a 30 deg C ambient temperature shall not exceed 65 deg C and 80 deg C hottest-spot temperature rise at rated kVA when tested according to IEEE C57.12.90, using combination of connections and taps that give the highest average winding temperature rise. E. Tap Changer: External handle, for de-energized operation. F. Tank: Sealed, with welded-on cover. G. Enclosure Integrity: Comply with IEEE C57.12.28 for pad-mounted enclosures that contain energized electrical equipment in excess of 600 V that may be exposed to the public. H. Mounting: An integral skid mounting frame, suitable to allow skidding or rolling of transformer in any direction, and with provision for anchoring frame to pad. I. Insulating Liquids: 1. Mineral Oil: ASTM D 3487, Type II, and tested for compliance with ASTM D 117. J. Sound level shall comply with NEMA TR 1 requirements. K. Corrosion Protection: 1. Transformer coating system shall be factory applied, complying with requirements of IEEE C57.12.28, in manufacturer's standard green color. 2.3 THREE-PHASE TRANSFORMERS A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. Cooper Industries 2. General Electric Company 3. Howard Industries 4. ERMCO 5. ABB 6. Or equal. B. Description: 1. 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. 2. Comply with IEEE C57.12.26. C. Compartment Construction: 1. Double-Compartment Construction: Individual compartments for high- and low-voltage sections, formed by steel isolating barriers that extend full height and depth of compartments, with hinged, lift-off doors and three-point latching, with a stop in the open position and provision for padlocking. D. Primary Fusing: Designed and rated to provide thermal protection of transformer by sensing overcurrent and high liquid temperature. 1. 150-kV BIL current-limiting fuses, conforming to requirements of IEEE C37.47. 2. Interrupting Rating: 50,000 rms A symmetrical at system voltage. 3. Fuse Assembly: Bayonet-type, liquid-immersed, expulsion fuses in series with liquid- immersed, partial-range, current-limiting fuses. Bayonet fuse shall sense both high currents and high oil temperature to provide thermal protection to the transformer. Project No. 18088080 4 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers 4. Provide bayonet fuse assembly with an oil retention valve and an external drip shield inside the housing to eliminate or minimize oil spills. Valve shall close when fuse holder is removed and an external drip shield is installed. 5. Provide a conspicuously displayed warning adjacent to bayonet fuse(s), cautioning against removing or inserting fuses unless transformer has been de-energized and tank pressure has been released. E. High-Voltage Section: Dead-front design. 1. To connect primary cable, use separable insulated connectors; coordinated with and complying with requirements of Section 260513 "Medium-Voltage Cables." Bushings shall be one-piece units, with ampere and BIL ratings the same as connectors. 2. Bushing inserts and feed-through inserts: a. Conform to the requirements of IEEE 386. b. Rated at 200 A, with voltage class matching connectors. Provide a parking stand near each bushing well. c. Provide insulated protective caps for insulating and sealing out moisture from unused bushing inserts. 3. Bushing wells configured for radial-feed application. 4. Access to liquid-immersed fuses. 5. Dead-front surge arresters. 6. Tap-changer operator. 7. Load-Break Switch: a. Radial-feed, liquid-immersed type with voltage class and BIL matching that of separable connectors, with a continuous current rating and load-break rating of 200 amperes, and a make-and-latch rating of 12 kA rms symmetrical. 8. Ground pad. F. Low-Voltage Section: 1. Bushings with spade terminals drilled for terminating the number of conductors indicated on the Drawings, and the lugs that comply with requirements of Section 260519 "Low- Voltage Electrical Power Conductors and Cables." G. Capacities and Characteristics: 1. Power Rating (kVA): Refer to contract drawings. 2. Voltage Ratings: 13.2kV Delta - 480Y/277 V Wye-Grounded. 3. Taps: Comply with IEEE C57.12.26 requirements 4. Transformer BIL (kV): Comply with IEEE C57.12.26 requirements. 5. Minimum Tested Impedance (Percent at 85 deg C): 2.87 6. Comply with FM Global Class No. 3990. 7. Comply with UL listing requirements for combination classification and listing for transformer and less-flammable insulating liquid. H. Transformer Accessories: 1. Drain and filter connection. 2. Filling and top filter press connections. 3. Pressure-vacuum gauge. 4. Dial-type analog thermometer with alarm contacts. 5. Magnetic liquid level indicator with high and low alarm contacts. 6. Automatically resetting pressure-relief device. Device flow shall be as recommended by manufacturer. 7. Stainless-steel ground connection pads. 8. Machine-engraved nameplate, made of anodized aluminum or stainless steel. 9. Sudden pressure relay for remote alarm or trip when internal transformer pressure rises at field-set rate. Provide with seal-in delay. Project No. 18088080 5 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers 2.4 SERVICE CONDITIONS A. Transformers shall be suitable for operation under service conditions specified as usual service conditions in IEEE C57.12.00. 2.5 WARNING LABELS AND SIGNS A. Comply with requirements for labels and signs specified in Section 260553 "Identification for Electrical Systems." 1. High-Voltage Warning Label: Provide self-adhesive warning signs on outside of high- voltage compartment door(s). Sign legend shall be "DANGER HIGH VOLTAGE" printed in two lines of nominal 2-inch high letters. The word "DANGER" shall be in white letters on a red background and the words "HIGH VOLTAGE" shall be in black letters on a white background. 2. Arc Flash Warning Label: Provide self-adhesive warning signs on outside of high-voltage compartment door(s), warning of potential electrical arc flash hazards and appropriate personal protective equipment required. 2.6 SOURCE QUALITY CONTROL A. Provide manufacturer's certificate that the transformer design tests comply with IEEE C57.12.90. 1. Perform the following factory-certified routine tests on each transformer for this Project: a. Resistance. b. Turns ratio, polarity, and phase relation. c. Transformer no-load losses and excitation current at 100 percent of ratings. d. Transformer impedance voltage and load loss. e. Operation of all devices. f. Lightning impulse. g. Low frequency. h. Leak. i. Transformer no-load losses and excitation current at 110 percent of ratings. j. Insulation power factor. k. Applied potential, except that this test is not required for single-phase transformers or for three-phase Y-Y-connected transformers. l. Induced potential. m. Resistance measurements of all windings on rated voltage connection and at tap extreme connections. n. Ratios on rated voltage connection and at tap extreme connections. o. Polarity and phase relation on rated voltage connection. p. No-load loss at rated voltage on rated voltage connection. q. Exciting current at rated voltage on rated voltage connection. r. Impedance. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine pad-mounted, liquid-filled, medium-voltage transformers upon delivery. 1. Upon delivery of transformers and prior to unloading, inspect equipment for any damage that may have occurred during shipment or storage. 2. Verify that tie rods and chains are undamaged and tight, and that all blocking and bracing is tight. Verify that there is no evidence of load shifting in transit, and that readings from transportation shock recorders, if equipped, are within manufacturer's recommendations. Project No. 18088080 6 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers 3. Verify that there is no indication of external damage and no dents or scratches in doors and sill, tank walls, radiators and fins, or termination provisions. 4. Verify that there is no evidence of insulating-liquid leakage on transformer surfaces, at weld seams, on high- or low-voltage bushing parts, and at transformer base. 5. Verify that there is positive pressure or vacuum on tank. Check pressure gauge; it is required to read other than zero. 6. Compare transformers and accessories received with bill of materials to verify that shipment is complete. Verify that transformers and accessories conform with manufacturer's quotation and shop drawings. If shipment is incomplete or does not comply with Project requirements, notify manufacturer in writing immediately. 7. Verify presence of polychlorinated biphenyl content labeling. 8. Unload transformers carefully, observing all packing label warnings and handling instructions. 9. Open termination compartment doors and inspect components for damage or displaced parts, loose or broken connections, cracked or chipped insulators, bent mounting flanges, dirt or foreign material, and water or moisture. B. Handling: 1. Handle transformers carefully, in accordance with manufacturer recommendations, to avoid damage to enclosure, termination compartments, base, frame, tank, and internal components. Do not subject transformers to impact, jolting, jarring, or rough handling. 2. Protect transformer termination compartments against entrance of dust, rain, and snow. 3. Transport transformers upright, to avoid internal stresses on core and coil mounting assembly and to prevent trapping air in windings. Do not tilt or tip transformers. 4. Verify that transformer weights are within rated capacity of handling equipment. 5. Use only manufacturer-recommended points for lifting, jacking, and pulling. Use all lifting lugs when lifting transformers. 6. Use jacks only at corners of tank base plate. 7. Use nylon straps of same length to balance and distribute weight when handling transformers with a crane. 8. Use spreaders or a lifting beam to obtain a vertical lift and to protect transformer from straps bearing against enclosure. Lifting cable pull angles may not be greater than 15 degrees from vertical. 9. Exercise care not to damage tank base structure when handling transformer using skids or rollers. Use skids to distribute stresses over tank base when using rollers under large transformers. C. Storage: 1. Store transformers in accordance with manufacturer's recommendations. 2. Transformers may be stored outdoors. If possible, store transformers at final installation locations on concrete pads. If dry concrete surfaces are unavailable, use pallets of adequate strength to protect transformers from direct contact with ground. Ensure transformer is level. 3. Ensure that transformer storage location is clean and protected from severe conditions. Protect transformers from dirt, water, contamination, and physical damage. Do not store transformers in presence of corrosive or explosive gases. Protect transformers from weather when stored for more than three months. 4. Store transformers with compartment doors closed. 5. Regularly inspect transformers while in storage and maintain documentation of storage conditions, noting any discrepancies or adverse conditions. Verify that an effective pressure seal is maintained using pressure gauges. Visually check for insulating-liquid leaks and rust spots. D. Examine areas and space conditions for compliance with requirements for pad-mounted, liquid- filled, medium-voltage transformers and other conditions affecting performance of the Work. Project No. 18088080 7 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers E. Examine roughing-in of conduits and grounding systems to verify the following: 1. Wiring entries comply with layout requirements. 2. Entries are within conduit-entry tolerances specified by manufacturer, and no feeders will cross section barriers to reach load or line lugs. F. Examine concrete bases for suitable conditions for transformer installation. G. Pre-Installation Checks: 1. Verify removal of any shipping bracing after placement. 2. Remove a sample of insulating liquid according to ASTM D 923. Insulating-liquid values shall comply with NETA ATS, Table 100.4. Sample shall be tested for the following: a. Dielectric Breakdown Voltage: ASTM D 877 or ASTM D 1816. b. Acid Neutralization Number: ASTM D 974. c. Interfacial Tension: ASTM D 971. d. Color: ASTM D 1500. e. Visual Condition: ASTM D 1524. H. Verify that ground connections are in place and that requirements in Section 260526 "Grounding and Bonding for Electrical Systems" have been met. I. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 INSTALLATION A. Install transformers on cast-in-place concrete equipment base(s). B. Transformer shall be installed level and plumb and shall tilt less than 1.5 degrees while energized. C. Comply with requirements for vibration isolation and seismic control devices specified in Section 260529 "Hangers and Supports for Electrical Systems" and Section 260548.16 "Seismic Controls for Electrical Systems." D. Maintain minimum clearances and workspace at equipment according to manufacturer's written instructions and IEEE C2. 3.3 CONNECTIONS A. Ground equipment according to Section 260526 "Grounding and Bonding for Electrical Systems." 1. For counterpoise, use tinned bare copper cable not smaller than No. 4/0 AWG, buried not less than 30 inches below grade interconnecting the grounding electrodes. Bond surge arrester and neutrals directly to transformer enclosure and then to grounding electrode system with bare copper conductors, sized as shown. Keep lead lengths as short as practicable, with no kinks or sharp bends. 2. Make joints in grounding conductors and loops by exothermic weld or compression connector. 3. Terminate all grounding and bonding conductors on a common equipment grounding terminal on transformer enclosure. 4. Complete transformer tank grounding and lightning arrester connections prior to making any other electrical connections. B. Connect wiring according to Section 260519 "Low-Voltage Electrical Power Conductors and Cables." Project No. 18088080 8 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers 1. Maintain air clearances between energized live parts and between live parts and ground for exposed connections in accordance with manufacturer recommendations. 2. Bundle associated phase, neutral, and equipment grounding conductors together within transformer enclosure. Arrange conductors such that there is not excessive strain that could cause loose connections. Allow adequate slack for expansion and contraction of conductors. C. Terminate medium-voltage cables in incoming section of transformers according to Section 260513 "Medium-Voltage Cables." 3.4 SIGNS AND LABELS A. Comply with installation requirements for labels and signs specified in Section 260553 "Identification for Electrical Systems." B. Install warning signs as required to comply with 29 CFR 1910.269. 3.5 FIELD QUALITY CONTROL A. Manufacturer's Field Service: Engage a factory-authorized service representative to test and inspect components, assemblies, and equipment installations, including connections. B. Perform the following tests and inspections and prepare test reports: 1. Comply with provisions of NFPA 70B Ch. "Testing and Test Methods." 2. Perform each visual and mechanical inspection and electrical test. Certify compliance with test parameters. 3. After installing transformer but before primary is energized, verify that grounding system at the transformer is tested at specified value or less. 4. After installing transformer and after electrical circuitry has been energized, test for compliance with requirements. 5. Visual and Mechanical Inspection: a. Verify equipment nameplate data complies with Contract Documents. b. 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 absence of manufacturer's published data, use NETA ATS, Table 100.12. 6. Remove and replace malfunctioning units and retest. 7. Prepare test and inspection reports. Record as-left set points of all adjustable devices. 8. Medium-Voltage Surge Arrester Field Tests: a. Visual and Mechanical Inspection: 1) Inspect physical and mechanical condition. 2) Verify arresters are clean. 3) Verify that ground lead on each device is individually attached to a ground bus or ground electrode. b. Electrical Test: 1) Perform an insulation-resistance test on each arrester, phase terminal-to- ground. Apply voltage according to manufacturer's published data. In the absence of manufacturer's published data, comply with NETA ATS, Table Project No. 18088080 9 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers 100.1. Replace units that fail to comply with recommended minimum insulation resistance listed in that table. 2) Perform a watts-loss test. Evaluate watts-loss values by comparison with similar units and test equipment manufacturer's published data. 9. Liquid-Filled Transformer Field Tests: a. Visual and Mechanical Inspection: 1) Test dew point of tank gases if applicable. 2) Inspect anchorage, alignment, and grounding. 3) Verify bushings are clean. 4) Verify that alarm, control, and trip settings on temperature and level indicators are set and operate within manufacturer's recommended settings. 5) Verify that liquid level in tanks is within manufacturer's published tolerances. 6) Perform specific inspections and mechanical tests recommended by manufacturer. 7) Verify presence of transformer surge arresters and that their ratings are as specified. 8) Verify that as-left tap connections are as specified. b. Electrical Tests: 1) Perform insulation-resistance tests winding-to-winding and each winding-to- ground. Apply voltage according to manufacturer's published data. In the absence of manufacturer's published data, comply with NETA ATS, Table 100.5. Calculate polarization index; the value of the index shall not be less than 1.0. 2) Perform power-factor or dissipation-factor tests on all windings according to test equipment manufacturer's published data. Maximum winding insulation power-factor/dissipation-factor values shall be according to manufacturer's published data. In the absence of manufacturer's published data, comply with NETA ATS, Table 100.3. 3) Measure core insulation resistance at 500-V dc if the core is insulated and the core ground strap is removable. Core insulation-resistance values shall not be less than 1 megohm at 500-V dc. 4) Verify correct secondary voltage, phase-to-phase and phase-to-neutral, after energization and prior to loading. 5) Remove a sample of insulating liquid according to ASTM D 923, and perform dissolved-gas analysis according to IEEE C57.104 or ASTM D 3612. 3.6 FOLLOW-UP SERVICE A. Voltage Monitoring and Adjusting: After Substantial Completion, if requested by Owner, but not more than six months after Final Acceptance, perform the following voltage monitoring: 1. During a period of normal load cycles as evaluated by Owner, perform seven days of three-phase voltage recording at the outgoing section of each transformer. Use voltmeters with calibration traceable to the 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 the nominal value by more than plus or minus 5 percent during test period, is unacceptable. 2. Corrective Action: If test results are unacceptable, perform the following corrective action, as appropriate: a. Adjust transformer taps. b. Prepare written request for voltage adjustment by electric utility. 3. Retests: Repeat monitoring, after corrective action is performed, until satisfactory results are obtained. 4. Report: Project No. 18088080 10 Section 26 12 19 Lake Lewisville WTP Dewatering Improvements Medium Voltage Transformers a. Prepare a written report covering monitoring performed and corrective action taken. B. Infrared Inspection: Perform survey during periods of maximum possible loading. Remove all necessary covers prior to inspection. 1. After Substantial Completion, but not more than 60 days after Final Acceptance, perform infrared inspection of transformer's electrical power connections. 2. Record of Infrared Inspection: Prepare a certified report that identifies testing technician and equipment used, and lists results as follows: a. Description of equipment to be tested. b. Discrepancies. c. Temperature difference between area of concern and reference area. d. Probable cause of temperature difference. e. Areas inspected. Identify inaccessible and unobservable areas and equipment. f. Identify load conditions at time of inspection. g. Provide photographs and thermograms of deficient area. 3. Act on inspection results according to recommendations of NETA ATS, Table 100.18. Correct possible and probable deficiencies as soon as Owner's operations permit. Retest until deficiencies are corrected. 3.7 DEMONSTRATION A. Train Owner's maintenance personnel to adjust, operate, and maintain systems. END OF SECTION Project No. 18088080 1 Section 26 22 00 Lake Lewisville WTP Dewatering Improvements Low Voltage Transformers SECTION 26 22 00 - LOW-VOLTAGE TRANSFORMERS PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following types of dry-type transformers rated 600 V and less, with capacities up to 1000 kVA: 1. Dry-Type distribution transformers. 1.2 SUBMITTALS A. Product Data: Include rated nameplate data, capacities, weights, dimensions, minimum clearances, installed devices and features and performance for each type and size of transformer indicated. 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. C. Qualification Data: For testing agency D. Source quality-control test reports. E. Field quality-control test reports. F. Operation and Maintenance Data: For transformers to include in emergency, operation and maintenance manuals. 1.3 QUALITY ASSURANCE A. Testing Agency Qualifications: An independent agency, with the experience and capability to conduct the testing indicated, that is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29 CFR 1910.7. B. Source Limitations: Obtain each transformer type through one source from a single manufacturer. 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. Comply with IEEE C57.12.91, “Test Code for Dry-Type Distribution and Power Transformers.” 1.4 DELIVERY, STORAGE AND HANDLING A. Temporary Heating: Apply temporary heat according to manufacturer’s written instructions within the enclosure of each ventilated-type unit, throughout periods during which equipment is not energized and when transformer is not in a space that is continuously under normal control of temperature and humidity. Project No. 18088080 2 Section 26 22 00 Lake Lewisville WTP Dewatering Improvements Low Voltage Transformers 1.5 COORDINATION A. Coordinate size and location of concrete bases with actual transformer provided. Cast anchor- bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 03. Construct housekeeping pad for floor mounted transformers. B. Coordinate installation of wall-mounting and structure-hanging supports with actual transformer provided. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to the following: 1. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric. 2.2 GENERAL TRANSFORMER REQUIREMENTS A. Description: Factory-assembled and –tested, air-cooled units for 60-Hz service. B. Cores: Grain-oriented, non-aging silicon steel. C. Coils: Continuous windings without splices except for taps. 1. Internal Coil Connections: Brazed or pressure type. 2. Coil Material: Aluminum 2.3 DISTRIBUTION TRANSFORMERS A. Comply with NEMA ST 20, and list and label as complying with UL 1561. B. Cores: One leg per phase. C. Enclosure: Ventilated, NEMA 250, Type 2. 1. Core and coil shall be encapsulated within resin compound, sealing out moisture and air. D. Taps for Transformers 7.5 to 24 kVA: Two 5 percent taps below rated voltage. E. Taps for Transformers 25 kVA and Larger: Two 2.5 percent taps above and two 2.5 percent taps below normal full capacity. F. Insulation Class: 220 deg C, UL-component-recognized insulation system with a maximum of 115 deg C rise above 40 deg C ambient temperature. G. Energy Efficiency for Transformers Rated 15 kVA and larger: 1. Complying with NEMA TP 1, Class 1 efficiency levels. 2. Tested according to NEMA TP 2. H. Electrostatic Shielding: Each winding shall have an independent, single full-width copper electrostatic shield arranged to minimize interwinding capacitance. 1. Arrange coil leads and terminal strips to minimize capacitive coupling between input and output terminals. 2. Include special terminal for grounding the shield. 3. Shield Effectiveness: Project No. 18088080 3 Section 26 22 00 Lake Lewisville WTP Dewatering Improvements Low Voltage Transformers a. Capacitance between Primary and Secondary windings: Not to exceed 33 picofarads over a frequency range of 20 Hz to 1 MHz. b. Common-Mode Noise Attenuation: Minimum of minus 120 dBA at 0.5 to 1.5 kHz; minimum of minus 65 dBA at 1.5 to 100 kHz. c. Normal-Mode Noise Attenuation: Minimum of minus 52 dBA at 1.5 to 10 kHz. I. Wall Brackets: Manufacturer’s standard brackets. J. Low-Sound-Level Requirements: Minimum of 3 dBA less than NEMA ST 20 standard sound levels when factory tested according to IEEE C57.12.91. 2.4 IDENTIFICATION DEVICES A. Nameplates: Engraved, laminated-plastic or metal nameplate for each distribution transformer, mounted with corrosion-resistant screws. Nameplates and label products are specified in Division 26 Section “Identification for Electrical Systems.” 2.5 SOURCE QUALITY CONTROL A. Test and inspect transformers according to IEEE C57.12.91. B. Factory Sound-Level Tests: Conduct sound-level tests on equipment for this Project. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine conditions for compliance with enclosure and ambient temperature requirements for each transformer. B. Verify that field measurements are as needed to maintain working clearances required by NFPA 70 and manufacturer’s written instructions. C. Examine walls, floors, roofs, and concrete bases for suitable mounting conditions where transformers will be installed. D. Verify that ground connections are in place and requirements in Division 16 Section “Grounding and Bonding for Electrical systems” have been met. Maximum ground resistance shall be 5 ohms at location of transformer. E. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 INSTALLATION A. Install wall-mounting transformers level and plumb with wall brackets fabricated by transformer manufacturer. B. Construct concrete bases and anchor floor-mounting transformers according to manufacturer’s written instructions and requirements. C. Ground the neutral on the secondary of all transformers. Project No. 18088080 4 Section 26 22 00 Lake Lewisville WTP Dewatering Improvements Low Voltage Transformers 3.3 CONNECTIONS A. Ground equipment according to Division 26 Section “Grounding and Bonding for Electrical Systems.” B. Connect wiring according to Division 26 Section “Low-Voltage Electrical Power Conductors and Cables.” 3.4 FIELD QUALITY CONTROL A. Perform tests and inspections and prepare test reports. B. Tests and Inspections: 1. Perform each visual and mechanical inspection and electrical test stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. C. Remove and replace units that do not pass tests or inspections and retest as specified above. D. Test Labeling: On completion of satisfactory testing of each unit, attach a dated and signed “Satisfactory Test” label to tested component. 3.5 ADJUSTING A. Monitor transformer secondary voltage at each unit for at least 2 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 10 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. 3.6 CLEANING A. Vacuum dirt and debris; do not use compressed air to assist in cleaning. END OF SECTION Project No. 18088080 1 Section 26 24 16 Lake Lewisville WTP Dewatering Improvements Panelboards SECTION 26 24 16 - PANELBOARDS PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Distribution panelboards. 2. Lighting and appliance branch-circuit panelboards. 1.2 PERFORMANCE REQUIREMENTS A. Seismic Performance: Panelboards shall withstand the effects of earthquake motions determined according to SEI/ASCE 7. 1. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified and the unit will be fully operational after the seismic event." 1.3 SUBMITTALS A. Product Data: For each type of panelboard, switching and overcurrent protective device, transient voltage suppression device, accessory, and component indicated. Include dimensions and manufacturers' technical data on features, performance, electrical characteristics, ratings, and finishes. B. Shop Drawings: For each panelboard and related equipment. 1. Include dimensioned plans, elevations, sections, and details. Show tabulations of installed devices, equipment features, and ratings. 2. Detail enclosure types and details for types other than NEMA 250, Type 1. 3. Detail bus configuration, current, and voltage ratings. 4. Short-circuit current rating of panelboards and overcurrent protective devices. 5. Include evidence of NRTL listing for series rating of installed devices. 6. Detail features, characteristics, ratings, and factory settings of individual overcurrent protective devices and auxiliary components. 7. Include wiring diagrams for power, signal, and control wiring. 8. Include time-current coordination curves for each type and rating of overcurrent protective device included in panelboards. Submit on translucent log-log graft paper; include selectable ranges for each type of overcurrent protective device. C. Seismic Qualification Certificates: Submit certification that panelboards, overcurrent protective devices, accessories, and components will withstand seismic forces defined in Division 26 Section "Vibration and Seismic Controls for Electrical Systems." Include the following: 1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation. 2. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions. 3. Detailed description of equipment anchorage devices on which the certification is based and their installation requirements. D. Field Quality-Control Reports: 1. Test procedures used. 2. Test results that comply with requirements. 3. Results of failed tests and corrective action taken to achieve test results that comply with requirements. Project No. 18088080 2 Section 26 24 16 Lake Lewisville WTP Dewatering Improvements Panelboards E. Panelboard Schedules: For installation in panelboards. Submit final versions after load balancing. F. Operation and Maintenance Data: For panelboards and components 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. Manufacturer's written instructions for testing and adjusting overcurrent protective devices. 2. Time-current curves, including selectable ranges for each type of overcurrent protective device that allows adjustments. 1.4 QUALITY ASSURANCE A. Source Limitations: Obtain panelboards, overcurrent protective devices, components, and accessories from single source from single manufacturer. B. Product Selection for Restricted Space: Drawings indicate maximum dimensions for panelboards including clearances between panelboards and adjacent surfaces and other items. Comply with indicated maximum dimensions. C. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. D. Comply with NEMA PB 1. A. Comply with NFPA 70. 1.5 DELIVERY, STORAGE, AND HANDLING A. Remove loose packing and flammable materials from inside panelboards; install temporary electric heating (250 W per panelboard) to prevent condensation. B. Handle and prepare panelboards for installation according to NEMA PB 1. 1.6 PROJECT CONDITIONS A. Environmental Limitations: 1. Do not deliver or install panelboards until spaces are enclosed and weathertight, wet work in spaces is complete and dry, work above panelboards is complete, and temporary HVAC system is operating and maintaining ambient temperature and humidity conditions at occupancy levels during the remainder of the construction period. 2. Rate equipment for continuous operation under the following conditions unless otherwise indicated: a. Ambient Temperature: Not exceeding 23 deg F (minus 5 deg C) to plus 104 deg F (plus 40 deg C). b. Altitude: Not exceeding 6600 feet (2000 m). B. Service Conditions: NEMA PB 1, usual service conditions, as follows: 1. Ambient temperatures within limits specified. 2. Altitude not exceeding 6600 feet (2000 m). C. Interruption of Existing Electric Service: Do not interrupt electric service to facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary electric service according to requirements indicated: 1. Notify Owner no fewer than two days in advance of proposed interruption of electric service. 2. Do not proceed with interruption of electric service without Owner's written permission. Project No. 18088080 3 Section 26 24 16 Lake Lewisville WTP Dewatering Improvements Panelboards 3. Comply with NFPA 70E. 1.7 COORDINATION A. Coordinate layout and installation of panelboards 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. Coordinate sizes and locations of concrete bases with actual equipment provided. Cast anchor- bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 03. 1.8 WARRANTY A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace transient voltage suppression devices that fail in materials or workmanship within specified warranty period. 1. Warranty Period: 1 year from date of Substantial Completion. PART 2 - PRODUCTS 2.1 GENERAL REQUIREMENTS FOR PANELBOARDS A. Fabricate and test panelboards according to IEEE 344 to withstand seismic forces defined in Division 26 Section "Vibration and Seismic Controls for Electrical Systems." B. Enclosures: Surface-mounted cabinets. 1. Rated for environmental conditions at installed location. a. Indoor Dry and Clean Locations: NEMA 250, Type 1. 2. Front: Secured to box with concealed trim clamps. For surface-mounted fronts, match box dimensions; for flush-mounted fronts, overlap box. 3. Hinged Front Cover: Entire front trim hinged to box and with standard door within hinged trim cover. 4. Skirt for Surface-Mounted Panelboards: Same gage and finish as panelboard front with flanges for attachment to panelboard, wall, and ceiling or floor. 5. Gutter Extension and Barrier: Same gage and finish as panelboard enclosure; integral with enclosure body. Arrange to isolate individual panel sections. 6. Finishes: a. Panels and Trim: Steel, factory finished immediately after cleaning and pretreating with manufacturer's standard two-coat, baked-on finish consisting of prime coat and thermosetting topcoat. b. Back Boxes: Galvanized steel. 7. Directory Card: Inside panelboard door, mounted in metal frame with transparent protective cover. C. Incoming Mains Location: Top and bottom as required by job conditions. D. Phase, Neutral, and Ground Buses: 1. Material: Hard-drawn copper, 98 percent conductivity. 2. Equipment Ground Bus: Adequate for feeder and branch-circuit equipment grounding conductors; bonded to box. E. Conductor Connectors: Suitable for use with conductor material and sizes. Project No. 18088080 4 Section 26 24 16 Lake Lewisville WTP Dewatering Improvements Panelboards 1. Material: Hard-drawn copper, 98 percent conductivity. 2. Main and Neutral Lugs: Compression type. 3. Ground Lugs and Bus-Configured Terminators: Compression type. 4. Extra-Capacity Neutral Lugs: Rated 200 percent of phase lugs mounted on extra-capacity neutral bus. F. Service Equipment Label: NRTL labeled for use as service equipment for panelboards or load centers with one or more main service disconnecting and overcurrent protective devices. G. Surge Protective Devices: Where indicated on the drawings, switchboards shall include surge protective devices factory-installed internal to the switchboard meeting the following requirements: 1. Comply with UL 1449, Type 1 or Type 2 as required for the application. 2. Peak Surge Current Rating: The minimum single-pulse surge current withstand rating per phase shall not be less than 160 kA. The peak surge current rating shall be the arithmetic sum of the ratings of the individual MOVs in a given mode. 3. Protection modes and UL 1449 VPR for grounded wye circuits with 480Y/277 V, three- phase, four-wire circuits shall not exceed the following: a. Line to Neutral: 1200 V. b. Line to Ground: 1200 V. c. Line to Line: 2000 V. 4. SCCR: Equal or exceed the short circuit current rating of the panelboard. 5. Inominal Rating: 20 kA H. Future Devices: Mounting brackets, bus connections, filler plates, and necessary appurtenances required for future installation of devices. I. Panelboard Short-Circuit Current Rating: Fully rated to interrupt symmetrical short-circuit current available at terminals. 2.2 DISTRIBUTION PANELBOARDS 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. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric. B. Panelboards: NEMA PB 1, power and feeder distribution type. C. Doors: Secured with vault-type latch with tumbler lock; keyed alike. 1. For doors more than 36 inches (914 mm) high, provide two latches, keyed alike. D. Mains: Circuit breaker. E. Branch Overcurrent Protective Devices for Circuit-Breaker Frame Sizes 125 A and Smaller: Bolt- on circuit breakers. F. Branch Overcurrent Protective Devices for Circuit-Breaker Frame Sizes Larger Than 125 A: Bolt- on circuit breakers; plug-in circuit breakers where individual positive-locking device requires mechanical release for removal. 2.3 LIGHTING AND APPLIANCE BRANCH-CIRCUIT PANELBOARDS 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: Project No. 18088080 5 Section 26 24 16 Lake Lewisville WTP Dewatering Improvements Panelboards 1. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric. B. Panelboards: NEMA PB 1, lighting and appliance branch-circuit type. C. Mains: Circuit breaker. D. Branch Overcurrent Protective Devices: Bolt-on circuit breakers, replaceable without disturbing adjacent units. E. Doors: Concealed hinges; secured with flush latch with tumbler lock; keyed alike. F. Column-Type Panelboards: Narrow gutter extension, with cover, to overhead junction box equipped with ground and neutral terminal buses. 2.4 DISCONNECTING AND OVERCURRENT PROTECTIVE DEVICES 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. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric. B. Molded-Case Circuit Breaker (MCCB): Comply with UL 489, with interrupting capacity to meet available fault currents. 1. Thermal-Magnetic Circuit Breakers: Inverse time-current element for low-level overloads, and instantaneous magnetic trip element for short circuits. Adjustable magnetic trip setting for circuit-breaker frame sizes 250 A and larger. a. Electronic Trip Trip Unit circuit Breakers: RMS Sensing; field-replaceable rating plug; with the following field-adjustable settings or as indicated on the drawings: 1) Instantaneous trip. 2) Long-and short-time pickup levels. 3) Long-and short-time time adjustments. 4) Ground-fault pickup level, time delay and I2t response 2. GFCI Circuit Breakers: Single- and two-pole configurations with Class A ground-fault protection (6-mA trip). 3. Ground-Fault Equipment Protection (GFEP) Circuit Breakers: Class B ground-fault protection (30-mA trip). 4. Molded-Case Circuit-Breaker (MCCB) Features and Accessories: a. Standard frame sizes, trip ratings, and number of poles. b. Lugs: Mechanical style, suitable for number, size, trip ratings, and conductor materials. c. Application Listing: Appropriate for application; Type SWD for switching fluorescent lighting loads; Type HID for feeding fluorescent and high-intensity discharge (HID) lighting circuits. d. Application Listing: Appropriate for application; Type HACR for breakers serving Heating, Air Conditioning and Refrigeration (HACR) loads. e. Dual rated SWD and HACR breakers are acceptable. 2.5 ACCESSORY COMPONENTS AND FEATURES A. Accessory Set: Include tools and miscellaneous items required for overcurrent protective device test, inspection, maintenance, and operation. Project No. 18088080 6 Section 26 24 16 Lake Lewisville WTP Dewatering Improvements Panelboards PART 3 - EXECUTION 3.1 EXAMINATION A. Receive, inspect, handle, and store panelboards according to NEMA PB 1.1. B. Examine panelboards before installation. Reject panelboards that are damaged or rusted or have been subjected to water saturation. C. Examine elements and surfaces to receive panelboards for compliance with installation tolerances and other conditions affecting performance of the Work. D. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 INSTALLATION A. Install panelboards and accessories according to NEMA PB 1.1. B. Equipment Mounting: Install panelboards on concrete bases, 4-inch (100-mm) nominal thickness. Comply with requirements for concrete base specified in Division 03 Section "Cast-in- Place Concrete or Miscellaneous Cast-in-Place Concrete." 1. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated, install dowel rods on 18-inch (450-mm) centers around full perimeter of base. 2. For panelboards, install epoxy-coated anchor bolts that extend through concrete base and anchor into structural concrete floor. 3. Place and secure anchorage devices. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded. 4. Install anchor bolts to elevations required for proper attachment to panelboards. 5. Attach panelboard to the vertical finished or structural surface behind the panelboard. C. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and temporary blocking of moving parts from panelboards. D. Comply with mounting and anchoring requirements specified in Division 26 Section "Vibration and Seismic Controls for Electrical Systems." E. Mount top of trim 90 inches (2286 mm) above finished floor unless otherwise indicated. F. Mount panelboard cabinet plumb and rigid without distortion of box. Mount recessed panelboards with fronts uniformly flush with wall finish and mating with back box. G. Install overcurrent protective devices and controllers not already factory installed. 1. Set field-adjustable, circuit-breaker trip ranges. H. Install filler plates in unused spaces. I. Stub four 1-inch (27-GRC) empty conduits from panelboard into accessible ceiling space or space designated to be ceiling space in the future. Stub four 1-inch (27-GRC) empty conduits into raised floor space or below slab not on grade. J. Arrange conductors in gutters into groups and bundle and wrap with wire ties after completing load balancing. K. Comply with NECA 1. Project No. 18088080 7 Section 26 24 16 Lake Lewisville WTP Dewatering Improvements Panelboards 3.3 IDENTIFICATION A. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs complying with Division 26 Section "Identification for Electrical Systems." B. Create a directory to indicate installed circuit loads; incorporate Owner's final room designations. Obtain approval before installing. Use a computer or typewriter to create directory; handwritten directories are not acceptable. C. Panelboard Nameplates: Label each panelboard with a nameplate complying with requirements for identification specified in Division 26 Section "Identification for Electrical Systems." D. Device Nameplates: Label each branch circuit device in distribution panelboards with a nameplate complying with requirements for identification specified in Division 26 Section "Identification for Electrical Systems." 3.4 FIELD QUALITY CONTROL A. Perform tests and inspections. 1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing. B. Acceptance Testing Preparation: 1. Test insulation resistance for each panelboard bus, component, connecting supply, feeder, and control circuit. 2. Test continuity of each circuit. C. Tests and Inspections: 1. Perform each visual and mechanical inspection and electrical test stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. 2. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest. 3. Perform the following infrared scan tests and inspections and prepare reports: a. Initial Infrared Scanning: After Substantial Completion, but not more than 60 days after Final Acceptance, perform an infrared scan of each panelboard. Remove front panels so joints and connections are accessible to portable scanner. b. Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of each panelboard 11 months after date of Substantial Completion. c. Instruments and Equipment: 1). Use an infrared scanning device designed to measure temperature or to detect significant deviations from normal values. Provide calibration record for de- vice. D. Panelboards will be considered defective if they do not pass tests and inspections. E. Prepare test and inspection reports, including a certified report that identifies panelboards included and that describes scanning results. Include notation of deficiencies detected, remedial action taken, and observations after remedial action. F. ADJUSTING G. Adjust moving parts and operable component to function smoothly, and lubricate as recommended by manufacturer. Project No. 18088080 8 Section 26 24 16 Lake Lewisville WTP Dewatering Improvements Panelboards H. Set field-adjustable circuit-breaker trip ranges as indicated and recommended by manufacturer. I. Load Balancing: After Substantial Completion, but not more than 60 days after Final Acceptance, measure load balancing and make circuit changes if directed by the Engineer. 1. Measure as directed during period of normal system loading. 2. Perform load-balancing circuit changes outside normal occupancy/working schedule of the facility and at time directed. Avoid disrupting critical 24-hour services such as fax machines and on-line data processing, computing, transmitting, and receiving equipment. 3. After circuit changes, recheck loads during normal load period. Record all load readings before and after changes and submit test records. 4. Tolerance: Difference exceeding 20 percent between phase loads, within a panelboard, is not acceptable. Rebalance and recheck as necessary to meet this minimum requirement. 3.5 PROTECTION A. Temporary Heating: Apply temporary heat to maintain temperature according to manufacturer's written instructions. END OF SECTION Project No. 18088080 1 Section 26 28 13 Lake Lewisville WTP Dewatering Improvements Fuses SECTION 26 28 13 - FUSES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Cartridge fuses rated 600-V ac and less for use in control circuits, enclosed switches, controllers and motor-control centers. 1.2 SUBMITTALS A. Product Data: For each type of product indicated. Include construction details, material, dimensions, descriptions of individual components and finishes for spare-fuse cabinets. 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. 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. 1.3 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. 1.4 COORDINATION A. Coordinate fuse ratings with utilization equipment nameplate limitations of maximum fuse size and with system short-circuit current levels. 1.5 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. Project No. 18088080 2 Section 26 28 13 Lake Lewisville WTP Dewatering Improvements Fuses PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Cooper Bussmann, Inc. 2. Edison Fuse, Inc. 3. Ferraz Shawmut, Inc. 4. Littelfuse, Inc. 2.2 CARTRIDGE FUSES A. Characteristics: NEMA FU 1, nonrenewable cartridge fuses with voltage ratings consistent with circuit voltages. PART 3 - EXECUTION 3.1 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. 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. 3.2 FUSE APPLICATIONS A. Cartridge Fuses: 1. Feeders: Class L, fast acting Class RK1or fast acting Class RK5. 2. Motor Branch Circuits: Class RK1, time delay. 3. Control Circuits: Class CC, fast acting. 3.3 INSTALLATION A. Install fuses in fusible devices. Arrange fuses so rating information is readable without removing fuse. 3.4 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 and adjacent to each fuse block, socket and holder. END OF SECTION Project No. 18088080 1 Section 26 28 16 Lake Lewisville WTP Dewatering Improvements Enclosed Switches and Circuit Breakers SECTION 26 28 16 - ENCLOSED SWITCHES AND CIRCUIT BREAKERS PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Fusible switches. 2. Nonfusible switches. 3. Molded-case circuit breakers (MCCBs). 4. Molded-case switches. 5. Enclosures. 1.2 SUBMITTALS A. Product Data: For each type of enclosed switch, circuit breaker, accessory, and component indicated. Include dimensioned elevations, sections, weights and manufacturers’ technical data on features, performance, electrical characteristics, ratings, accessories and finishes. 1. Enclosure types and details for all types indicated, including NEMA 250, Type 1. 2. Current and voltage ratings. 3. Short-circuit current ratings (interrupting and withstand, as appropriate). 4. Include evidence of Nationally Recognized Testing Laboratory listing for series rating of installed devices. 5. Detail features, characteristics, ratings, and factory settings of individual overcurrent protective devices, accessories, and auxiliary components. B. Shop Drawings: For enclosed switches and circuit breakers. Include plans, elevations, sections, details, and attachments to other work. 1. Wiring Diagrams: for power, signal, and control wiring. C. Qualification Data: For qualified testing agency. D. Field quality-control reports. 1. Test procedures used. 2. Test results that comply with requirements. 3. Results of failed tests and corrective action taken to achieve test results that comply with requirements. E. Operation and Maintenance Data: For enclosed switches and circuit breakers to include in emergency, operation, and maintenance manuals. In addition to items specified in Division 01 Section “Operation and Maintenance Data,” include the following: 1. Manufacturer’s written instructions for testing and adjusting enclosed switches and circuit breakers. 1.3 QUALITY ASSURANCE A. Source Limitations: Obtain enclosed switches and circuit breakers, overcurrent protective devices, components, and accessories, within same product category from single 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 NFPA 70. Project No. 18088080 2 Section 26 28 16 Lake Lewisville WTP Dewatering Improvements Enclosed Switches and Circuit Breakers 1.4 COORDINATION A. Coordinate layout and installation of switches, circuit breakers, and components with equipment served and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels. 1.5 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 three of each size and type. 2. Fuse Pullers: Two for each size and type. PART 2 - PRODUCTS 2.1 FUSIBLE SWITCHES 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. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric. B. Type HD, Heavy Duty, Single Throw, 600-V ac, 1200 A and Smaller: UL98 and NEMA KS 1, horsepower rated, with clips or bolt pads to accommodate fuses, lockable handle with capability to accept three padlocks, and interlocked with cover in closed position. C. Accessories: 1. Equipment Ground Kit: Internally mounted and labeled for copper and aluminum ground conductors. 2. Neutral Kit: Internally mounted; insulated, capable of being grounded and bonded; labeled for copper and aluminum neutral conductors. 3. Class R Fuse Kit: Provides rejection of other fuse types when Class R fuses are specified. 4. Lugs: Mechanical type, suitable for number, size and conductor material. 2.2 NONFUSIBLE SWITCHES 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. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric. B. Type HD, Heavy Duty, Single Throw, 600-V ac, 1200 A and Smaller: UL 98 and NEMA KS 1, horsepower rated, lockable handle with capability to accept three padlocks, and interlocked with cover in closed position. C. Accessories: 1. Equipment Ground Kit: Internally mounted and labeled for copper and aluminum ground conductors. 2. Neutral Kit: Internally mounted; insulated, capable of being grounded and bonded; labeled for copper and aluminum neutral conductors. Project No. 18088080 3 Section 26 28 16 Lake Lewisville WTP Dewatering Improvements Enclosed Switches and Circuit Breakers 2.3 MOLDED-CASE CIRCUIT BREAKERS 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. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric. B. General Requirements: Comply with UL 489, NEMA AB 1, and NEMA AB 3, with interrupting capacity to comply with available fault currents. C. Thermal-Magnetic Circuit Breakers: Inverse time-current element for low-level overloads and instantaneous magnetic trip element for short circuits. Adjustable magnetic trip setting for circuit- breaker frame sizes 250 A and larger. 1. Electronic Trip Trip Unit circuit Breakers: RMS Sensing; field-replaceable rating plug; with the following field-adjustable settings or as indicated on the drawings: a. Instantaneous trip. b. Long-and short-time pickup levels. c. Long-and short-time time adjustments. d. Ground-fault pickup level, time delay and I2t response. D. Features and Accessories: 1. Standard frame sizes, trip ratings and number of poles. 2.4 MOLDED-CASE SWITCHES 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. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric. B. General Requirements: MCCB with fixed, high-set instantaneous trip only, and short-circuit withstand rating equal to equivalent breaker frame size interrupting rating. C. Features and Accessories: 1. Standard frame sizes and number of poles. 2.5 ENCLOSURES A. Enclosed Switches and Circuit Breakers: NEMA AB 1, NEMA KS 1, NEMA 250, and UL 50, to comply with environmental conditions at installed location. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine elements and surfaces to receive enclosed switches and circuit breakers for compliance with installation tolerances and other conditions affecting performance of the Work. B. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 INSTALLATION A. Install individual wall-mounted switches and circuit breakers with tops at uniform height unless otherwise indicated. Project No. 18088080 4 Section 26 28 16 Lake Lewisville WTP Dewatering Improvements Enclosed Switches and Circuit Breakers B. Installation height of disconnect devices shall be in conformance with NFPA 70, Article 240.24. C. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and temporary blocking of moving parts form enclosures and components. D. Furnish and install fuses in fusible devices. E. Comply with NECA 1. 3.3 IDENTIFICATION A. Comply with requirements in Division 26 Section “Identification for Electrical Systems.” 1. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs. 2. Label each enclosure with engraved metal or laminated-plastic nameplate. 3.4 FIELD QUALITY CONTROL A. Perform tests and inspections. B. Acceptance Testing Preparation: 1. Test insulation resistance for each enclosed switch and circuit breaker, component, connecting supply, feeder, and control circuit. 2. Test continuity of each circuit. C. Tests and Inspections: 1. Perform each visual and mechanical inspection and electrical test stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. 2. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest. 3. Test and adjust controls, remote monitoring, and safeties. Replace damaged and malfunctioning controls and equipment. D. Enclosed switches and circuit breakers will be considered defective if they do not pass tests and inspections. E. Prepare test and inspection reports, including a certified report that identifies enclosed switches and circuit breakers. Include notation of deficiencies detected, remedial action taken and observations after remedial action. 3.5 ADJUSTING A. Adjust moving parts and operable components to function smoothly, and lubricate as recommended by manufacturer. END OF SECTION Project No. 18088080 1 Section 26 29 13 Lake Lewisville WTP Dewatering Improvements Enclosed Controllers SECTION 26 29 13 - ENCLOSED CONTROLLERS PART 1 - GENERAL 1.1 SUMMARY A. Section includes the following enclosed controllers rated 600 V and less: 1. Full-voltage magnetic. 1.2 DEFINITIONS A. CPT: Control power transformer. B. MCCB: Molded-case circuit breaker. C. MCP: Motor circuit protector. D. N.C.: Normally closed. E. N.O.: Normally open. F. NRTL: Nationally Recognized Testing Laboratory G. OCPD: Overcurrent protective device. H. SCR: Silicon-controlled rectifier. 1.3 SUBMITTALS A. Product Data: For each type of enclosed controller. Include manufacturer’s technical data on features, performance, electrical characteristics, ratings, and enclosure types and finishes. B. Shop Drawings: for each enclosed controller: Include dimensioned plans, elevations, sections, details, and required clearances and service spaces around controller enclosures. 1. Show tabulations of 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. e. Listed and labeled for integrated short-circuit current (withstand) rating of OCPDs in combination controllers by an NRTL acceptable to authorities having jurisdiction. f. Features, characteristics, ratings and factory settings of individual OCPDs in combination controllers. 2. Wiring Diagrams: For power, signal, and control wiring. C. Field quality-control reports. D. Operation and Maintenance Data: For enclosed controllers 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. Routing maintenance requirements for enclosed controllers and installed components. 2. Manufacturer’s written instructions for testing and adjusting circuit breaker and MCP trip settings. 3. Manufacturer’s written instructions for setting field-adjustable overload relays. Project No. 18088080 2 Section 26 29 13 Lake Lewisville WTP Dewatering Improvements Enclosed Controllers E. 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. F. Load-Current and List 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. 1.4 QUALITY ASSURANCE A. 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. B. Comply with NFPA 70. 1.5 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; install temporary electric heating, with at least 250 W per controller. 1.6 COORDINATION A. Coordinate layout and installation of enclosed controllers with other construction including conduit, piping, equipment and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels. PART 2 - PRODUCTS 2.1 MANUFACTURED UNITS 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. Eaton Electrical Inc.; Cutler-Hammer Products. 2. Square D; Schneider Electric 2.2 FULL-VOLTAGE CONTROLLERS A. General Requirements for Full-voltage Controllers: comply with NEMA ICS 2, general purpose, Class A. 1. Control Circuit: 120 V; obtained from integral control power transformer with a control power transformer of sufficient capacity to operate connected pilot, indicating and control devices, plus 100 percent spare capacity. B. Combination Magnetic Controller: Factory-assembled combination of magnetic controller, OCPD, 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. Project No. 18088080 3 Section 26 29 13 Lake Lewisville WTP Dewatering Improvements Enclosed Controllers b. Lockable Handle: Accepts three padlocks and interlocks with cover in closed position. c. Auxiliary NO/NC contact that operates to indicate “ON” or “OFF”. C. Overloads: Solid state type, electronic design with a 5:1 adjustment range, current based measurement protection, thermal memory, integrated I/O points, and enhanced phase loss protection. 2.3 ENCLOSURES A. Enclosed Controllers: NEMA ICS 6, to comply with environmental conditions at installed location, constructed of stainless steel unless otherwise indicated on the drawings. 2.4 ACCESSORIES A. General Requirements for Control Circuit and Pilot Devices: NEMA ICS 5; factory installed in controller enclosure cover unless otherwise indicated. 1. Push buttons, Pilot Lights and Selector Switches: Heavy-duty, oil tight type. a. Push Buttons: Unguarded types; as indicated. b. Pilot Lights: LED types; colors as indicated; push to test. c. Selector Switches: Rotary type. 2. Elapsed Time Meters: Heavy duty with digital readout in hours. B. Control Relays: Auxiliary and adjustable solid-state time-delay relays. C. Phase-Failure, Phase-Reversal, and Undervoltage and Overvoltage Relays: solid-state sensing circuit with isolated output contacts for hard-wired connections. Provide adjustable undervoltage, overvoltage, and time-delay settings. PART 3 - EXECUTION 3.1 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. C. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 INSTALLATION A. 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 Division 16 Section “Hangers and Supports for Electrical Systems.” B. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and temporary blocking of moving parts from enclosures and components. C. Install fuses in each fusible-switch enclosed controller. D. Install fuses in control circuits if not factory installed. Comply with requirements in Division 26 Section “Fuses.” Project No. 18088080 4 Section 26 29 13 Lake Lewisville WTP Dewatering Improvements Enclosed Controllers E. Install, connect and fuse thermal-protector monitoring relays furnished with motor-driven equipment. F. Comply with NECA 1. 3.3 IDENTIFICATION A. Identify enclosed controllers, components and control wiring. Comply with requirements for identification specified in Division 26 Section “Identification for Electrical Systems.” 1. Identify field-installed conductors, interconnecting wiring and components; provide warning signs. 2. Label each enclosure with engraved nameplate. 3. Label each enclosure-mounted control and pilot device. 3.4 CONTROL WIRING INSTALLATION A. Install wiring between enclosed controllers and remote devices. Comply with requirements in Division 26 Section “Low Voltage Electrical Power Conductors and Cables.” B. Bundle, train, and support wiring in enclosures. C. Connect selector switches and other automatic-control selection devices where applicable. 3.5 FIELD QUALITY CONTROL A. Perform tests and inspections. 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 Engineer 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 National Electrical Testing Association 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. 8. Test and adjust controls, remote monitoring and safeties. Replace damaged and malfunctioning controls and equipment. 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. Project No. 18088080 5 Section 26 29 13 Lake Lewisville WTP Dewatering Improvements Enclosed Controllers 3.6 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 Engineer before increasing settings. 3.7 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 Project No. 18088080 1 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers SECTION 26 29 23 - VARIABLE-FREQUENCY MOTOR CONTROLLERS PART 1 - GENERAL 1.1 SUMMARY A. Section includes separately enclosed, pre-assembled, combination VFCs, rated 600 V and less, for speed control of three-phase, squirrel-cage induction motors. 1.2 QUALIFICATIONS A. Manufacturer 1. The manufacturer shall have a minimum of 15 years experience in the manufacturer of variable frequency motor controllers. B. Support 1. The manufacturer shall maintain factory trained and authorized service facilities within 100 miles of the project and shall have a demonstrated record of service for at least the previous ten years. 2. Support personnel are to be direct employees of the manufacturer. 3. The manufacturer shall provide all required start-up and training services. 1.3 DEFINITIONS A. CE: Conformite Europeene (European Compliance). B. CPT: Control power transformer. C. EMI: Electromagnetic interference. D. IGBT: Insulated-gate bipolar transistor. E. LED: Light-emitting diode. F. MCP: Motor-circuit protector. G. NC: Normally closed. H. NO: Normally open. I. OCPD: Overcurrent protective device. J. PCC: Point of common coupling. K. PID: Control action, proportional plus integral plus derivative. L. PWM: Pulse-width modulated. M. RFI: Radio-frequency interference. N. TDD: Total demand (harmonic current) distortion. O. THD(V): Total harmonic voltage demand. P. VFC: Variable frequency motor controller. Project No. 18088080 2 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers Q. MPS: Motor Protection System 1.4 PERFORMANCE REQUIREMENTS A. Seismic Performance: VFCs shall withstand the effects of earthquake motions determined according to ASCE/SEI 7. 1. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified and the unit will be fully operational after the seismic event." 1.5 SUBMITTALS A. Product Data: For each type and rating of VFC indicated. Include features, performance, electrical ratings, operating characteristics, shipping and operating weights, and furnished specialties and accessories. B. Shop Drawings: For each VFC indicated. Include dimensioned plans, elevations, and sections; and conduit entry locations and sizes, mounting arrangements, and details, including required clearances and service space around equipment. 1. Show tabulations of installed devices, equipment features, and ratings. Include the following: a. Each installed unit's type and details. b. Factory-installed devices. c. Enclosure types and details. d. Nameplate legends. e. Short-circuit current (withstand) rating of enclosed unit. f. Features, characteristics, ratings, and factory settings of each VFC and installed devices. g. Specified modifications. 2. Schematic and Connection Wiring Diagrams: For power, signal, and control wiring. C. Coordination Drawings: Floor plans, drawn to scale, showing dimensioned layout, required working clearances, and required area above and around VFCs. Show VFC layout and relationships between electrical components and adjacent structural and mechanical elements. Show support locations, type of support, and weight on each support. Indicate field measurements. D. Seismic Qualification Certificates: For VFCs, accessories, and components, from manufacturer. 1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation. 2. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions. 3. Detailed description of equipment anchorage devices on which the certification is based, and their installation requirements. E. Product Certificates: For each VFC, from manufacturer. F. Operation and Maintenance Data: For VFCs 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. Manufacturer's written instructions for testing and adjusting thermal-magnetic circuit breaker and MCP trip settings. 2. Manufacturer's written instructions for setting field-adjustable overload relays. 3. Manufacturer's written instructions for testing, adjusting, and reprogramming microprocessor control modules. Project No. 18088080 3 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers 4. Manufacturer's written instructions for setting field-adjustable timers, controls, and status and alarm points. G. 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. 1.6 QUALITY ASSURANCE A. 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. B. Comply with NFPA 70. C. IEEE Compliance: Fabricate and test VFC according to IEEE 344 to withstand seismic forces defined in Division 26 Section "Vibration and Seismic Controls for Electrical Systems." 1.7 DELIVERY, STORAGE, AND HANDLING A. If stored in space that is not permanently enclosed and air conditioned, remove loose packing and flammable materials from inside controllers and install temporary electric heating, with at least 250 W per controller and connect factory-installed space heaters to temporary electrical service. 1.8 PROJECT CONDITIONS A. Environmental Limitations: Rate equipment for continuous operation, capable of driving full load without derating, under the following conditions unless otherwise indicated: 1. Operating Ambient Temperature Range: 32 degrees F to 122 deg F. 2. Storage Ambient Temperature Range: -40 degrees F to 158 degrees F. 3. Relative Humidity Range: 5% to 95% non-condensing. 4. Altitude: Up to 3,300 feet. B. Product Selection for Restricted Space: Drawings indicate maximum dimensions for VFCs, including clearances between VFCs, and adjacent surfaces and other items. 1.9 COORDINATION A. Coordinate features of motors, load characteristics, installed units, and accessory devices to be compatible with the following: 1. Torque, speed, and horsepower requirements of the load. 2. Ratings and characteristics of supply circuit and required control sequence. 3. Ambient and environmental conditions of installation location. B. Coordinate sizes and locations of concrete bases with actual equipment provided. Cast anchor- bolt inserts into bases. C. Coordinate sizes and locations of roof curbs, equipment supports, and roof penetrations with actual equipment provided. 1.10 WARRANTY A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace VFCs that fail in materials or workmanship within specified warranty period. 1. Warranty Period: 1 year from date of Substantial Completion. Project No. 18088080 4 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers PART 2 - PRODUCTS 2.1 MANUFACTURED UNITS A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the work include the following: 1. Rockwell Automation – Allen Bradley 2. Schneider Electric – Square D 3. ABB B. General Requirements for VFCs: Comply with NEMA ICS 7, NEMA ICS 61800-2, and UL 508C. C. Application: As indicated on the plans, including but not limited to, blowers, centrifugal pumps, positive displacement pumps, process equipment. D. VFC Description: Variable-frequency power converter (rectifier, dc bus, and IGBT, PWM inverter) factory packaged in an enclosure, with integral disconnecting means and overcurrent and overload protection; listed and labeled by an NRTL as a complete unit; arranged to provide self- protection, protection, and variable-speed control of one or more three-phase induction motors by adjusting output voltage and frequency. 1. Units suitable for operation of NEMA MG 1, Design A and Design B motors as defined by NEMA MG 1, Section IV, Part 30, "Application Considerations for Constant Speed Motors Used on a Sinusoidal Bus with Harmonic Content and General Purpose Motors Used with Adjustable-Voltage or Adjustable-Frequency Controls or Both." 2. Units suitable for operation of inverter-duty motors as defined by NEMA MG 1, Section IV, Part 31, "Definite-Purpose Inverter-Fed Polyphase Motors." 3. Listed and labeled for integrated short-circuit current (withstand) rating by an NRTL acceptable to authorities having jurisdiction. E. Design and Rating: Match load type, such as fans, blowers, and pumps; and type of connection used between motor and load such as direct or through a power-transmission connection. Provide variable torque or constant torque rated equipment as appropriate for the process load type. F. Output Rating: Three-phase; 10 to 60 Hz, with voltage proportional to frequency throughout voltage range; maximum voltage equals input voltage. G. Converter: VFCs 50 horsepower and greater shall include an 18 pulse rectifier with manufacturer recommended phase shifting auto transformer. The transformer shall be installed into the VFC enclosure where possible. H. Unit Operating Requirements: 1. The VFC shall accept nominal plant power of 480 VAC at 60 Hertz. 2. Input AC Voltage Tolerance: Plus 10 and minus 15 percent of VFC input voltage rating. 3. Input AC Voltage Unbalance: Not exceeding 5 percent. 4. Input Frequency Tolerance: Plus or minus 3 percent of VFC frequency rating. 5. Minimum Efficiency: 97 percent at 60 Hz, full load. 6. Minimum Displacement Primary-Side Power Factor: 95 percent under any load or speed condition. 7. Minimum Short-Circuit Current (Withstand) Rating: Shall be greater than maximum available fault current available at the site. 8. Vibration Withstand: Comply with IEC 60068-2-6. 9. Overload Capability: 1.1 times the base load current for 60 seconds; minimum of 1.5 times the base load current for three seconds. 10. Starting Torque: Minimum 100 percent of rated torque from 3 to 60 Hz. 11. Speed Regulation: Plus or minus 5 percent. Project No. 18088080 5 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers 12. Stop Modes: Programmable; includes ramp, coast, fast, and dc injection braking. I. Isolated Control Interface: Allows VFCs to follow remote-control signal over a minimum 40:1 speed range. 1. Signal: Electrical, 4 to 20 mA DC. J. Internal Adjustability Capabilities: 1. Minimum Speed: 5 to 25 percent of maximum rpm. 2. Maximum Speed: 80 to 100 percent of maximum rpm. 3. Acceleration: 0.1 to 999.9 seconds. 4. Deceleration: 0.1 to 999.9 seconds. 5. Current Limit: 30 to minimum of 150 percent of maximum rating. K. Self-Protection and Reliability Features: 1. Input transient protection by means of surge suppressors to provide three-phase protection against damage from supply voltage surges 10 percent or more above nominal line voltage. 2. Loss of Input Signal Protection: Selectable response strategy, including speed default to a percent of the most recent speed, a preset speed, or stop; with alarm. 3. Under- and overvoltage trips. 4. Inverter overcurrent trips. 5. VFC and Motor Overload/Overtemperature Protection: Microprocessor-based thermal protection system for monitoring VFCs and motor thermal characteristics, and for providing VFC overtemperature and motor overload alarm and trip; settings selectable via the keypad; NRTL approved. 6. Critical frequency rejection, with three selectable and adjustable deadbands. 7. Instantaneous line-to-line and line-to-ground overcurrent trips. 8. Loss-of-phase protection. 9. Reverse-phase protection. 10. Short-circuit protection. 11. Motor overtemperature fault. A. Automatic Reset/Restart: Attempt three restarts after drive fault or on return of power after an interruption and before shutting down for manual reset or fault correction; adjustable delay time between restart attempts. B. Power-Interruption Protection: To prevent motor from re-energizing after a power interruption until motor has stopped, unless "Bidirectional Autospeed Search" feature is available and engaged. C. Bidirectional Autospeed Search: Capable of starting VFC into rotating loads spinning in either direction and returning motor to set speed in proper direction, without causing damage to drive, motor, or load. D. Torque Boost: Automatically varies starting and continuous torque to at least 1.5 times the minimum torque to ensure high-starting torque and increased torque at slow speeds. E. Motor Temperature Compensation at Slow Speeds: Adjustable current fall-back based on output frequency for temperature protection of self-cooled, fan-ventilated motors at slow speeds. F. Integral Input Disconnecting Means and OCPD: NEMA AB 1, thermal-magnetic circuit breaker with pad-lockable, door-mounted handle mechanism. 1. Disconnect Rating: Not less than 115 percent of NFPA 70 motor full-load current rating or VFC input current rating, whichever is larger. 2. Auxiliary Contacts: NO/NC, arranged to activate before switch blades open. 3. Auxiliary contacts "a" and "b" arranged to activate with circuit-breaker handle. Project No. 18088080 6 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers 4. NC and NO alarm contact that operates only when circuit breaker has tripped. 2.2 CONTROLS AND INDICATION A. Panel-Mounted Operator Station: Manufacturer's standard front-accessible, LCD display and keypad. B. Control Signal Interfaces: 1. Electric Input Signal Interface: a. A minimum of two programmable analog inputs: 4 to 20 mA DC. b. A minimum of six multifunction programmable digital inputs. 2. Output Signal Interface: A minimum of one programmable analog output signal(s) ( 4 to 20 mA DC), which can be configured for any of the following: a. Output frequency (Hz). b. Output current (load). c. DC-link voltage (V dc). d. Motor torque (percent). e. Motor speed (rpm). f. Set point frequency (Hz). 3. Remote Indication Interface: A minimum of two programmable dry-circuit relay outputs (120-V ac, 1 A) for remote indication of the following: a. Motor running. b. Set point speed reached. c. Fault and warning indication (overtemperature or overcurrent). 4. Communication: Provide Ethernet communication support. 2.3 LINE CONDITIONING AND FILTERING A. Input Line Conditioning: Provide input line reactor meeting VFC manufacturer’s recommendations, to limit TDD and THD(V) at the defined PCC per IEEE 519. B. Output Filtering: Provide output line reactor meeting VFC manufacturer’s recommendations for application and conductor length. 2.4 ENCLOSURES A. VFC Enclosures: NEMA 250, to comply with environmental conditions at installed location. 1. Unconditioned Indoor or Outdoor locations: Type 4X. 2. Conditioned Indoor locations: Type 1. B. Plenum Rating: UL 1995; NRTL certification label on enclosure, clearly identifying VFC as "Plenum Rated." 2.5 ACCESSORIES A. General Requirements for Control-Circuit and Pilot Devices: NEMA ICS 5; factory installed in VFC enclosure cover unless otherwise indicated. 1. Push Buttons, Pilot Lights, and Selector Switches: Heavy-duty, oil tight type. a. Push Buttons: Recessed types; maintained or momentary as required. b. Pilot Lights: LED types; push to test. c. Selector Switches: Rotary type. d. Stop and Lockout Push-Button Station: Momentary-break, push-button station with a factory-applied hasp arranged so padlock can be used to lock push button in depressed position with control circuit open. Project No. 18088080 7 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers B. Control Relays: Auxiliary and adjustable solid-state time-delay relays. C. Phase-Failure, Phase-Reversal, and Undervoltage and Overvoltage Relays: Solid-state sensing circuit with isolated output contacts for hard-wired connections. Provide adjustable undervoltage, overvoltage, and time-delay settings. 1. Current Transformers: Continuous current rating, basic impulse insulating level (BIL) rating, burden, and accuracy class suitable for connected circuitry. Comply with IEEE C57.13. D. Space heaters, with NC auxiliary contacts, to mitigate condensation in NEMA 250, Type 1 enclosures installed outdoors or in unconditioned interior spaces subject to humidity and temperature swings. E. Cooling Fan and Exhaust System: For NEMA 250, Type 1; UL 508 component recognized: Supply fan, with composite stainless steel intake and exhaust grills and filters; 120 -V ac; obtained from integral CPT. F. Spare control-wiring terminal blocks; wired. PART 3 - EXECUTION 3.1 EXAMINATION A. Examine areas, surfaces, and substrates to receive VFCs, with Installer present, for compliance with requirements for installation tolerances, and other conditions affecting performance. B. Examine VFC before installation. Reject VFCs that are wet, moisture damaged, or mold damaged. C. Examine roughing-in for conduit systems to verify actual locations of conduit connections before VFC installation. D. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 INSTALLATION A. Coordinate layout and installation of VFCs with other construction including conduit, piping, equipment, and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels. B. Floor-Mounting Controllers: Install VFCs on 4-inch (100-mm) nominal thickness concrete base. Comply with requirements for concrete base specified in Division 03 Section "Cast-in-Place Concrete or Miscellaneous Cast-in-Place Concrete." 1. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated, install dowel rods on 18-inch (450-mm) centers around the full perimeter of concrete base. 2. For supported equipment, install epoxy-coated anchor bolts that extend through concrete base and anchor into structural concrete floor. 3. Place and secure anchorage devices. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded. 4. Install anchor bolts to elevations required for proper attachment to supported equipment. C. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and temporary blocking of moving parts from enclosures and components. D. Install fuses in each fusible-switch. Project No. 18088080 8 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers E. Install fuses in control circuits if not factory installed. F. Install, connect, and fuse thermal-protector monitoring relays furnished with motor-driven equipment. G. Comply with NECA 1. 3.3 IDENTIFICATION A. Identify VFCs, components, and control wiring. 1. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs. 2. Label each VFC with engraved nameplate. 3. Label each enclosure-mounted control and pilot device. B. Operating Instructions: Frame printed operating instructions for VFCs, including control sequences and emergency procedures. Fabricate frame of finished metal, and cover instructions with clear acrylic plastic. Mount on front of VFC units. 3.4 CONTROL WIRING INSTALLATION A. Install wiring between VFCs and remote devices and facility's central-control system. B. Bundle, train, and support wiring in enclosures. C. Connect selector switches and other automatic control devices where applicable. 1. Connect selector switches to bypass only those manual- and automatic control devices that have no safety functions when switches are in manual-control position. 2. Connect selector switches with control 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. 3.5 STARTUP SERVICE A. Engage a factory-authorized service representative to perform startup service. 1. Complete installation and startup checks according to manufacturer's written instructions. 3.6 ADJUSTING A. Program microprocessors for required operational sequences, status indications, alarms, event recording, and display features. Clear events memory after final acceptance testing and prior to Substantial Completion. B. Set field-adjustable switches, auxiliary relays, time-delay relays, timers, and overload-relay pickup and trip ranges. C. Set field-adjustable circuit-breaker trip ranges as recommended by the manufacturer. 3.7 PROTECTION A. Temporary Heating: Apply temporary heat to maintain temperature according to manufacturer's written instructions until controllers are ready to be energized and placed into service. B. Replace VFCs whose interiors have been exposed to water or other liquids prior to Substantial Completion. Project No. 18088080 9 Section 26 29 23 Lake Lewisville WTP Dewatering Improvements Variable Frequency Motor Controllers 3.8 DEMONSTRATION A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, reprogram, and maintain VFCs. END OF SECTION Project No. 18088080 1 Section 26 41 13 Lake Lewisville WTP Dewatering Improvements Lightning Protection for Structures SECTION 26 41 13 - LIGHTNING PROTECTION FOR STRUCTURES PART 1 - GENERAL 1.1 SUMMARY A. Section includes lightning protection for building site components. 1.2 SUBMITTALS A. Product Data: For each type of product indicated. B. Shop Drawings: for air terminals and mounting accessories. 1. Layout of the lightning protection system, along with details of the components to be used in the installation. 2. Include indications for use of raceway, data on how concealment requirements will be met, and calculations required by NFPA 780 for bonding of grounded and isolated metal bodies. C. Qualification Data: For qualified Installer and manufacturer. Include data on listing or certification by UL. D. Certification, signed by Contractor, that roof adhesive is approved by manufacturer of roofing material. E. Field quality-control reports. F. Other Informational Submittals: Plans showing dimensioned as-built locations of grounding features, including the following: 1. Ground rods. 2. Ground loop conductor. 1.3 QUALITY ASSURANCE A. Installer Qualifications: Certified by UL or LPI as a Master Installer/Designer, trained and approved for installation of units required for this Project. B. Electrical components, Devices and Accessories: Listed and labeled as defined in NFPA 780, “Definitions” Article. 1.4 COORDINATION A. Coordinate installation of lightning protection with installation of other building systems and components, including electrical wiring, supporting structures and building materials, metal bodies requiring bonding to lightning protection components, and building finishes. B. Coordinate installation of air terminals attached to roof systems with roofing manufacturer and Installer. C. Flashings of through-roof assemblies shall comply with roofing manufacturer’s specifications. Project No. 18088080 2 Section 26 41 13 Lake Lewisville WTP Dewatering Improvements Lightning Protection for Structures PART 2 - PRODUCTS 2.1 LIGHTNING PROTECTION SYSTEM COMPONENTS A. Comply with UL 96 and NFPA 780. B. Roof-Mounted Air Terminals: NFPA 780, Class I copper unless otherwise indicated. 1. Manufacturers: subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: a. East Coast Lightning Equipment Inc. b. ERICO International Corporation. c. Harger. d. Heary Bros. Lightning Protection Co., Inc. e. Independent Protection Co. f. Preferred Lightning Protection. g. Robbins Lightning, Inc. h. Thompson Lightning Protection, Inc. 2. Air Terminals More than 24 Inches Long: With brace attached to the terminal at not less than half the height of the terminal. 3. Single-membrane, Roof-Mounted, Air Terminals: Designed specifically for single- membrane roof system materials. C. Main and Bonding Conductors: Copper. D. Ground Loop Conductor: The same size and type as the main conductor except tinned. E. Ground Rods: Copper-clad steel; ¾ inch in diameter by 10 feet long. PART 3 - EXECUTION 3.1 INSTALLATION A. Install lightning protection components and systems according to UL 96A and NFPA 780. B. Install conductors with direct paths from air terminals to ground connections. Avoid sharp bends. C. Conceal the following conductors: 1. System conductors. 2. Down conductors. 3. Interior conductors. 4. Conductors within normal view of exterior locations at grade within 200 feet of building. D. Cable Connections: Use crimped or bolted connections for all conductor splices and connections between conductors and other components. Use exothermic-welded connections in underground portions of the system. E. Bond extremities of vertical metal bodies exceeding 60 feet in length of lightning protection components. F. Ground Loop: Install ground-level, potential equalization conductor and extend around the perimeter of structure. 1. Bury ground ring not less than 30 inches. 2. Bond ground terminals to the ground loop. Project No. 18088080 3 Section 26 41 13 Lake Lewisville WTP Dewatering Improvements Lightning Protection for Structures 3. Bond grounded building systems to the ground loop conductor within 12 feet of grade level. G. Bond lightning protection components with intermediate-level interconnection loop conductors to grounded metal bodies of building at 60-foot intervals. 3.2 CORROSION PROTECTION A. Do not combine materials that can form an electrolytic couple that will accelerate corrosion in the presence of moisture unless moisture is permanently excluded from junction of such materials. B. Use conductors with protective coatings where conditions cause deterioration or corrosion of conductors. 3.3 FIELD QUALITY CONTROL A. Notify Engineer at least 48 hours in advance of inspection before concealing lightning protection components. END OF SECTION Project No. 18088080 1 Section 26 51 00 Lake Lewisville WTP Dewatering Improvements Interior Lighting SECTION 26 51 00 - INTERIOR LIGHTING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Interior lighting fixtures, lamps, and ballasts. 2. Emergency lighting units. 3. Exit signs. 4. Lighting fixture supports. 1.2 DEFINITIONS A. BF: Ballast factor. B. CCT: Correlated color temperature. C. CRI: Color-rendering index. D. HID: High-intensity discharge. E. Lumen: Measured output of lamp and luminaire, or both. F. Luminaire: Complete lighting fixture, including ballast housing if provided. 1.3 SUBMITTALS A. Product Data: For each type of lighting fixture, arranged in order of fixture designation. Include data on features, accessories, finishes and the following: 1. Physical description of lighting fixture including dimensions. 2. Emergency lighting units including battery and charger. 3. Ballast, including BF. 4. Energy-efficiency data. 5. Life, output (lumens, CCT, and CRI) and energy-efficiency data for lamps. 6. Photometric data and adjustment factors based on laboratory tests, complying with IESNA Lighting Measurements Testing & Calculation Guides, of each lighting fixture type. The adjustment factors shall be for lamps, ballasts and accessories identical to those indicated for the lighting fixture as applied in this Project. a. Manufacturer Certified Data: Photometric data shall be certified by a manufacturer’s laboratory with a current accreditation under the National Voluntary Laboratory Accreditation Program for Energy efficient Lighting Products. B. Installation instructions. C. Qualification Data: For qualified agencies providing photometric data for lighting fixtures. D. Product Certificates: For each type of ballast for bi-level and dimmer-controlled fixtures, from manufacturer. E. Field quality-control reports. F. Operation and Maintenance Data: For lighting equipment and fixtures to include in emergency, operation and maintenance manuals. 1. Provide a list of all lamp types used on Project; use ANSI and manufacturers’ codes. Project No. 18088080 2 Section 26 51 00 Lake Lewisville WTP Dewatering Improvements Interior Lighting G. Warranty: 12 months after project acceptance. 1.4 QUALITY ASSURANCE A. Luminaire Photometric Data Testing Laboratory Qualifications: Provided by manufacturer’s laboratories that are accredited under the National volunteer Laboratory Accreditation Program for Energy Efficient Lighting Products. B. Electric 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 NFPA 70. 1.5 COORDINATION A. Coordinate layout and installation of lighting fixtures and suspension system with other construction that penetrates ceilings or is supported by them, including HVAC equipment, fire- suppression system and partition assemblies. 1.6 WARRANTY A. Special Warranty for Emergency Lighting Batteries: Manufacturer’s standard form in which manufacturer of battery powered emergency lighting unit agrees to repair or replace components of rechargeable batteries that fail in materials or workmanship within specified warranty period. 1. Warranty Period for Emergency Lighting Unit Batteries: 10 years from date of Substantial Completion. Full warranty shall apply for first year, and prorated warranty for the remaining nine years. 2. Warranty Period for Emergency Fluorescent Ballast and Self-Powered Exit Sign Batteries: Seven years from date of Substantial Completion. Full warranty shall apply for first year, and prorated warranty for the remaining six years. 1.7 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. Lamps: 10 for every 100 Insert quantity of each type and rating installed. Furnish at least one of each type. 2. Plastic Diffusers and Lenses: One for every 100 of each type and rating installed. Furnish at least one of each type. 3. Fluorescent-fixture-mounted, emergency battery pack: One for every 20 emergency lighting unit. 4. Ballasts: One for every 100 of each type and rating installed. Furnish at least one of each type. 5. Globes and Guards: One for every 20 of each type and rating installed. Furnish at least one of each type. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Products: Subject to compliance with requirements, available products that may be incorporated into the Work include, but are not limited to, product(s) indicated on Drawings. B. Substitutions: Project No. 18088080 3 Section 26 51 00 Lake Lewisville WTP Dewatering Improvements Interior Lighting 1. Provide complete literature for each luminaire substitution: 2. Submittals for substituted luminaires shall be sufficient for competent comparison of the proposed luminaire to the originally specified luminaire: a. Photometric data: 1) IES file in standard IES format. 2) Coefficient of utilization tables based on the IES zonal cavity system by an approved testing laboratory. 3) Candlepower distribution curves. 4) Average luminaire brightness. 5) Lumen output charts. 6) Power requirements in watts and volt-amperes. b. Calculations: 1) Provide software generated calculations showing illuminance levels in footcandles and power usage in watts per square foot for each of the areas in which substitutions are proposed: a) Use surface reflectance values and luminaire light loss factors approved by the ENGINEER to perform all calculations. 3. Substitutions for specified luminaires will be evaluated upon quality of construction, light distribution, energy use, appearance, and maintenance. 4. Substitutions shall comply with all applicable building codes. 2.2 GENERAL REQUIREMENTS FOR LIGHTING FIXTURES AND COMPONENTS A. Metal Parts: Free of burrs and sharp corners and edges. B. Sheet Metal Components: Steel unless otherwise indicated. Form and support to prevent warping and sagging. C. Doors, Frames, and Other Internal Access: Smooth operating, free of light leakage under operating conditions and designed to permit relamping without use of tools. Designed to prevent doors, frames, lenses, diffusers, and other components from falling accidentally during relamping and when secured in operating position. D. Diffusers and Globes: 1. Acrylic Lighting Diffusers: 100 percent virgin acrylic plastic. High resistance to yellowing and other changes due to aging, exposure to heat and UV radiation. a. Lens thickness: At least 0.125 inch minimum unless otherwise indicated. b. UV stabilized. 2. Glass: Annealed crystal glass unless otherwise indicated. E. Factory-Applied Labels: Comply with UL 1598. Include recommended lamps and ballasts. Labels shall be located where they will be readily visible to service personnel, but not seen from normal viewing angles when lamps are in place. 1. Label shall include the following lamp and ballast characteristics: a. “USE ONLY” and include specific lamp type. b. Lamp diameter code (T-4, T-5, T-8, T-12, etc), tube configuration (twin, quad, triple, etc.), base type, and nominal wattage for fluorescent and compact fluorescent luminaires. c. Lamp type, wattage, bulb type (ED17, BD56, etc.) and coating (clear or coated) for HID luminaires. d. Start type (preheat, rapid start, instant start, etc.) for fluorescent and compact fluorescent lunimaires. e. ANSI ballast type (M98, M57, etc.) for HID luminaires. f. CCT and CRI for all luminaires. Project No. 18088080 4 Section 26 51 00 Lake Lewisville WTP Dewatering Improvements Interior Lighting 2.3 BALLASTS FOR LINEAR FLUORESCENT LAMPS A. General Requirements for Electronic Ballasts. 1. Comply with UL 935 and with ANSI C82.11. 2. Designed for type and quantity of lamps served. 3. Ballasts shall be designed for full light output unless another BF, dimmer, or bi-level control is indicated. 4. Sound Rating: Class A. 5. Total Harmonic Distortion Rating: Less than 10 percent. 6. Transient Voltage Protection: IEEE C62.41 and IEEE C62.41.2, Category A or better. 7. Operating Frequency: 42 kHz or higher. 8. BF: 0.88 insert value or higher. 9. Power Factor: 0.95 or higher. B. Electronic Programmed Start Ballasts for T5 and T8 Lamps: comply with ANSI C82.11 and the following: 1. Lamp end-of-life detection and shutdown circuit for T5 diameter lamps. 2. Automatic lamp starting after lamp replacement. C. Electromagnetic Ballasts: Comply with ANSI C82.1; energy saving, high-power factor, Class P, and having automatic-reset thermal protection. 1. Ballast Manufacturer Certification: Indicated by label. D. Ballasts for Low-Temperature Environments: 1. Temperatures 0 Degrees F and Higher: electronic type rated for 0 degrees F starting and operating temperature with indicated lamp types. 2. Temperature Minus 20 degrees F and Higher. Electromagnetic type designed for use with indicated lamp types. E. Ballasts for Low Electromagnetic-Interference Environments: Comply with 47 CFR18, Ch. 1, subpart C, for imitations on electromagnetic and radio-frequency interference for consumer equipment. 2.4 BALLASTS FOR COMPACT FLUORESCENT LAMPS A. Description: Electronic-programmed rapid-start type, complying with UL 935 and with ANSI C82.11, designed for type and quantity of lamps indicated. Ballast shall be designed for full light output unless dimmer or bi-level control is indicated: 1. Lamp end-of-life detection and shutdown circuit. 2. Automatic lamp starting after lamp replacement. 3. Sound Rating: Class A. 4. Total Harmonic Distortion Rating: Less than 20 percent. 5. Transient Voltage Protection: IEEE C62.41.1 and IEEE C62.41.2, Category A or better. 6. Operating Frequency: 20 kHz or higher. 7. Lamp Current Crest Factor: 1.7 or less. 8. BF: 0.95 or higher unless otherwise indicated. 9. Power Factor: 0.95 or higher. 2.5 EMERGENCY FLUORESCENT POWER UNIT A. Internal Type: Self-contained, modular, battery-inverter unit, factory mounted within lighting fixture body and compatible with ballast. Comply with UL 924. 1. Emergency Connection: Operate one fluorescent lamp(s) continuously at an output of 1100 lumens each. Connect unswitched circuit to battery-inverter unit and switched circuit to fixture ballast. Project No. 18088080 5 Section 26 51 00 Lake Lewisville WTP Dewatering Improvements Interior Lighting 2. Test Push Button and Indicator Light: Visible and accessible without opening fixture or entering ceiling space. a. Push Button: Push-to-test type, in unit housing, simulates loss of normal power and demonstrates unit operability. b. Indicator Light: LED indicates normal power on. Normal glow indicates trickle charge; bright glow indicates charging at end of discharge cycle. 3. Battery: Sealed, maintenance-free, nickel-cadmium type. 4. Charger: Fully automatic, solid-state, constant-current type with sealed power transfer relay. 2.6 BALLASTS FOR HID LAMPS A. Electronic Ballast for Metal-Halide Lamps: Include the following features unless otherwise indicated: 1. Minimum Starting Temperature: Minus 20 degrees F for single-lamp ballasts. 2. Rated Ambient Operating Temperature: 130 degrees F. 3. Lamp end-of-life detection and shutdown circuit. 4. Sound Rating: Class A 5. Total Harmonic Distortion Rating: Less than 20 percent. 6. Transient Voltage Protection: IEEE C62.41.1 and IEEE C62.41.2, Category A or better. 7. Lamp Current Crest Factor: 1.5 or less. 8. Power Factor: 0.90 or higher. 9. Protection: Class P thermal cutout. 2.7 QUARTZ LAMP LIGHTING CONTROLLER A. General Requirements for Controllers: Factory installed by lighting fixture manufacturer. Comply with UL 1598. B. Standby (Quartz Restrike): automatically switches quartz lamp on when a HID lamp in the fixture is initially energized and during the HID lamp restrike period after brief power outages. C. Connections: Designed for a single branch-circuit connection. D. Switching Off: automatically switches quartz lamp off when HID lamp strikes. E. Switching Off: Automatically switches quartz lamp off when HID lamp reaches approximately 60 percent light output. 2.8 EXIT SIGNS A. General Requirements for Exit Signs: comply with UL 924; for sign colors, visibility, luminance and lettering size, comply with authorities having jurisdiction. B. Internally Lighted Signs: 1. Lamps for AC Operation: LEDs, 50,000 hours minimum rated lamp life. 2. Self-Powered Exit Signs (Battery type): Integral automatic charger in a self-contained power pack. a. Battery: Sealed, maintenance-free, nickel-cadmium type. b. Charger: fully automatic, solid-state type with sealed transfer relay. c. Operation: Relay automatically energizes lamp from battery when circuit voltage drops to 80 percent of nominal voltage or below. When normal voltage is restored, relay disconnects lamps from battery, and battery is automatically recharged and floated on charger. Project No. 18088080 6 Section 26 51 00 Lake Lewisville WTP Dewatering Improvements Interior Lighting d. Test Push button: Push-to-test type, in unit housing, simulates loss of normal power and demonstrates unit operability. e. LED Indicator Light: Indicates normal power on. Normal glow indicates trickle charge; bright glow indicates charging at end of discharge cycle. f. Integral Self-Test: Factory-installed electronic device automatically initiates code- required test of unit emergency operation at required intervals. Test failure is annunciated by an integral audible alarm and a flashing red LED. 2.9 EMERGENCY LIGHTING UNITS A. General Requirements for Emergency Lighting Units: Self-contained units complying with UL 924. 1. Battery: Sealed, maintenance-free, lead-acid type. 2. Charger: fully automatic, solid-state type with sealed transfer relay. 3. Operation: Relay automatically turns lamp on when power-supply circuit voltage drops to 80 percent of nominal voltage or below. Lamp automatically disconnects from battery when voltage approaches deep-discharge level. When normal voltage is restored, relay disconnects lamps from battery, and battery is automatically recharged and floated on charger. 4. Test Push Button: Push-to-test type, in unit housing, simulates loss of normal power and demonstrates unit operability. 5. LED Indicator Light: Indicates normal power on. Normal glow indicated trickle charge; bright glow indicates charging at end of discharge cycle. 2.10 FLUORESCENT LAMPS A. T8 rapid-start lamps, rated 32 W maximum, nominal length of 48 inches, 28000 initial lumens (minimum), CRI 75 (minimum), color temperature 3500 K, and average rated life 20,000 hours unless otherwise indicated. B. Compact Fluorescent Lamps: 4-Pin, CRI 80 (minimum), color temperature 3500 K, average rated life of 10,000 hours at three hours operation per start unless otherwise indicated. 1. 26 W: T4 double or triple tube, rated 1800 initial lumens (minimum). 2.11 HID LAMPS A. Ceramic, Pulse-Start, Metal-Halide Lamps: Minimum CRI 80, and color temperature 4000K. 2.12 LIGHTING FIXTURE SUPPORT COMPONENTS A. Comply with Division 26 Section “Hangers and Supports for Electrical Systems” for channel- and angle-iron supports and nonmetallic channel and angle supports. B. Single-Stem Hangers: 1/2-inch steel tubing with swivel ball fittings and ceiling canopy. Finish same as fixture. C. Twin-Stem Hangers: Two, 1/2-inch steel tubes with single canopy designed to mount a single fixture. Finish same as fixture. D. Rod Hangers: 3/16-inch minimum diameter, cadmium-plated, threaded steel rod. Project No. 18088080 7 Section 26 51 00 Lake Lewisville WTP Dewatering Improvements Interior Lighting PART 3 - EXECUTION 3.1 INSTALLATION A. Lighting fixtures: 1. Set level, plumb, and square with ceilings and walls unless otherwise indicated. 2. Install lamps in each luminaire. B. Temporary Lighting: If it is necessary, and approved by Engineer, to use permanent luminaires for temporary lighting, install and energize the minimum number of luminiaires necessary. When construction is sufficiently complete, remove the temporary luminaires, disassemble, clean thoroughly, install new lamps and reinstall. C. Suspended Lighting Fixture Support: 1. Pendants and Rods: Where longer than 48 inches, brace to limit swinging. 2. Stem-Mounted, Single-Unit Fixtures: suspend with twin-stem hangers. 3. Continuous Rows: Use tubing or stem for wiring at one point and tubing or rod for suspension for each unit length of fixture chassis, including one at each end. 4. Do not use grid as support for pendant luminaires. Connect support wires or rods to building structure. D. Connect wiring according to Division 26 Section “Low-Voltage Electrical Power Conductors and Cables.” 3.2 IDENTIFICATION A. Install labels with panel and circuit numbers on concealed junction and outlet boxes. Comply with requirements for identification specified in Division 26 Section “Identification for Electrical Systems.” 3.3 FIELD QUALITY CONTROL A. Test for Emergency Lighting: Interrupt power supply to demonstrate proper operation. Verify transfer from normal power to battery and retransfer to normal. B. Prepare a written report of tests, inspections, observations and verifications indicating and interpreting results. If adjustments are made to lighting system, retest to demonstrate compliance with standards. 3.4 STARTUP SERVICE A. Burn-in all lamps that require specific aging period to operate properly, prior to occupancy by owner. Burn-in fluorescent and compact fluorescent lamps intended to be dimmed, for at least 100 hours at full voltage. 3.5 ADJUSTING A. Adjust aimable luminaires in the presence of Owner and Engineer. END OF SECTION Project No. 18088080 1 Section 26 56 00 Lake Lewisville WTP Dewatering Improvements Exterior Lighting SECTION 26 56 00 - EXTERIOR LIGHTING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Exterior luminaires with lamps and ballasts. 2. Luminarie-mounted photoelectric relays. 3. Poles and accessories. B. Related Sections: 1. Division 26 Section “Interior Lighting” for exterior luminaires normally mounted on exterior surfaces of buildings. 1.2 DEFINITIONS A. CCT: Correlated color temperature. B. CRI: Color-rendering index. C. HID: High-intensity discharge. D. LER: Luminaire efficacy rating. E. Luminaire: Complete lighting fixture, including ballast housing if provided. F. Pole: Luminaire support structure, including tower used for larger area illumination. G. Standard: Same definition as “Pole” above. 1.3 SUBMITTALS A. Product Data: For each luminaire, pole, and support component, arranged in order of lighting unit designation. Include data on features, accessories, finishes and the following: 1. Physical description of luminaire, including materials, dimensions, effective projected area, and verification of indicated parameters. 2. Details of attaching luminaires and accessories. 3. Details of installation and construction. 4. Luminaire materials. 5. Photometric data based on laboratory tests of each luminaire type, complete with indicated lamps, ballasts and accessories. a. Manufacturer Certified Data: Photometric data shall be certified by manufacturer’s laboratory with a current accreditation under the National Voluntary Laboratory Accreditation Program for Energy Efficient Lighting Products. 6. Photoelectric relays. 7. Ballasts, including energy-efficiency data. 8. Lamps, including life, output, CCT, CRI, lumens and energy-efficiency data. 9. Materials, dimensions and finishes of poles. 10. Means of attaching luminaires to supports, and indication that attachment is suitable for components involved. 11. Anchor bolts for poles. B. Shop Drawings: Include plans, elevations sections, details and attachments to other work. Project No. 18088080 2 Section 26 56 00 Lake Lewisville WTP Dewatering Improvements Exterior Lighting 1. Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components and location and size of each field connection. 2. Anchor-bolt templates keyed to specific poles and certified by manufacturer. 3. Wiring Diagrams: for power, signal, and control wiring. C. Qualification Data: for qualified agencies providing photometric data for lighting fixtures. D. Field quality-control reports. E. Operation and Maintenance Data: For luminaires and poles to include in emergency, operation and maintenance manuals. F. Warranty: Sample of special warranty. 1.4 QUALITY ASSURANCE A. Luminaire Photometric Data Testing laboratory Qualifications: Provided by an independent agency, with the experience and capability to conduct the testing indicated, that is an NRTL as defined by OSHA in 29 CFR 1910. 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 IEEE C2, “National Electrical Safety Code.” D. Comply with NFPA 70. 1.5 DELIVERY, STORAGE, AND HANDLING A. Package aluminum poles for shipping according to ASTM B 660. 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. 1.6 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 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 three years from date of Substantial Completion. 1.7 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. Project No. 18088080 3 Section 26 56 00 Lake Lewisville WTP Dewatering Improvements Exterior Lighting 1. Lamps: One for every 10 of each type and rating installed. Furnish at least one of each type. 2. Glass and Plastic Lenses, Covers and Other Optical Parts: One for every 100 of each type and rating installed. Furnish at least one of each type. 3. Ballasts: One for every 10 of each type and rating installed. Furnish at least one of each type. 4. Gloves and Guards: One for every 20 of each type and rating installed. Furnish at least one of each type. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Products: Subject to compliance with requirements, available products that may be incorporated into the work include, but are not limited to, product(s) indicated on Drawings. B. Substitutions: 1. Provide complete literature for each luminaire substitution: 2. Submittals for substituted luminaires shall be sufficient for competent comparison of the proposed luminaire to the originally specified luminaire: a. Photometric data: 1) IES file in standard IES format. 2) Coefficient of utilization tables based on the IES zonal cavity system by an approved testing laboratory. 3) Candlepower distribution curves. 4) Average luminaire brightness. 5) Lumen output charts. 6) Power requirements in watts and volt-amperes. b. Calculations: 1) Provide software generated calculations showing illuminance levels in footcandles and power usage in watts per square foot for each of the areas in which substitutions are proposed: a) Use surface reflectance values and luminaire light loss factors approved by the ENGINEER to perform all calculations. 3. Substitutions for specified luminaires will be evaluated upon quality of construction, light distribution, energy use, appearance, and maintenance. 4. Substitutions shall comply with all applicable building codes. 2.2 GENERAL REQUIREMENTS FOR LUMINAIRES A. Luminaires shall comply with UL 1598 and be listed and labeled for installation in wet locations by an NRTL acceptable to authorities having jurisdiction. B. Lateral Light Distribution Patterns: Comply with IESNA RP-8 for parameters of lateral light distribution patterns indicated for luminaires. C. Metal Parts: Free of burrs and sharp corners and edges. D. Sheet Metal Components: corrosion-resistant aluminum unless otherwise indicated. Form and support to prevent warping and sagging. E. Housings: Rigidly formed, weather- and light-tight enclosures that will not warp, sag or deform in use. Provide filter/breather for enclosed luminaires. Project No. 18088080 4 Section 26 56 00 Lake Lewisville WTP Dewatering Improvements Exterior Lighting F. Doors, Frames, and other Internal Access: Smooth operating, free of light leakage under operating conditions, and designed to permit relamping without use of tools. Designed to prevent doors, frames, lenses, diffusers, and other components from falling accidentally during relamping and when secured in operating position. Doors shall be removable for cleaning or replacing lenses. Designed to disconnect ballast when door opens. G. Exposed Hardware Material: Stainless steel. H. Plastic Parts: High resistance to yellowing and other changes due to aging, exposure to heat, and UV radiation. I. Reflecting surfaces shall have minimum reflectance as follows unless otherwise indicated: 1. White Surfaces: 85 percent. 2. Specular Surfaces: 83 percent 3. Diffusing specular Surfaces: 75 percent. J. Lenses and Refractors Gaskets: Use heat- and aging-resistant resilient gaskets to seal and cushion lenses and refractors in luminaire doors. K. Luminaire Finish: Manufacturer’s standard paint applied to factory-assembled and test luminaire before shipping. Where indicated, match finish process and color of pole or support materials. L. Factory-Applied Finish for Steel Luminaires: Comply with NAAMM’s “Metal Finishes Manual for Architectural and Metal Products” for recommendations for applying and designating finishes. 1. Surface Preparation: Clean surfaces to comply with SSPC-SP 1, “Solvent Cleaning,” to remove dirt, oil, grease, and other contaminants that could impair paint bond. Grind welds and polish surfaces to a smooth, even finish. Remove mill scale and rust, if present, from uncoated steel, complying with SSPC-SP 5/NACE No. 1, “White Metal Blast Cleaning,” or SSPC-SP 8, “Pickling.” 2. Exterior Surfaces: Manufacturer’s standard finish consisting of one or more coats of primer and two finish coats of high-gloss, high-build polyurethane enamel. a. Color: As selected by Engineer from manufacturer’s full range. M. Factory-Applied Finish for aluminum Luninaires: comply with NAAMM’s “Metal finishes Manual for Architectural and Metal Products” for recommendations for applying and designating finishes. 1. Finish designations prefixed by AA comply with the system established by the Aluminum Association for designating aluminum finishes. 2. Class 1, Color Anodic Finish: AA-M32C22A42/A44 (Mechanical Finish: medium satin; Chemical Finish: etched, medium matte; Anodic Coating: Engineerural Class I, integrally colored or electrolytically deposited color coating 0.018 mm or thicker) complying with AAMA 611. N. Factory-Applied Labels: Comply with UL 1598. Include recommended lamps and ballasts. Labels shall be located where they will be readily visible to service personnel, but not seen from normal viewing angles when lamps are in place. 1. Label shall include the following lamp and ballast characteristics: a. “USES ONLY” and include specific lamp type. b. Lamp diameter code (T-4, T-5, T-8, T-12), tube configuration (twin, quad, triple), base type, and nominal wattage for fluorescent and compact fluorescent luminaires. c. Lamp type, wattage, bulb type (ED17, BD56, etc.) and coating (clear or coated) for HID luminaires. d. Start type (preheat, rapid start, instant start) for fluorescent and compact fluorescent luminaires. e. ANSI ballast type (M98, M57, etc.) for HID luminaires. Project No. 18088080 5 Section 26 56 00 Lake Lewisville WTP Dewatering Improvements Exterior Lighting f. CCT and CRI for all luminaires. 2.3 LUMINAIRE-MOUNTED PHOTOELECTRIC RELAYS A. Comply with UL 773 or UL 773A. B. Contact Relays: Factory mounted, single throw, designed to fail in the on position, and factory set to turn light unit on at 1.5 to 3 fc and off at 4.5 to 10 fc with 15-second minimum time delay. Relay shall have directional lens in front of photocell to prevent artificial light sources from causing false turnoff. 1. Relay with locking-type receptacle shall comply with ANSI C136.10. 2. Adjustable window slide for adjusting on-off set points. 2.4 BALLASTS FOR HID LAMPS A. Comply with ANSI C82.4 and UL 1029 and capable of open-circuit operation without reduction of average lamp life. Include the following features unless otherwise indicated: 1. Ballast Circuit: Constant-wattage autotransformer or regulating high-power-factor type. 2. Minimum Starting Temperature: Minus 22 deg. F. 3. Normal Ambient Operating Temperature: 104 deg F. 4. Ballast Fuses: One in each ungrounded power supply conductor. Voltage and current ratings as recommended by ballast manufacturer. 2.5 HID LAMPS A. Metal-Halide Lamps: ANSI C78.43, with minimum CRI 65 Insert value, and CCT color temperature 4000 K. 2.6 GENERAL REQUIREMENTS FOR POLES AND SUPPORT COMPONENTS A. Structural Characteristics: Comply with AASHTO LTS-4-M. 1. Wind-Load Strength of Poles: Adequate at indicated heights above grade without failure, permanent deflection, or whipping in steady winds of speed. 2. Strength Analysis: for each pole, multiply the actual equivalent projected area of luminaires and brackets by a factor of 1.1 to obtain the equivalent projected area to be used in pole selection strength analysis. B. Luminaire Attachment Provisions: Comply with luminaire manufacturers’ mounting requirements. Use stainless-steel fasteners and mounting bolts unless otherwise indicated. C. Mountings, Fasteners and Appurtenances: Corrosion-resistant items compatible with support components. 1. Materials: shall not cause galvanic action at contact points. 2. Anchor Bolts, Leveling Nuts, Bolt Caps, and washers: Stainless steel unless otherwise indicated. 3. Anchor-bolt Template: Plywood or steel. D. Handhole: Oval-shaped, with minimum clear opening of 2-1/2 by 5 inches, with cover secured by stainless-steel captive screws. Provide on all poles. E. Concrete Pole Foundations: Cast in place, with anchor bolts to match pole-base flange. Project No. 18088080 6 Section 26 56 00 Lake Lewisville WTP Dewatering Improvements Exterior Lighting 2.7 ALUMINUM POLES A. Poles: Seamless, extruded structural tube complying with STM B429/B 429M, alloy 6063-T6 with access handhole in pole wall. B. Poles: ASTM B209, 5052-H34 marine sheet alloy with access handhole in pole wall. 1. Shape: Round, tapered Round, straight Square, tapered Square, straight. 2. Mounting Provisions: Butt flange for bolted mounting on foundation or breakaway support. C. Pole-Top Tenons: Fabricated to support luminaire or luminaires and brackets indicated, and securely fastened to pole top. D. Grounding and Bonding Lugs: Welded ½-inch threaded lug, complying with requirements in Division 26 Section “Grounding and Bonding for Electrical Systems,” listed for attaching grounding and bonding conductors of type and size listed in that Section, and accessible through handhole. E. Brackets for Luminaires: Detachable, with pole and adapter fittings of cast aluminum. Adapter fitting welded to pole and bracket, then bolted together with stainless-steel bolts. 1. Tapered oval cross section, with straight tubular end section to accommodate luminaire. 2. Finish: Same as pole and luminaire. F. Aluminum Finish: Comply with NAAMM’s “Metal Finishes Manual for Architectural and Metal Products” for recommendations for applying and designating finishes. 1. Finish designations prefixed by AA comply with the system established by the aluminum Association for designating aluminum finishes. 2. Class 1, Color Anodic Finish: AA-M32C22A42/A44 (Mechanical Finish: medium satin; Chemical Finish: etched, medium matte; Anodic Coating: Engineerural Class I, integrally colored or electrolytically deposited color coating 0.018 mm or thicker) complying with AAMA 611. a. Color: As selected by Engineer from manufacturer’s full range. 2.8 POLE ACCESSORIES A. Base Covers: Manufacturers’ standard metal units, arranged to cover pole’s mounting bolts and nuts. Finish same as pole. PART 3 - EXECUTION 3.1 LUMINAIRE INSTALLATION A. Install lamps in each luminaire. B. Fasten luminaire to indicated structural supports. C. Adjust luminaires that require field adjustment or aiming. Include adjustment of photoelectric device to prevent false operation of relay by artificial light sources, favoring a north orientation. 3.2 POLE INSTALLATION A. Alignment: Align pole foundations and poles for optimum directional alignment of luminaires and their mounting provisions on the pole. B. Clearances: Maintain the following minimum horizontal distances of poles from surface and underground features unless otherwise indicated on Drawings: Project No. 18088080 7 Section 26 56 00 Lake Lewisville WTP Dewatering Improvements Exterior Lighting 1. Fire Hydrants and Storm Drainage Piping: 60 inches. 2. Water, Gas, Electric, Communication, and Sewer Lines: 10 feet. 3. Trees: 15 feet from tree trunk. C. Concrete Pole Foundations: Set anchor bolts according to anchor-bolt templates furnished by pole manufacturer. D. Foundation-Mounted Poles: Mount pole with leveling nuts, and tighten top nuts to torque level recommended by pole manufacturer. 1. Grout void between pole base and foundation. Use nonshrink or expanding concrete grout firmly packed to fill space. 2. Install base covers unless otherwise indicated. 3. Use a short piece of ½ inch diameter pipe to make a drain hole through grout. Arrange to drain condensation from interior of pole. E. Raise and set poles using web fabric slings (not chain or cable). 3.3 CORROSION PREVENTION A. Aluminum: Do not use in contact with earth or concrete. When in direct contact with a dissimilar metal, protect aluminum by insulating fittings or treatment. B. Steel Conduits: Comply with Division 26 Section “Raceway and Boxes for Electrical Systems.” In concrete foundations, wrap conduit with 0.010-inch-thick, pipe-wrapping plastic tape applied with a 50 percent overlap. 3.4 GROUNDING A. Ground metal poles and support structures according to Division 26 Section “Grounding and Bonding for Electrical Systems.” 1. Install grounding electrode for each pole unless otherwise indicated. 2. Install grounding conductor pigtail in the base for connecting luminaire to grounding system. B. Ground nonmetallic poles and support structures according to Division 26 Section “Grounding and Bonding for Electrical Systems.” 1. Install grounding electrode for each pole. 2. Install grounding conductor and conductor protector. 3. Ground metallic components of pole accessories and foundations. 3.5 FIELD QUALITY CONTROL A. Inspect each installed fixture for damage. Replace damaged fixtures and components. B. Illumination Observations: Verify normal operation of lighting units after installing luminaires and energizing circuits with normal power source. 1. Verify operation of photoelectric controls. C. Prepare a written report of tests, inspections, observations, and verifications indicating and interpreting results. If adjustments are made to lighting system, retest to demonstrate compliance with standards. Project No. 18088080 8 Section 26 56 00 Lake Lewisville WTP Dewatering Improvements Exterior Lighting 3.6 DEMONSTRATION A. Train Owner’s maintenance personnel to adjust, operate and maintain luminaire lowering devices. END OF SECTION Project No. 18088080 1 Section 26 67 05 Lake Lewisville WTP Dewatering Improvements Communication Cable & Equipment SECTION 26 67 05 - COMMUNICATION CABLE AND EQUIPMENT PART 1 - GENERAL 1.1 SUMMARY A. Section includes the following wiring system components: 1. Communication cable. 1.2 SYSTEM DESCRIPTION A. Ethernet cabling. B. Instrumentation cable. 1.3 SUBMITTALS A. Procedures for submittals. 1. Product Data: Provide for each material or equipment item specified. 2. Shop Drawings: a. Point-to-point wiring diagrams for cables installed under this Section. b. Detailed plan views and elevations of telecommunications spaces showing termination equipment, and cable paths. c. Minimum Scale for Details: 1/4 inch. 3. Termination Schedule: Indicate the following. a. Cable identification number. b. Room location. 4. Assurance/Control Submittals: a. Certificates: Manufacturer's certificate that Products meet or exceed specified requirements. b. Qualification Documentation: Submit documentation of experience indicating compliance with specified qualification requirements. B. Procedures for closeout submittals. Deliver prior to Final Acceptance. 1. Certification: Comprehensive test results for category 6, and fiber optic certification of cable plant per specifications of TIA/EIA 568A. Test results must be provided on 8.5 X 11 inch sheets of paper, and furnished in electronic PDF format. 2. Project Record Documents: Accurately record the following: a. Cable pulling schedules, in printed form and on CD-R data disks. b. Labeling shall conform to the ANSI/TIA/EIA-606 guidelines. 1.4 QUALITY ASSURANCE A. Qualifications: 1. Manufacturer: Company specializing in manufacturing Products specified with minimum 5 years documented experience. 2. Installer: Company specializing in the installation of category 6, and fiber optic structured wiring systems with minimum 5 years documented experience. Contractor shall have a minimum of one person on job site at all times with documented formal training in the installation of category 6, and fiber optic cabling systems if fiber optic cabling is required. B. Regulatory Requirements: 1. Conform to requirements of NFPA 70. 2. Products: Listed and classified by Underwriter's Laboratories Incorporated as suitable for the purpose specified and indicated. Project No. 18088080 2 Section 26 67 05 Lake Lewisville WTP Dewatering Improvements Communication Cable & Equipment C. Pre-Installation Meetings: 1. Convene a pre-installation meeting one week prior to commencing Work of this Section. 2. Require attendance of parties directly affecting Work of this Section. 3. Review conditions of operations, procedures and coordination with related work. 4. Agenda: a. Tour, inspect, and discuss conditions relating to communications cable. b. Review exact location of each item within building construction, casework, and fixtures and their requirements. c. Review required submittals, both completed and yet to be completed. d. Review Drawings and Specifications. e. Review and finalize construction schedule and verify availability of materials, personnel, equipment, and facilities needed to make progress and avoid delays. f. Review cable routing and support. 1.5 DELIVERY, STORAGE, AND HANDLING A. Transport, handle, store, and protect products. B. Deliver in accordance with NEMA WC 26. 1.6 REFERENCES A. Telecommunication Industry Association (TIA), Electronic Industries Association (EIA): 1. TIA/EIA-568-A - Commercial Building Telecommunications Cabling Standard 2. TIA/EIA-569 - Commercial Building Standard for Telecommunications Pathways 3. TIA/EIA-606 - Administration Standard for the Telecommunications Wiring Standard 4. TIA/EIA-607 - Commercial Building Grounding and Bonding Requirements for Telecommunications B. National Electrical Manufacturer's Association (NEMA): 1. NEMA WC 26 - Wire and Cable Packaging. C. National Fire Protection Association (NFPA): 1. NFPA 70 - National Electrical Code. PART 2 - PRODUCTS 2.1 PATCH CORDS A. Subject to compliance with project requirements, manufacturer's offering products which may be incorporated in the Work include the following: 1. AMP Incorporated. 2. Interlink Technologies. 3. Lucent Technologies. 4. NORDX/CDT, Incorporated. 5. Siemon Company. 6. Or Equal. B. Conductors: Straight through type 4 twisted pair - 24 AWG, stranded copper. 1. Terminated with male 8-pin modular plugs. 2. Complies with individual characteristics established in TIA for category 6a cable performance specification. Project No. 18088080 3 Section 26 67 05 Lake Lewisville WTP Dewatering Improvements Communication Cable & Equipment 2.2 INSTRUMENTATION CABLE A. Subject to compliance with project requirements, manufacturer’s offering products which may be incorporated in the work include: 1. Belden 2. Approved equal. B. Conductors: For all 4-20mA signals, use 18 AWG stranded tinned copper, two pair minimum, wet location rated. 1. Individually shielded with shield drain wire. 2. Insulation to be polyethylene PE or PVC. 3. Outer jacket to be polyvinyl chloride PVC. PART 3 - EXECUTION 3.1 EXAMINATION A. Verify existing conditions before starting work. B. Report in writing to the Engineer prevailing conditions that will adversely affect satisfactory execution of the Work of this Section. Do not proceed with Work until unsatisfactory conditions have been corrected. C. By beginning Work, Contractor accepts conditions and assumes responsibility for correcting unsuitable conditions encountered at no additional cost to the Owner. 3.2 INSTALLATION A. Cross electrical cables with communications cable at 90 degrees only. B. Run communication cables and power cables in separate conduits and separate pull boxes. C. Comply with cable manufacturers minimum bend radius requirements. 1. Do not stretch, stress, tightly coil, bend or crimp cables. 2. Replace cables that are severely stressed during installation at no additional cost to Owner. D. Furnish and install machine generated labels. 1. Communications Cables: a. Display cable identification number in black uppercase lettering on permanent adhesive white label stock covered with water resistant sealer. b. Place labels on each end of cable, maximum 6 inches from cable termination. 3.3 CONSTRUCTION A. Interface with Other Work: 1. Provide information to affected trades regarding requirements and responsibilities for preparation of Work of a particular trade for installation of Work installed under this Section. 3.4 FIELD QUALITY CONTROL A. Field testing and inspection. B. Inspect installation of cables and equipment during and at completion of installation. Project No. 18088080 4 Section 26 67 05 Lake Lewisville WTP Dewatering Improvements Communication Cable & Equipment C. Perform end-to-end tests of each cable as follows: 1. Pair/conductor for proper pinouts and continuity. 2. Ground fault. 3. Proper termination, shorts, and crossed pairs. 4. Channel attenuation per ANSI/TIA/EIA-568-A, Annex E or later. 5. Channel bi-directional worst case near end cross talk (NEXT) at frequencies up to 100 MHz, per ANSI/TIA/EIA-568-A, Annex E or later. 6. Measured effective cable run length. END OF SECTION Project No. 18088080 1 Section 26 70 00 Lake Lewisville WTP Dewatering Improvements Video Surveillance SECTION 26 70 00 – VIDEO SURVEILLANCE PART 1 - GENERAL 1.1 SUMMARY A. The work to be included under this section shall consist of furnishing all materials, labor, equipment, tools, supplies, and incidentals necessary for the installation and testing of all video surveillance systems for the new dewatering building. Provided systems shall match the equipment installed at similar buildings at the Lake Lewisville facility. Coordinate desired surveillance features with the Owner. B. The electrical contractor shall be responsible for providing all conduit runs from proposed camera locations to the network switch location. 1.2 PROVIDERS A. All video surveillance camera installation, configuration, and testing shall be performed by STS360. Contact John Paul Hoffman, john@sts360.com, 214-427-5566. B. All cabling from cameras to the network switch shall be provided and installed by TDataCom. END OF SECTION Project No. 18088080 1 Section 26 80 00 Lake Lewisville WTP Dewatering Improvements Access Control SECTION 26 80 00 – ACCESS CONTROL PART 1 - GENERAL 1.1 SUMMARY A. The work to be included under this section shall consist of furnishing all materials, labor, equipment, tools, supplies, and incidentals necessary for the installation and testing of all access control systems for the new dewatering building. Provided systems shall match the equipment installed at similar buildings at the Lake Lewisville facility. Coordinate desired access control features with the Owner. B. The electrical contractor shall be responsible for providing all conduit runs required for access control devices. 1.2 PROVIDERS A. All access control work shall be performed by American Business Electronics Inc. Contact Roy Riedinger, accessroy@theabecorp.com, 972-620-7667. 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IUHHRIGHIHFWVLQPDWHULDOVDQGZRUNPDQVKLSIRUDSHULRGRIWZR\HDUVIURPDQGDIWHU WKHGDWHRIILQDODFFHSWDQFHRIWKHZRUNE\WKH2ZQHUDQGDQ\VXFKGHIHFWVZKLFKDSSHDU ZLWKLQWKHVWLSXODWHGJXDUDQW\SHULRGVKDOOEHUHSDLUHGUHSODFHGRUPDGHJRRGZLWKRXW FKDUJH 7KLV JXDUDQWHH VKDOO LQFOXGH WKH FDSDFLW\ DQG LQWHJUDWHG SHUIRUPDQFH RI WKH FRPSRQHQW VSDUWV (1'2)6(&7,21 Project No. 18088080 1 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments SECTION 26 90 10 – PROCESS AND ANALYTICAL INSTRUMENTS PART 1 - GENERAL 1.1 SUMMARY A. The work to be included under this section of the Specifications shall consist of furnishing all materials, labor, equipment, tools, supplies, and incidentals for installation of all instrumentation equipment. The work shall include every item of construction necessary for a complete and acceptable installation as shown on the Drawings and as specified herein. B. Related Sections: 1. 26 90 00 - General Instrumentation and Control 2. 26 90 20 – PLC Control Panels 3. 26 90 35 – PLC and HMI Programming 4. 26 90 40 – Process Control Descriptions 1.2 REFERENCES A. ISA S20 - Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves B. ISA S50.1 - Compatibility of Analog Signals for Electronic Industrial Process Instruments C. ISA S51.1 - Process Instrumentation Terminology D. ISA S51.1; Sec. 5 - Test Procedures E. Definitions: Symbols, Definitions, and Abbreviations: All symbols, definitions, and engineering unit abbreviations utilized shall conform to IEEE 100-84, S50.1, and S51.1, where applicable. 1. SCADA – Supervisory Control and Data Acquisition 2. HMI – Human Machine Interface 3. VFD – Variable Frequency Drive 4. PLC – Programmable Logic Controller 5. SSRVS – Solid State Reduced Voltage Starter (“Soft Starter”) 6. I/O – Input/Output 7. OIT – Operator Interface Terminal 8. RTU – Remote Telemetry Unit 9. MTU – Master Telemetry Unit 10. N.O. – Normally Open 11. N.C. – Normally Closed 1.3 SCOPE A. This section of the Specifications covers the instrumentation equipment. The major items of instrumentation equipment to be furnished and installed shall include the following: 1. Magnetic Flow Indicating Transmitters 2. Pressure Gauges 3. Pressure Switches 4. Pressure Indicating Transmitters 5. Float Switches 6. Weight Scales Project No. 18088080 2 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments 1.4 SYSTEM REQUIREMENTS A. Design Requirements: 1. Provide analog field instruments with transmitters which condition the signal to output a 4-20 mA signal linear to the measured variable. 2. Similar instruments shall be by the same Manufacturer to the extent practical. B. Performance Requirements: 1. Accuracy: a. Accuracy shall be as defined in ISA S51.1 and ISA S51.1, Sec. 5. Provide a complete and operating instrument installation with measurement accuracy determined by adding the accuracy of the element and the transmitter and any wiring to the field terminal enclosure of 0.75% of calibrated span or better, unless specified otherwise below, at any environmental condition specified. 2. Ranges: a. The expected range of each instrument shall be as directed by the Owner and Engineer. Expected ranges shall correspond to actual field conditions. PART 2 - PRODUCTS 2.1 EQUIPMENT A. Furnish instruments specified in the instrument specification sheets at the end of this section. Instruments for services not listed shall be equal in quality, performance, and environmental and functional characteristics as instruments listed and shall be approved in writing by the Owner. 2.2 INSTRUMENT ACCESSORIES A. Instrument and Control Device Tags: Each field mounted field device shall be identified by its unique tag number as it appears on the original P&I diagrams and the Instrument Loop Diagram. The tag number shall be stamped on a 1" x 2" stainless steel tag permanently attached to the instrument by braided stainless steel wire which has been sealed by an approved method such that the wire must be cut or the seal broken to remove the tag. The tag number shall not be stamped on the nameplate of the instrument. This requirement shall be documented on the Instrumentation Specification Sheet. B. Sunshades: Furnish stainless steel sunshades for all outdoor instruments not shaded by adjacent or integral equipment. C. Process Tubing: Stainless Steel, ASTM A 269, TP316, seamless, annealed, 1/2" x 0.065" W.T. minimum. D. Pneumatic Supply Tubing: Stainless Steel, ASTM A 269, TP316, seamless, annealed, 1/2" x 0.065" W.T., 3/8" x 0.049" W.T. and 1/4" x 0.035" W.T. minimum. E. Fittings: 316 Stainless Steel ferrule type, SWAGELOCK or equal. F. Pipe Stand Type Supports for Instrumentation: Pipe stands shall be stainless steel using welded fabrications with 2” schedule 40 pipe, 2” square tube x 0.188” thick, 3/8 zinc/cadmium plated hardware, 1/2” expansion anchors, 12 gauge mounting channel and 1/4” thick stainless steel plate as a minimums. Supply u-bolts or cable mounts as necessary. Acceptable alternatives include engineered pipe stand systems such as O'Brien Saddlepak. G. Enclosures for outdoor locations: Furnish and install NEMA 4X enclosures. All outdoor enclosures with instrumentation accessible in enclosure door shall have a stainless steel sunshade. Project No. 18088080 3 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments 2.3 CALIBRATION A. Order instruments factory calibrated to the range indicated with calibration sheets indicating certification of traceability to National Institute of Standards and Technology (NIST). Instruments shall be ranged as directed by Engineer. 2.4 FABRICATION A. Materials of Construction: Provide 316 Stainless Steel for wetted and other parts unless otherwise specified. PART 3 - EXECUTION 3.1 APPLICATION A. Installation 1. Install sensing elements at the point of measurement and route sensing line or cable to the transmitter. Install the transmitters 4'-6" above grade or platform in an easily accessible location adjacent to the sensor location. Mount on pipe stanchion or steel support designed for the purpose individually or grouped with other transmitters. Furnish and install surge protector Phoenix Contact PipeTrab 2818122 or equal in each 4-20 mA current loop, adjacent to each respective instrument. Route signal cable in conduit from transmitter to terminal cabinet or control panel for termination to test terminals. Steel supports shall be in accordance with this Section, and all other sections and specification requirements. Process connections for instrumentation shall be in accordance with piping sections and all other specification requirements. Provide block valves at taps for pressure or sampling sensor lines. Provide plugged tees at taps suitable for rodding or blowing out taps. Make pipe taps with weld-o-let type fittings or equal. Install block valves suitable for the service and rated as the pipe at each tap, generally use NPT threaded ball valves. Use materials rated for the service and transition to tubing for sensor runs. Use 1/2” OD 316 SS tubing or as shown on the Drawing details. B. Flow Instruments: Mount magnetic flowmeters according to manufacturer's instructions with any reducers necessary. Install grounding rings and ground magnetic flowmeters according to manufacturer's instructions. C. Pressure Instruments: Make pressure taps in top of pipe for gas service and side of pipe for liquid or steam service. D. Pressure Gauges: Use 1/2" NPT pipe and ball or needle valve for pressure gauge taps. Mount gauges vertically; provide 90° fitting, seal, snubber or siphon tube as required. Where 90° fitting is required, install a tee-fitting with plug. E. Differential pressure and level transmitters: Use 1/2" tubing and ball or needle valves for pressure taps. Slope tubing runs 1" per foot to drain the sensing line to the pipe where the transmitter is higher than the tap and to drain the line to the transmitter where the transmitter is lower than the tap. At the transmitter connection provide a valve manifold that can block, bleed, vent, purge and provide calibration ports to the transmitter. For gas service transmitters, route 1/2" tubing straight up from the tap for a minimum of 12" to a high point in the line, then with a minimum slope of 1" per foot to the transmitter connection. Provide an automatic condensate drain at the transmitter. F. Temperature instruments: Generally mount thermocouple assemblies in the side of the pipe at a minimum angle of 15° up from horizontal and route thermocouple or RTD cable to the transmitter Project No. 18088080 4 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments in conduit. Do not mount thermocouples absolutely horizontal or at angles below horizontal. Provide adequate clearance for removal of head assembly and extraction of sensor. G. pH elements: For pH elements mounted in sample lines, mount according to Manufacturer's instructions in an insertion assembly which permits removal of the element while the process line is pressurized. Mount with the element vertical and in a trap to keep electrodes hydrated. Arrange taps and sensor lines to keep flow velocity at sensor below 10 ft. / sec. 1. Mount all instrumentation according to manufacturer's instructions except as specified. H. Tubing and Fittings: 1. Install tubing and fittings in a neat, orderly and functional manner; level and plumb except as required, noted on approved drawings, or specified. Make offsets required for fittings or equipment level in the horizontal plane to prevent high or low spots. I. Conduit and fittings: 1. Install conduit as required. Provide a cast body tee fitting at the instrument connections at the low point of all conduit runs below the instrument with a drain fitting for condensate. Make connections from instrument to tee with liquid-tight flexible conduit and use sealing compound inside the conduit and shrink-fit tubing over the outside of the connection to prevent entry of water into the instrument. Heat trace and insulate all liquid filled lines and the sensing body of all instruments connected to liquid service in exterior locations. J. Calibration: Calibrate each and every instrument connected to the work of this contract in its range, whether furnished under this contract, owner-furnished or existing and fill out a signed and dated five point calibration sheet and install an initialed and dated calibration sticker. Notify the Owner in writing immediately of any instrument which will not calibrate. Instruments that do not calibrate will require the on-site services of a factory authorized representative at no cost to the Owner. INSTRUMENT SPECIFICATION SHEETS: Project No. 18088080 5 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments INSTRUMENT SPECIFICATION SHEET MAGNETIC FLOW METER Output 4-20 mA Hart , proportional to flow Power Supply 120 VAC, 1- phase, 60 Hz Environment Transmitter: -4 to +140 °F Sensor: +14 to +140 °F Enclosure Transmitter: Remote IP68 Sensor: IP68 Features Automatic zeroing Hard rubber or polyurethane non-conductive liner and liner protector Epoxy coated housing Display Integral LCD display Accuracy: +/- 0.2% Accessories Furnish all required equipment for complete and operational installation including, but not limited to, grounding rings, grounding electrodes, and flange connectors. Suppliers Endress+Houser Proline Promag 53W or approved equal Instrument Tag Application Measurement Range 771FIT01 Belt Press 1 sludge flow rate 771FIT02 Belt Press 2 sludge flow rate Project No. 18088080 6 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments INSTRUMENT SPECIFICATION SHEET PRESSURE SWITCH Operating Pressure Range Varies with application Pressure Connection Internal ¼” National Pipe Tapered Thread Compatibility Air, water Contact Material Gold plated AgCdO Power Supply 120 VAC Mounting See Drawings for location. Enclosure NEMA 4X (Minimum) FM Class I, DIV 01 as required. Seal Supply annular or diaphragm seal as required; if supplying separate units, the seal and switch shall be from the same manufacturer Pressure Gauge Supply as required; if supplying separate units, the gauge and switch shall be from the same manufacturer Suppliers Ashcroft or equal Instrument Tag Application Range 773PS01 Polymer system 1 discharge pressure switch 773PS02 Polymer system 2 discharge pressure switch Project No. 18088080 7 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments INSTRUMENT SPECIFICATION SHEET FLOAT SWITCH Features Float housing constructed of polypropylene; an epoxy encapsulated non-mercury switch with a minimum electrical rating of 10 amps (resistive load); UL listed Mounting See Drawings for location. Power Supply 120 VAC Suppliers Flygt ENM-10 or equal Instrument Tag Application 68LSLL02A WWEB Low level shutoff 68LSL02B WWEB Pump “OFF” 68LSM02C WWEB Duty pump “ON” 68LSH02D WWEB Standby pump “ON” 68LSHH02E WWEB High level alarm 69LSLL01 WWRB Low level 69LSHH02 WWRB High level INSTRUMENT SPECIFICATION SHEET Project No. 18088080 8 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments PRESSURE GAUGE Operating Pressure Range Varies with application Pressure Connection ¼” OR ½” National Pipe Tapered Thread Wetted Material Brass Mounting See Drawings for location. Suppliers Ashcroft Duragauge Model 1279/1379, Robert Shaw Acragage, or equal Instrument Tag Application Range 751PI01A Sludge Pump 1 Suction Pressure 751PI01B Sludge Pump 1 Discharge Pressure 751PI02A Sludge Pump 2 Suction Pressure 751PI02B Sludge Pump 2 Discharge Pressure 751PI03A Sludge Pump 3 Suction Pressure 751PI03B Sludge Pump 3 Discharge Pressure 772PI01 Plant Water RPZ Upstream Pressure 772PI02 Plant Water RPZ Downstream Pressure Project No. 18088080 9 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments INSTRUMENT SPECIFICATION SHEET TOTE WEIGHT SCALE Power Supply 120 VAC, 1-phase, 60 Hz Output 4-20 mA analog output scaled to application measurement range, two dry contacts actuated by separately programmable setpoints Platform Size As required. Measurement Range Adjustable up to 5000 lb Controller Scaletron 1020 5 digit controller. LED display scalable to display % full or gallons Suppliers Scaletron model 4040 or equal. Instrument Tag Application 773WIT01 Polymer Storage Tote #1 Level 773WIT02 Polymer Storage Tote #2 Level Project No. 18088080 10 Section 26 90 10 Lake Lewisville WTP Dewatering Improvements Process and Analytical Instruments INSTRUMENT SPECIFICATION SHEET PRESSURE INDICATING TRANSMITTER Output 4-20 mA, proportional to pressure Accuracy ±0.05% of span Operating Temperature 0 °F to 250 °F Process Connection ½” NPT Power Supply 24 VDC Suppliers Endress+Hauser PMC71 or equal Instrument Tag Application Range 772PIT01 Plant Water Discharge Header Pressure 0-200 PSIG END OF SECTION Project No. 18088080 1 Section 26 90 20 Lake Lewisville WTP Dewatering Improvements PLC Control Panels SECTION 26 90 20 – PLC CONTROL PANELS PART 1 - GENERAL 1.1 SUMMARY A. The work to be included under this section of the Specifications shall consist of furnishing all materials, labor, equipment, tools, supplies, and incidentals for installation of all programmable logic controller (PLC) and control panels. The work shall include every item of construction necessary for a complete and acceptable installation as shown on the Drawings and as specified herein. B. Related Sections: 1. Section 26 90 00 – General Instrumentation and Control 2. Section 26 90 10 – Process and Analytical Instruments 3. Section 26 90 30 – Computer System and Network 4. Section 26 90 35 – PLC and HMI Programming 5. Section 26 90 40 – Process Control Descriptions C. Manufacturer’s Support: The PLC system manufacturer shall maintain, as a part of a national network, engineering service facilities within 100 miles of the project, to provide start-up service, emergency service calls, repair work, service contracts, maintenance, and training. Emergency service shall be available within twenty-four hours of notification. 1.2 REFERENCES A. Definitions: Symbols, Definitions, and Abbreviations: All symbols, definitions, and engineering unit abbreviations utilized shall conform to IEEE 100-84, S50.1, and S51.1, where applicable. 1. SCADA – Supervisory Control and Data Acquisition 2. PLC – Programmable Logic Controller 3. RIO – Remote Input/Output chassis 4. HMI – Human Machine Interface 5. OIT – Operator Interface Terminal 6. I/O – Input/Output 7. MTU – Master Telemetry Unit 8. RTU – Remote Telemetry Unit 9. Operating Program – Operating system, SCADA or other core software 10. Integrated Operating Platform – System of installed, connected, and configured hardware, operating programs, and networking equipment 11. PLC and HMI Programming – Software configuration of operating programs to implement plant control strategies 1.3 SCOPE A. The following lists the control panels that are provided by the Control System Specialist as part of the control system at the facilities. 1. 77PLCCP01 PART 2 - PRODUCTS 2.1 MANUFACTURERS A. The following PLCs installed at the facility shall be Modicon M340: 1. 77PLC01 Project No. 18088080 2 Section 26 90 20 Lake Lewisville WTP Dewatering Improvements PLC Control Panels B. Other PLCs provided under this contract, including those furnished as part of vendor supplied equipment packages, shall be Modicon M340 as required for the application. 2.2 EQUIPMENT A. Programmable Logic Controllers 1. Each Modicon M340 PLC shall consist of the following basic components: a. Power supply module properly sized for the I/O load. b. M340 processor module suitable for executing all control functions. c. Integral communication ports as required for communication with the existing plant SCADA system. d. The following I/O modules as required for the application. 1) Analog Input Modules for 4-20mA signals 2) Analog Output Modules for 4-20mA signals 3) Digital Input Modules for 120VAC discrete signals 4) Digital Output Modules for 120VAC discrete signals 2. Provide I/O points as indicated in the drawings. 3. Each PLC shall be installed with a minimum of 20% spare I/O points of each type utilized in its I/O structure. 4. Each PLC shall have a removable nonvolatile memory card installed with capacity greater than or equal to processor internal memory. The controller shall be configured to load a copy of the program from nonvolatile memory whenever there is no project in the controller and power is applied. 5. The PLCs shall be capable of and shall be configured to provide stand-alone operation in the event of a communications link failure. 6. The necessary interface cables, communications cables, power cables, bus extension cables, modular card slot fillers, and other ancillary parts shall be furnished and installed as integral parts of the control system. 7. Nameplates shall be provided for each module, device, and other equipment with appropriate data such as the equipment number, rating, serial number, and manufacturer. 8. All I/O cards shall be furnished with removable terminal blocks to simplify card wiring and replacement. 9. The Contractor shall furnish the Owner the following spare replacement parts: a. One (1) Processor Module of each type b. Two (2) I/O modules of each type B. Panel Monitor 1. PLC control panel 77PLCCP01 shall be provided with a monitor mounted to the front of the panel, connected to the SCADA PC for interaction with the plant SCADA HMI. a. Industrial display for panel-mounted applications with touch interface. b. Minimum 19” diagonal color touchscreen. Coordinate aspect ratio and resolution to match existing plant SCADA workstation monitors. c. Display Input: HDMI, DVI, VGA C. PLC Control Panel Materials 1. Enclosures for indoor dry locations: Furnish and install NEMA 12 enclosures unless noted otherwise. 2. Enclosures for indoor wet locations: Furnish and install NEMA 4X stainless steel enclosures. 3. Enclosures for outdoor locations: Furnish and install NEMA 4X stainless steel enclosures. All outdoor enclosures with OITs or other indication devices shall have a stainless steel sun shade. D. PLC Control Panel Components – Each PLC control panel shall contain the following components: Project No. 18088080 3 Section 26 90 20 Lake Lewisville WTP Dewatering Improvements PLC Control Panels 1. Current Loop Surge Protection Devices: The 4-20mA signal loop channels on the PLC analog inputs and outputs shall be protected against static discharge, lightning, and faulty wiring with three stage surge protection terminal block devices. Devices shall be pluggable with indication status lights. Devices shall be PLUGTRAB series as manufactured by Phoenix Contact or equal. 2. Discrete Output Relays: Terminal block style interposing relays shall be used for all 120VAC PLC outputs. Devices shall be PLC-RSC-120UC/21 as manufactured by Phoenix Contact or equal. Provide pull-up or pull-down resistors on all digital outputs. 3. Current Loop Power Supplies: When required, the instrument transmitter shall be furnished with a separate power supply to provide the loop power for 2-wire instruments. The power supplies shall be DIN rail mounted, 120VAC input, 24VDC output, with output load rated as required for the instrument. Power supplies shall be provided by Phoenix Contact, Allen-Bradley, or Sola. 4. Terminal Strips and Accessories: Provide DIN rail mounted terminal strips including fused terminals with blown fuse indication, ground terminals and terminal groups for each incoming or outgoing device circuit including group tag identifying the device and identified terminals for each incoming or outgoing wire. Provide terminal end, partition and separation plates as required. Provide pre-engraved vinyl marking strips with terminal and group identification as shown on the submittal drawings. Provide group tags and terminals or as indicated on the drawings or equals. Do not splice control wires. Provide DIN rail mounted relay bases with LED coil indicators and arc suppression for plug-base relays. Identify each terminal with the wire designator from the wire number i.e. "+", "-", "SH", "NO", "NC", "COM", "L1", "N", etc. Provide 20% spare terminals and I.D. tags of each designation. Provide 20% spare connectors, fittings, wire ties, labels and markers of each type provided. 5. Wiring: Panel wiring shall comply with requirements of Division 26 specification sections “Low Voltage Electrical Power Conductors and Cables” and “Communication Cable and Equipment”. Wire colors inside the control panels shall comply with the following: a. BLACK – Incoming 120VAC power b. WHITE – Neutral c. GREEN – Ground d. RED – Switched 120VAC control power e. YELLOW – Foreign control voltage (power source external to panel) f. BLUE – 24VDC positive g. BLUE w/ WHITE STRIPE – 24VDC common 6. Relays: Provide relays as required to implement indicated control functions. General purpose, alternating and time delay relays may be used within their ratings for logic, timing and sequencing but shall not be used to drive loads in excess of 80% of their contact "make" or "break" ratings. Provide interposing power relays to drive loads such as starters larger than NEMA size 1 and all other utilization equipment with loads greater than specified for general purpose and time delay relays. Provide relays rated to drive the load as required. Relays shall be provided with an LED status indicator. a. General Purpose Relays: Provide tube-base relays rated 120VAC, DPDT or 3PDT, 10 Amp contacts rated to break inductive loads of 3 Amperes. Provide Allen-Bradley 700 Type HA, Potter Brumfield or as indicated on drawings or equal. Provide additional relays as required to obtain sufficient numbers of contacts. b. Time Delay Relays: Provide relays for which the time delay is based on the presence or absence of control voltage at the relay. Unless indicated otherwise, provide DIP switch programmable multifunction relays including time delay on energization, time delay on de-energization or one-shot timing as indicated. Provide continuous control power to the relay if required, whether indicated or not. The shop drawings shall reflect the actual proposed connection and timing diagram for the specific relays to be provided. Provide relays rated 120VAC, DPDT or 3PDT, 10 Amp contacts rated to break inductive loads of 3 Amperes. Provide tube-base relays as manufactured by SSAC or equal. Project No. 18088080 4 Section 26 90 20 Lake Lewisville WTP Dewatering Improvements PLC Control Panels c. Power Relays: Provide heavy-duty solenoid type relays with contacts rated not less than 10 amperes continuous at 300 volts AC. Provide a minimum of four reversible poles or four universal or double-throw poles. Relays shall be type 700N as manufactured by Allen-Bradley or equal. 7. Grounding: Each panel shall be provided with a copper equipment grounding bar, ground lugs, and bonding cable and fittings as required. 8. Nameplates: Each enclosure shall be identified by a nameplate including its designation and service name as specified. Panel mounted instruments and control devices shall be identified by a nameplate including the tag number and service name. Control devices shall be provided with Manufacturer's standard legends indicating function (example: STOP, START, HAND-OFF-AUTO, etc.) Provide engraved, acrylic plastic laminate nameplates, 1/16” thick, 1" x 6" minimum for junction boxes and panels, sized to fit for control devices and stations, engraved in black letters on white face and punched for and fastened with self-tapping 10/32 stainless steel screws and silicone adhesive. 9. Panel Interface Connector (PIC): Each PLC enclosure shall include a PIC mounted on the outside of the enclosure for providing a Ethernet connection to internal devices. The PIC shall include a 120 VAC single phase duplex receptacle with 3 Ampere externally resettable circuit breaker and an RJ45 pass-through connector. E. Uninterruptible Power Supply (UPS) 1. Each PLC panel shall contain a UPS to provide seamless and continuous operation of control panel equipment during power outages. The UPS shall provide backup power meeting the following requirements: a. True sine wave output with on-line double conversion configuration b. Fault, overload, and replace batteries indicators c. Voltage input: 120 VAC single phase d. Voltage output: 120VAC single phase e. Output power capacity: 1000 watts / 1500VA minimum f. Internal or external bypass g. Hot-swap batteries h. UPS to be manufactured by APC, Falcon or Trip-lite F. PLC Control Panel Networking Equipment. 1. Copper Ethernet cables entering PLC control panels from other sources shall be protected against static discharge, lightning, and faulty wiring with network surge protective devices. The devices shall have integral RJ-45 connectors with all lines protected. Provide Phoenix Contact Datatrab D-LAN-CAT.5E or equal. PART 3 - EXECUTION 3.1 GENERAL A. The PLC control panel components specified herein shall be configured as part of the Integrated Operating Platform as defined in 26 90 00 – General Instrumentation and Control. B. The Contractor shall utilize personnel who are skilled and experienced in the panel fabrication, installation, setup, and configuration of the PLCs being furnished under this contract. C. The Contractor shall furnish and install all of the I/O listed in the Drawings utilizing the I/O modules listed in this Specification. D. All wiring shall be neatly installed and wire ways shall be used wherever possible. All wiring shall be identified at all terminating locations by Tag ID as identified in Drawings. Project No. 18088080 5 Section 26 90 20 Lake Lewisville WTP Dewatering Improvements PLC Control Panels E. Any PLC furnished as part of a vendor supplied equipment package shall be accessible for future program monitoring and revisions. If password protection of any kind is implemented, the vendor or Contractor shall supply all passwords or other security information to the Owner and the Engineer. F. The Contractor shall furnish the Owner final as-built copies of documented PLC programs for vendor supplied equipment packages, on electronic media, suitable for future troubleshooting or modifications by others. G. The Contractor shall furnish and install the conduit, power wiring, signal wiring, communications wiring, fiber optic cables, and network components that make up the distributed control system as shown on the Drawings. H. The Contractor shall furnish the necessary enclosures, racks, power supplies, surge protection devices, communications modules, PLC processors, I/O modules, PLC power supplies, loop power supplies, and Ethernet devices for all of the programmable logic controller units. The Contractor shall furnish and install the necessary fiber optic cables, Ethernet cables, instrument signal cables, and control circuits required for monitoring and controlling the equipment within the project site facilities. I. All accessories and assemblies shall be installed in accordance with the manufacturer’s installation instructions. J. The Contractor shall furnish the Owner two complete copies of the operations and maintenance manuals for all PLC components detailed in this Specification. END OF SECTION Project No. 18088080 1 Section 26 90 30 Lake Lewisville WTP Dewatering Improvements Computer System and Network SECTION 26 90 30 –COMPUTER SYSTEM AND NETWORK PART 1 - GENERAL 1.1 SUMMARY A. The work to be included under this section of the Specifications shall consist of furnishing all materials, labor, equipment, tools, supplies, and incidentals for installation and configuration of all computer system and network components. The work shall include every item of construction necessary for a complete and acceptable installation as shown on the Drawings and as specified herein. B. Related Sections: 1. 26 90 00 - General Instrumentation and Control 2. 26 90 20 – PLC Control Panels 3. 26 90 40 - Process Control Descriptions 1.2 REFERENCES A. Definitions: Symbols, Definitions, and Abbreviations: All symbols, definitions, and engineering unit abbreviations utilized shall conform to IEEE 100-84, S50.1, and S51.1, where applicable. 1. SCADA – Supervisory Control and Data Acquisition 2. HMI – Human Machine Interface 3. OIT – Operator Interface Terminal 4. PLC – Programmable Logic Controller 5. I/O – Input/Output 6. VFD – Variable Frequency Drive 7. SSRVS – Solid State Reduced Voltage Starter (“Soft Starter”) 8. RTU – Remote Telemetry Unit 9. MTU – Master Telemetry Unit 10. MCC – Motor Control Center 11. Operating Program – Operating system, SCADA or other core software 12. Integrated Operating Platform – System of installed, connected, and configured hardware, operating programs, and networking equipment 13. PLC and HMI Programming – Software configuration of operating programs to implement plant control strategies 1.3 SCOPE A. This section of the Specifications covers the computer and network equipment. The major items to be furnished and installed shall include the following: 1. Network cabinet 2. Managed Ethernet switch 3. SCADA workstation computer 4. Uninterruptible power supply 5. Fiber patch panel PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Equipment manufacturers shall be as specified herein, or equal. Project No. 18088080 2 Section 26 90 30 Lake Lewisville WTP Dewatering Improvements Computer System and Network 2.2 EQUIPMENT A. Network Cabinet 1. Provide a network cabinet for the housing of networking and computer equipment described herein. Cabinet shall be floor standing, with doors and removable side panels, suitable for standard 19 inch rack mounted equipment. Coordinate required vertical height with supplied equipment. Tripp Lite SmartRack or equal. B. Computers 1. Workstation: Dell, HP, Lenovo, or equal. Business class PC for rack mounting in network cabinet, with the following minimum requirements: a. 16GB memory b. 512GB solid state drive c. Windows operating system d. Intel Core i7 processor e. Intel HD graphics f. 10/100/1000 Ethernet adapter g. Installed software: 1) Latest version of Microsoft Office Professional. 2) iFix SCADA client software, version matching plant’s existing iFix SCADA workstation computers. 3) Windows operating system version matching plant’s existing SCADA workstation computers. 2. Remote mounted monitor in PLC cabinet – refer to specification 26 90 20. 3. KVM station mounted in network cabinet for keyboard, video, and mouse interface to workstation PC. Tripp Lite B021 or equal. C. Uninterruptible Power Supply (UPS) 1. The UPS shall meet the following requirements: a. Voltage input: 120 VAC single phase b. Voltage output: 120 VAC single phase c. Output power capacity: 1000 Watts / 1500 VA d. Bypass: Internal (automatic or manual) D. Managed Network Switch 1. Provide a Cisco IE 4010 series managed network switch installed in the network cabinet with a minimum of 24 RJ45 ethernet ports and 4 fiber-optic ports. E. Fiber Patch Panel 1. Provide a fiber patch panel for installation in the network cabinet. Patch panel shall be sized to accommodate the number of fiber strands included in the installation. Corning CCH or equal. PART 3 - EXECUTION 3.1 GENERAL A. The computer and networking equipment specified herein shall be configured as part of the Integrated Operating Platform as defined in 26 90 00 – General Instrumentation and Control. B. The Contractor shall be responsible for furnishing, installing, and configuring all SCADA related hardware components along with the required software. This includes workstation communication configuration and system testing. Project No. 18088080 3 Section 26 90 30 Lake Lewisville WTP Dewatering Improvements Computer System and Network C. The workstations shall be configured to interface between all components of the network, including PLCs and SCADA servers. In general, this interface capability shall include: 1. Receiving and transmitting data to/from PLCs to populate real-time parameters and a historical database. D. The Contractor shall furnish and install the conduit, communication cables, and network components between each network device location as shown on the Drawings. E. The Contractor shall furnish and install all software that is required to operate, configure, or maintain all system components, (UPS units, network equipment, etc.) that makeup the SCADA system. The software shall be delivered to the Owner. F. All software, subscriptions, and hardware shall be registered to the Owner. G. All software, hardware, accessories and assemblies shall be installed in accordance with the manufacturer’s installation instructions. H. The Contractor shall furnish the Owner two complete copies of the operations and maintenance manuals for all components detailed in this Specification. END OF SECTION Project No. 18088080 1 Section 26 90 35 Lake Lewisville WTP Dewatering Improvements PLC and HMI Programming SECTION 26 90 35 – PLC AND HMI PROGRAMMING PART 1 - GENERAL 1.1 SUMMARY A. The work to be included under this section of the Specifications shall consist of furnishing all materials, labor, equipment, tools, supplies, and incidentals for the programming of PLCs and SCADA software that make up the process control system. The work shall include every item of programming and configuration necessary for a complete and acceptable installation as shown on the Drawings and as specified herein. B. Related Sections: 1. 26 90 00 - General Instrumentation and Control 2. 26 90 10 - Process and Analytical Instruments 3. 26 90 20 – PLC Control Panels 4. 26 90 40 - Process Control Descriptions 1.2 REFERENCES A. Definitions: Symbols, Definitions, and Abbreviations: All symbols, definitions, and engineering unit abbreviations utilized shall conform to IEEE 100-84, S50.1, and S51.1, where applicable. 1. SCADA – Supervisory Control and Data Acquisition 2. HMI – Human Machine Interface 3. OIT – Operator Interface Terminal 4. PLC – Programmable Logic Controller 5. I/O – Input/Output 6. VFD – Variable Frequency Drive 7. SSRVS – Solid State Reduced Voltage Starter (“Soft Starter”) 8. RTU – Remote Telemetry Unit 9. MTU – Master Telemetry Unit 10. MCC – Motor Control Center 11. Operating Program – Operating system, SCADA or other core software 12. Integrated Operating Platform – System of installed, connected, and configured hardware, operating programs, and networking equipment 13. PLC and HMI Programming – Software configuration of operating programs to implement plant control strategies 14. Control System Specialist – a company specializing in control, computer, and software system implementation, networking, installation, and configuration PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 GENERAL A. The Control System Specialist shall be responsible for design of the PLC and HMI programs. The Contractor shall fully coordinate all components and details of the control system with all other equipment on the project. B. The Control System Specialist shall furnish and install the conduit, cables, and network components between each network device location as shown in the Drawings. C. All software, hardware, accessories and assemblies shall be installed in accordance with the manufacturer’s installation instructions. Project No. 18088080 2 Section 26 90 35 Lake Lewisville WTP Dewatering Improvements PLC and HMI Programming D. The Control System Specialist shall furnish the Owner final as-built copies of documented PLC and OIT programs, on electronic media, suitable for future troubleshooting or modifications by others. E. The Control System Specialist shall furnish the Owner two complete copies of the operations and maintenance manuals for all components furnished. 3.2 OPERATOR INTERFACE GRAPHIC DISPLAY PAGES A. The system shall include custom process screen displays developed by the Control System Specialist. The screens will provide the major vehicle for operators to monitor and interact with the treatment process. These displays shall enable speedy access and provide the capability to manipulate process control variables along with performing standard operator tasks such as ramping values, responding to alarms, and printing reports. User defined graphics displays shall depict specific views of the plant operations and control. They shall be created and configured for monitoring and managing the process through the software. B. Prior to performing the Functional System Test as described in specification 26 90 00, the Control System Specialist shall submit screen captures of the proposed HMI screens to the Engineer and Owner for review. The submitted screen captures shall be sufficient to display the contents of the system, and to determine visual conformance with the Owner’s SCADA HMI standards. The Control System Specialist shall modify the screen contents based on the Owner and Engineer review prior to functional system testing. Review of the screens at this stage is preliminary and is not a final approval of all SCADA HMI content and functionality as required by the contract documents. 3.3 SYSTEM FUNCTIONALITY A. The SCADA system shall be setup initially with the basic functionality as described in Specification 26 90 40 – Process Control Descriptions. These descriptions shall be used as a guide for controlling various items by location and the Control System Specialist shall be expected to continually refine the SCADA system functionality throughout the execution of the project. Each automatic, manual and operator initiated set point shall be configured with upper and lower limits to keep the process operating within an expected operating range. The Control System Specialist shall coordinate the functionality of each item in the control description with the Owner and Operator. The Control System Specialist shall provide support for all functions in the HMI screens. 3.4 PLC AND HMI PROGRAMMING STANDARDS A. All PLC and HMI programming shall comply with the City of Denton Programming Standards document that is included herein. It is the responsibility of the Control System Specialist to review this document and comply with all applicable standards. END OF SECTION City of Denton Programming Standards Programming Standards Final Version A VERSION TRACKING VERSION DATE REVIEWED BY APPROVED BY DESCRIPTION A 2/17/2012 DAG KG Final B C D E F G H Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards i Contents 1. INTRODUCTION 1-1 2. HMI SYSTEM ARCHITECTURE 2-1 2.1. Servers .......................................................................................................................... 2-1 2.1.1. Server Definition ............................................................................................ 2-1 2.1.2. Redundant Server Naming ............................................................................ 2-1 2.1.3. Stand Alone Server Naming .......................................................................... 2-1 2.2. Client Machine Naming ................................................................................................. 2-1 2.3. Local Machine Naming ................................................................................................. 2-1 3. GRAPHIC CONVENTIONS 3-1 3.1. Overview ....................................................................................................................... 3-1 3.2. Graphic Display Regions .............................................................................................. 3-2 3.2.1. Graphic Display Color Scheme ..................................................................... 3-3 3.2.2. Graphic Display Text Styles .......................................................................... 3-5 3.2.3. Menu Bar ....................................................................................................... 3-6 3.2.4. Alarm Banner ................................................................................................ 3-7 3.3. Menu Graphics .............................................................................................................. 3-8 3.3.1. Facilities Menu .............................................................................................. 3-8 3.3.2. Main Menu ..................................................................................................... 3-9 3.3.4. Plant Overview ............................................................................................ 3-10 3.3.5. Unit Process ................................................................................................ 3-11 3.4. Process Graphics ........................................................................................................ 3-12 3.4.1. Process Equipment Symbols ...................................................................... 3-13 3.4.2. Process Piping ............................................................................................ 3-14 3.4.3. Process Structures ...................................................................................... 3-15 3.5. Alarms ......................................................................................................................... 3-16 3.5.1. Alarm Summaries ........................................................................................ 3-16 3.5.2. Alarm Histories ............................................................................................ 3-18 3.6. Totalizer Graphics ....................................................................................................... 3-19 3.6.1. Flow Totals .................................................................................................. 3-19 3.6.2. Equipment Runtimes ................................................................................... 3-20 3.7. Trend Graphics ........................................................................................................... 3-21 3.8. Reports Graphics ........................................................................................................ 3-23 3.9. System Architecture Graphics .................................................................................... 3-23 3.10. Help Graphics ............................................................................................................. 3-23 4. GRAPHIC NAVIGATION ORGANIZATION AND METHODS 4-1 4.1. Navigation Systems ...................................................................................................... 4-1 4.1.1. System of Menus ........................................................................................... 4-1 4.1.2. System of Overviews ..................................................................................... 4-1 4.1.3. Pipe Chasing ................................................................................................. 4-2 4.2. Graphic Hierarchy ......................................................................................................... 4-2 5. HMI DRIVERS 5-1 Table of Contents Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards ii 5.1. Overview ....................................................................................................................... 5-1 5.2. MBE Driver .................................................................................................................... 5-1 6. HMI REAL TIME DATABASE 6-1 6.1. Overview ....................................................................................................................... 6-1 6.2. Database Naming ......................................................................................................... 6-1 6.3. Tag Naming................................................................................................................... 6-1 7. HMI ANIMATIONS 7-1 7.1. Overview ....................................................................................................................... 7-1 7.2. Animation States & Methods ......................................................................................... 7-1 7.3. Valve Animations .......................................................................................................... 7-2 7.3.1. Opened/Closed Motorized Valve .................................................................. 7-2 7.3.2. Valve with Limit Switches Only ..................................................................... 7-3 7.3.3. Modulating Motorized Valve .......................................................................... 7-4 7.4. Gate Animations ........................................................................................................... 7-5 7.4.1. Opened/Closed Motorized Gate .................................................................... 7-5 7.4.2. Gate with Limit Switches Only ....................................................................... 7-6 7.4.3. Modulating Gate ............................................................................................ 7-7 7.5. Motor & Pump Animations ............................................................................................ 7-7 7.5.1. On/Off Motor .................................................................................................. 7-8 7.5.2. Variable Speed Motor .................................................................................... 7-8 7.6. Control Mode Animations .............................................................................................. 7-9 7.7. Control Mode Configuration ........................................................................................ 7-10 7.8. Alarm Summary Animations ....................................................................................... 7-11 8. CONTROL POP-UPS AND METHODS 8-1 8.1. Overview ....................................................................................................................... 8-1 8.2. Open/Close Control ...................................................................................................... 8-2 8.3. On/Off Control ............................................................................................................... 8-2 8.4. Modulating Control ........................................................................................................ 8-3 8.5. Variable Speed Control ................................................................................................. 8-4 9. SECURITY 9-1 9.1. Overview ....................................................................................................................... 9-1 10. FILE NAMING CONVENTIONS 10-1 10.1. Process Graphics ........................................................................................................ 10-1 10.2. Control Pop-ups .......................................................................................................... 10-1 10.3. Menus ......................................................................................................................... 10-1 10.4. Alarm Graphics ........................................................................................................... 10-2 10.5. Historical Trend Graphics ........................................................................................... 10-2 11. HMI GRAPHIC SAMPLES 11-1 Table of Contents Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards iii 11.1. Overview ..................................................................................................................... 11-1 Appendices A. PLC Common Instructions Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 1-1 1. INTRODUCTION The following is guidance for building a complete Human Machine Interface (HMI) system based on the latest version of iFIX byGE Fanuc as the HMI software. The document is written around the current version of iFIX (4.5, September, 2007). These HMI standards establish uniform design and development concepts (including configurations, programming, and styles/graphics) for use by any developer and provide the basis for a common look and feel of any HMI system for the City of Denton’s water production facilities. Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 2-1 2 2. HMI SYSTEM ARCHITECTURE 2.1. Servers 2.1.1. Server Definition A server is a centralized machine which receives and distributes data traffic (SCADA inputs and outputs) to computer clients and process controllers within the same network. Server hardware is typically more robust than the PC clients since they process a greater amount of information. The machine normally includes redundant hard drives and is located in a hardware rack not accessible to operators. 2.1.2. Redundant Server Naming SCADA has a logical name that refers to the redundant servers as a pair. Each machine also has a local machine name. The logical pair name reflects which network loops that redundant pair of machines carries. The database name is the same as the logical pair name. “Lake Lewisville WTP” y Logical name: LLSCADA o Local machine name: LLWTP01S o Local machine name: LLWTP02S “Ray Roberts WTP” y Logical name: RRSCADA o Local machine name: RRWTP01S o Local machine name: RRWTP02S 2.1.3. Stand Alone Server Naming SCADA servers may be stand-alone. The logical name is the same as the machine name in this case. The database name matches the logical name. 2.2. Client Machine Naming The logical name is the same as the machine name in this case. The clients do not have databases. 2.3. Local Machine Naming The physical computer name follows a naming system similar to the following: Section 2 Current Situation Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 2-2 BBBLLN BBB = building code for which building the computer resides in LL = workstation/server number use 0 to 99 N = S – server or C – Client Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-1 3 3. GRAPHIC CONVENTIONS 3.1. Overview The graphic display includes information from a number of distinct I/O points from various Process Controllers (PLCs), for the formation of actual and pseudo graphics. All graphic pages use "poke points", buttons, or icons to facilitate the operator choosing specific characters or images for further representation in the graphic. Using these poke points, the operator is able to request linked graphic pages via a mouse. Navigation through screens and access to features (data acquisition or control) should be efficiently designed and avoid unnecessary actions, e.g. too many buttons, keystrokes, or displays to page through. User defined menus allow easy viewing of predetermined summaries and graphics with simple keystrokes and mouse directions. Each operator workstation should have access to all of the graphics in PWPCS (Plant Wide Process Control System). Field conditions with text can commonly alternate (i.e. OPENED/CLOSED, RUNNING/STOPPED, HIGH/LOW) and change color correspondingly. Field devices that are tri-state should be represented in three conditions. Conditions of field devices will cause the corresponding graphic symbol to change color and provide a blinking image to alert the operator viewing the graphic. Graphic displays should be multifunctional, providing an interface suitable for each level of user (operators and administrators), with display of and access to information determined by means of password administration. User groups should be considered in the overall design of the interface. Minimize the use of abbreviations. In cases where an abbreviation must be used (due to space limitations), use the standard abbreviations provided in this document. Be consistent with the use of static and dynamic text. Exceptions may be made to font size in certain instances to achieve a more desirable appearance or provide greater clarity. Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-2 3.2. Graphic Display Regions Each graphic screen should be designed using two standard screen areas, as shown. The following are general descriptions of the two areas. Area 1 is a rectangular band across the top of the graphic (approximately 10 percent of screen area), which contains in order as they appear from left to right: The City of Denton Seal, button links for LOGIN/LOGOUT, TOGGLING TAGNAME VISIBILITY (TAGNAME), ALARM SUMMARIES (ALARMS), FACILITIES MENU (FACILITIES), MAIN MENU (MAIN MENU), PLANT OVERVIEW (OVERVIEW), HMI SYSTEM MONITORING (SYSTEM), PROCESS OVERVIEW (PROCESS OVERVIEW), PROCESS MENU (PROCESS MENU), HELP INFORMATION (HELP), VIEW LAST GRAPHIC (BACK). PAGE FORWARD/PAGE BACKWARD command buttons call up the next or previous graphic in the hierarchy, respectively. Logging on and off the system is done by clicking on the LOGIN command button. If an alarm condition occurs, the ALARMS button should flash, and by clicking on the button, the Alarm Summary Screen should open. Area 2 is immediately below Area 1 and covers approximately 80 percent of the total screen area. Area 2 consists of a gray background, which is filled with process depiction or other information. Area 1 Area 2 Figure - Picture Template Area 3 Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-3 Area 3 is a rectangular band across the bottom of the graphic (approximately 10 percent of screen area), which contains the last three active alarms at the plant and current status of these alarms including active or inactive, acknowledge or unacknowledged. 3.2.1. Graphic Display Color Scheme General guidelines for display color scheme include: y Backgrounds for all graphic screens should be color GRAY 75. y All graphical displays that include operational equipment should have the equipment’s run status shown. A text indication should also be available on the graphical displays to provide a verification of the color scheme. y All process piping is static and does not change color to indicate flow conditions in that line. y To establish a quick understanding of the process flow, the graphic displays should follow where possible, the actual color scheme used for painting process piping as define by the standards provided in this document. Colored “bands” are not used. The main color should conform as closely as possible to the standard process piping main color. Colors used should be selected from the custom iFIX color palette in the SCADA workspace. The tables below represent the colors to be used for various graphical items. TABLE 3.2.1 COLOR PALETTE FLOW ID NAME OF FLOW COLOR NAME HPA Air, High Pressure COLOR 7 ISA Air, Instrument Supply COLOR 7, GREEN STRIPE FLA Air, Foul COLOR 7 AIR Air, Fresh COLOR 7 ALM Alum COLOR 66, GREEN STRIPE AML Ammonia, Liquid Solution BROWN, BRIGHT RED STRIPE CLG Chlorine Gas BRIGHT YELLOW CLS Chlorine Solution BRIGHT YELLOW DRN Drain CYAN FCL Ferric Chloride, Liquid Solution BROWN, BRIGHT YELLOW STRIPE FSL Ferric Sulfate, Liquid Solution COLOR 66, BRIGHT RED STRIPE FLW Filter Raw Water COLOR 70 FNE Final Effluent GREEN FNW Finished Water COLOR 10 Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-4 TABLE 3.2.1 COLOR PALETTE FLOW ID NAME OF FLOW COLOR NAME FLL Fluoride, Liquid Solution WHITE, COLOR 7 STRIPE GRW Ground Water COLOR 2 LOX Liquid Oxygen COLOR 7, BRIGHT BLUE STRIPE NTG Natural Gas BRIGHT RED NPW Non-Potable Water COLOR 156 OZN Ozone COLOR 7, WHITE STRIPE PTW Potable Water COLOR 10 PPL Potassium Permanganate, Liquid Solution COLOR 7, BRIGHT RED STRIPE PLY Polymer WHITE RAW Raw Water COLOR 2 SCN Screens Discharge COLOR 128 SCM Scum COLOR 177 STW Settled Water COLOR 39 SLG Sludge COLOR 113 SHP Sodium Hypochlorite (Bleach), Liquid Solution WHITE, BRIGHT YELLOW STRIPE SHX Sodium Hydroxide (Caustic), Liquid Solution WHITE, GREEN STRIPE SSD Suspended Solids iFIX YELLOW TSL Thickened Sludge COLOR 129 WSW Waste Water CYAN Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-5 TABLE 3.1.2 MISCELLANEOUS COLOR PALETTE ITEM COLOR NAME Workspace Background GRAY Title Bar Background GRAY Username Background LIGHT GRAY Screen Title Background BLUE Link Button LIGHT BLUE Command Button LIGHT GRAY Black Text BLACK White Text WHITE Date and Time BLUE Running/Open Devices GREEN Stopped/Closed Devices RED Device Transition CYAN Device Failure YELLOW (background) Communications Failure YELLOW (background) Device Labels BLACK 3.2.2. Graphic Display Text Styles General guidelines for text styles include: y Use upper case, black, Arial font, bold style, and 10-point size text inside a white text box for dynamic text. y Use upper case black Arial font, regular style, and 10-point size for static text descriptors as a minimum. y Picture title banner should use white, Arial font, bold style, 13-point size text. y Set points are black Arial font, 15-point, bold style, on a command button. y Analog values should be represented by black, 10-point text, with black 10-point Arial text showing the engineering unit for the measurement. Dynamic values and engineering units are shown inside a white text box with black border. Black text, 10-point, Arial above the box should indicate what value is being measured. If the position of the box on the screen causes the description of the value being measured to be intuitively obvious and space on the screen is constricted, then the description text may be omitted. Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-6 y Connect the analog value box to the area of measurement on the graphic depiction of the process as shown in figure below. Where this is not possible, position the analog value box display as close as possible. 3.2.3. Menu Bar A Menu Bar should be provided across the top of every primary level graphical display. The Menu Bar should include links such as LOGIN/LOGOUT, TOGGLING TAGNAME VISIBILITY (TAGNAME), ALARM SUMMARIES (ALARMS), FACILITIES MENU (FACILITIES), MAIN MENU (MAIN MENU), PLANT OVERVIEW (OVERVIEW), HMI SYSTEM MONITORING (SYSTEM), PROCESS OVERVIEW (PROCESS OVERVIEW), PROCESS MENU (PROCESS MENU), HELP INFORMATION (HELP), VIEW LAST GRAPHIC (BACK) AND PAGE FORWARD/PAGE BACKWARD. The Menu Bar should also display the current date and time. Titles may be abbreviated as indicated in parentheses so that all selectable targets (buttons) appear in Figure - Analog Text Example Figure - Analog Text Example Engineering units inside box Analog value Control mode Valve/Line Error Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-7 one line at the top of the screen. Graphics called from any menu graphic that are considered primary level displays. Figure - Typical Menu Bar 3.2.4. Alarm Banner An Alarm Banner should be provided across the bottom of every primary level graphical display. The Alarm Banner should include the last three active alarms and the status of these alarms which include active or inactive, acknowledged or unacknowledged. Figure – Generic Alarm Banner Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-8 3.3. Menu Graphics The operator should be able to access every primary level through a system of menu screens. The menu screens should include a Menu Bar and a Title Header listing the name of the plant, city and state. 3.3.1. Facilities Menu The top level of menus is the FACILITIES MENU which includes links to each available City facility. From here, operators can select a facility leading them to the MAIN MENU of that facility. Figure – Facilities Menu Sample Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-9 3.3.2. Main Menu The MAIN MENU of the facility provides link buttons to access each unit process sub menu. The unit process sub menus contain navigation links to all of the graphics in that unit process. b. Unit process sub menus have a navigation link to every graphic associated with a particular unit process. If a unit process contains too many a. The Figure - Main Menu Sample Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-10 3.3.4. Plant Overview The PLANT OVERVIEW should be a primary display and should be the initial screen that is shown each time the SCADA system is started. The plant displayed will depend on the location of the user. There should be a Menu Bar across the top and a Title Header identifying the page as the PROCESS EQUIPMENT OVERVIEW. The Operator should be able to access the process overview graphic for each unit process by clicking on the process location. The plant overview graphic should indicate if there is an alarm in a particular unit process by making the symbols on the plan overview graphic representing it flash. Figure - Plant Overview Graphic Sample Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-11 3.3.5. Unit Process Unit process sub menus have a navigation link to every graphic associated with a particular unit process. If a unit process contains too many graphics to fit on one sub menu graphic, the unit process sub menus are divided into multiple sub menu graphics based on the categories below. Unit process sub menu should have all of the graphics for a unit process organized into the following categories: y Process Graphics y Historical y Reports y Alarm Set Points y System Data Communications Figure - Sample Unit Process Sub Menu Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-12 3.4. Process Graphics Each stage of the plant operation should have a primary graphic display. A Menu Bar should be across the top along with a Title Header identifying the process subsystem and an alarm banner should be located at the bottom. A navigation arrow button should be shown in the top right corner of the page, which should take the operator to the previous stage of the process, and another should take the operator to the next stage. Each piece of equipment or device on a process display should include a status text box near it. Figure - Process Graphic Sample Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-13 3.4.1. Process Equipment Symbols Process equipment is represented on the graphics through the use of a standard set of symbols as shown in the figure below. Not all possible types of process equipment are shown. Additional symbols may be created to appear in a similar fashion as the standard symbols. All additional symbols should be approved through a City approval process before becoming a standard symbol. All instrument signals and process equipment being displayed should have their associated equipment loop numbers displayed near the device. These numbers should match those as identified in the Contract Documents. The ID numbers should be invisible when not needed during normal operations. These numbers can be toggled visible or invisible as required by pressing the “Show Tags/Hide Tags” button on the main header in Section 1 of the display. Figure - Standard Equipment Symbols Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-14 3.4.2. Process Piping General guidelines for piping include: y Process piping should follow the color standard as described in Table 3.2.1. y Process piping should not be animated to indicate flow. y Process piping should have rounded corners and bends. y Piping should look continuous through bends and turns. Piping should not have transverse edges or lines that would make the pipe appear to be broken or cut. y When two pipes need to cross each other on the graphic a pipe break should be used. y When a pipe enters a structure or tank the pipe end should look open. Equipment ID’s should be toggled visible or invisible Figure – ID Label Figure - Piping Sample Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-15 3.4.3. Process Structures Process structures represent large concrete structures such as flow splitters, junction boxes, channels, mixing chambers, etc. Structures when in plan view should appear as filled with the color representing the fluid in it with a dark gray edge as shown in the figure. Figure - Structure in Plan View Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-16 3.5. Alarms 3.5.1. Alarm Summaries The ALARM SUMMARIES page should be a primary display, with a Menu Bar and a Title Header. It should list all points that are in an alarm state, as well as system events such as device failures, program terminations, system startups and system shutdowns. The ALARM command button provides a link to the Alarm Summary Screen, which displays all pre-configured area and plant alarms for the workstation, dependent on designation and location. Alarms should be handled in the following fashion: y A point that enters into an alarm state is displayed in the summary listing. y There should be three priorities of alarms: o High Priority - Immediate Attention Required - examples include: personnel safety, flood, spills, actual or potential permit violations, and the potential for major equipment damage. o Medium Priority - Prompt Attention Required. Examples are a piece of equipment that has failed with back-up unit available. o Low Priority - Attention Required, but action could wait until high and medium priority alarms are investigated and secured. y The Alarm Summary screen displays a series of active alarms with the following information: acknowledged status (acknowledged alarm should have check mark "" next to it in ACK column), date/time in, tag name, description and priority (LOW, MEDIUM, or HIGH). An individual alarm can be acknowledged by double clicking anywhere on the line where the alarm appears. y Alarms should use the following color schemes as they come in, are acknowledged and cleared. o A point currently in an alarm state and unacknowledged should be displayed in RED text on a GRAY background and blinking. o A point currently in an alarm state and acknowledged should be displayed in RED text on a WHITE background. o An Alarm that returns to a normal state and has not been acknowledged is displayed in YELLOW with a WHITE background. o An alarm that returns to a normal state and has been acknowledged is automatically deleted from the alarm summary listing. o Manual alarm deletion should not be allowed. Alarm messages should include the following attributes: Date, Time, Point ID, Point Description, Value, Alarm State, Acknowledgment Status, Priority, Node, and Area. Alarms are logged as events and should be recorded on the historical database and printed out on demand. An alarm record should be made each time a point enters an alarm state, an alarm is acknowledged and a point returns to a normal state. Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-17 When an alarm occurs, the ALARM button at the top of each screen should automatically flash YELLOW and WHITE. The Operator may then select the ALARM button and be taken to the ALARM SUMMARIES display where the ACKNOWLEDGE ALARM button may be selected. When all alarms have been acknowledged but the alarm condition remains, the ALARM button should continue to display YELLOW until the alarm clears. When all alarms are cleared or there are no alarms present, the ALARM button should be BLUE with BLACK text. d. Alarm terminology FAIL should be used in the description of an alarm condition that simultaneously stops the respective equipment through an interlock. FAIL should not be used in the description of an alarm condition where the equipment continues to operate. Alarm terminology COMMON ALARM should be used where a single alarm point is utilized to communicate two or more alarm conditions over a single point. Alarm terminology FAIL should be used in the description of an alarm condition that simultaneously stops the respective equipment through an interlock. FAIL should not be used in the description of an alarm condition where the equipment continues to operate. Alarm terminology COMMON ALARM should be used where a single alarm point is utilized to communicate two or more alarm conditions over a single point. Alarm areas for each process should be named according to it’s the plant identifier and building code, PPBBB, as detailed in the database tagging standard. Button Flashes when alarm is present Figure - Alarm Button Animation Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-18 3.5.2. Alarm Histories The ALARM HISTORIES page should be a primary display, with a Menu Bar and a Title Header. It should list all points that were previously in alarm state and contain information similar to the Alarms Summary Screen. Refer to the Alarms Summaries section for more information. The Alarm Summary Screen provides a link to the Alarm History Screen, which displays all pre-configured area and plant alarms for the workstation, dependent on designation and location. Figure - Sample Alarm Summary Graphic Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-19 3.6. Totalizer Graphics 3.6.1. Flow Totals The FLOW TOTALS should be a primary display that includes a Menu Bar, a Title Header and should provide the operator with a running total of all plant flows associated with a unit process. Flow totals for flows measured in MGD should be displayed in millions of gallons (MG) with two-decimal digit accuracy. These flow totals must reach at least 99,999.99 MG units before they rollover. Flow totals for flows measured in GPM should be displayed in thousands of gallons (KG). These flow totals must reach at least 999,999 KG units before rollover. Each flow should have the following totals. x Daily flow which is a midnight to midnight total. The total automatically resets to zero at midnight each night. x Previous Day total is a total of the previous 24 hour day from midnight to midnight. x Accumulated Flow is a running total that does not roll over until the counting registers in the PLC are filled. Figure - Sample Flow Totals Graphic Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-20 3.6.2. Equipment Runtimes The EQUIPMENT RUNTIMES page should be a primary display. A Menu Bar should be across the top, along with a Title Header identifying the display. Each piece of motorized equipment should have the runtime recorded in minutes. The number of starts/stops for each piece of motorized equipment should also be recorded. Figure - Sample Runtime Graphic. Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-21 3.7. Trend Graphics Trends should be available for configuration by the user or be available as pre-configured trend groups. Trend graphic should be able to display up to 7 pens. TRENDS should be a full screen sized pop-up display that includes a Title Header, and the following buttons: y 15 MINUTE y 4 HOUR y 8 HOUR y 1 DAY y 1 WEEK y 1 MONTH y FORWARD, FAST FORWARD, BACK and FAST BACK Buttons to scroll through time. A current Button should take the Trend back to the current time. y SET CURRENT button to restore trend to current time The TREND MENUs should be secondary graphic displays. They should include a Title Header that identifies which time span they cover, an EXIT button, and an ALARMS button for quick access to the alarms page. The EXIT button should be colored RED. Buttons should be provided for every important process-monitoring group. For example, measured flow rates in the plant, grouped to show the flow trends for specific areas, e.g. Plant Influent Flows, Plant Sludge Flows, etc. Each group should display no more than seven parameters per chart. Selecting a button should take the Operator to a pop-up display showing the TREND CHART. TREND CHARTs should be displays with a Title Header, CLOSE button and chart. Data for the charts should be displayed according to the time-periods selected under Trends. The TREND CHART background should be WHITE for ease of the printing. Each Trend line and description in a trend should be represented by a unique color. Where possible, the more common data types should use the same color. The common data types and associated colors are listed in Table 3.7.1. However, these colors should still be available for other data types and these common data types should be open to color changes. Trend lines should have a default line weight of 2. A vertical line, or chart slider, should extend over the chart area. The value of each trend line along with the time and date it was collected should be updated as the slider moves across the chart. Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-22 TABLE 3.7.1 COMMON DATA TYPES COMMON DATA TYPE COLOR Tank Level BLUE Flow Rate RED Pressure YELLOW Chlorine Residual GREEN The X-axis of the trend chart should display the date and time of the collected data. The Y-axis of the trend chart should display the range of database points trended in the chart with the corresponding color assignment. A zoom feature should allow the operator to examine portions of the trend more closely. Figure - Sample Alarm Summary Graphic Section 3 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 3-23 3.8. Reports Graphics Standard Reports are developed using Microsoft Excel interfacing to the SCADA system’s historical database, iHistorian. These reports should be generated and updated automatically from the historical database without manual entry of data. The report format and content should be edited using standard Microsoft Excel tools and should not require extensive use programming language such as Visual Basic. From the unit process sub menus a button should be placed to bring up each report available on the system. Microsoft Excel should open in an embedded window with an iFIX graphic for viewing a report. Refer to the Security section for discussions about editing permissions for reports. Also, refer to discussions later in this section on embedded applications in iFIX graphics. 3.9. System Architecture Graphics The System Architecture graphics indicate the health of network devices, indicate PLC to HMI server communication path health, and provide some network diagnostic information. y The Data Communication Graphics indicates the health and path of the data flow to/from the PLC and associated iFIX server pair. y PLC Architecture Graphics should indicate the health of the PLC and/or communication module down to the point on card level where available. 3.10. Help Graphics The HELP button on each graphic should call up the appropriate section of the on-line SOPs that relate to that graphic. Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 4-1 4 4. GRAPHIC NAVIGATION ORGANIZATION AND METHODS The HMI system for each facility or plant will have hundreds of graphics that represent the facility processes, equipment, alarms, system architecture, reports, etc. To enable facility staff to effectively use and operate the HMI, the graphics must be organized in a logical, predictable and hierarchical system. The process graphics have been designed to allow the users to move from any one process to any other process in the facility in 3 mouse clicks or less. The user will also be able to access other facilities city-wide from the facilities menu. 4.1. Navigation Systems There are three primary routes by which the HMI graphics can be navigated. No single way of navigation if preferred to the other, the methods are all used in parallel. Which method each user utilizes is a manner of personal preference. The three navigation methods are a system of menus, system of overviews and pipe chasing. 4.1.1. System of Menus The system of menus starts with the facilities menu, which lists the water production plants and remote sites. Once a facility is selected, the main menu of each facility is used to access each unit process within the facility. Each unit process leads to a unit process sub menu. The unit process sub menu lists all of the graphics associated with a particular unit process. The user can then select which graphic to view. The user may also use the graphic hierarchy to step down through each graphic for a unit process from the starting from the unit process sub menu. To navigate within a facility in 3 clicks the user: y Selects MAIN MENU at the top of any primary graphic y Selects the unit process y Selects the desired graphic 4.1.2. System of Overviews The system of overviews starts with the facility overview. The facility overview is a map of all of the unit process in a facility. The user selects which unit process and is directed to a unit process overview. The unit process overview shows all of the major process and equipment associated with a unit process. The user can then select which process or equipment to view. The user may also use the graphic hierarchy to step through each graphic for a unit process from the overview. To navigate within a facility in 3 clicks the user: Section 4 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 4-2 y Selects OVERVIEW at the top of any primary graphic y Selects the unit process y Selects the desired process or equipment 4.1.3. Pipe Chasing From unit process overview or the process graphics pipes may end into link buttons. To follow the flow through the plant from process to process the user may click on the process flow linking buttons. This method may involve going through many graphics to transverse the plant since every detailed process graphic will be looked at between the two points. 4.2. Graphic Hierarchy PAGE FORWARD/PAGE BACKWARD command buttons on the menu bar of each display screen, when single clicked, summon the next and previous screens in the current system hierarchy respectively. The graphics for each unit process are arranged in a similar pattern to form the hierarchical order as depicted in the figure. Figure - HMI Graphic Hierarchy Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 5-1 5 5. HMI DRIVERS 5.1. Overview HMI drivers are used to communicate to a data source such as a PLC, other control system, instruments, etc. HMI Drivers should be set up to run as services in Windows. Logging the current user out of Windows should not affect the data communications of the driver. Refer to Security for details on security configuration of HMI drivers. 5.2. MBE Driver The MBE driver is used to communicate with Modicon PLCs via Modbus TCP/IP. Data polling should occur at 1 second intervals. Phasing may be used to optimize communication bandwidth utilization. Note: Using the automatic create for creating data polling block should not be permitted. Often the automatic create will not create data blocks that do not align with the registers used for analog values. An analog value takes two registers, which cannot be split between data polling blocks. Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-1 6 6. HMI REAL TIME DATABASE 6.1. Overview The real time database contains all of the tags polled from/to the PLC’s and any calculated points used for graphic animations. The use of data blocks that do not refresh their value each scan should not be permitted. The type of data blocks used in the iFIX database should be: y DI for digital inputs y DI with output enabled for digital outputs y AI for analog inputs y AI with output enabled for analog outputs y DA for all alarms y Secondary data blocks, which are chained to another block to trigger a scan, may be used as needed. 6.2. Database Naming The database name shall be the same as the machine logical name. Refer to HMI System Architecture for details on logical names. 6.3. Tag Naming The tag naming convention is described in the tables below. Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-2 TABLE 6.3.1 TAG FORMAT: ##AAA$$$%%%_BB SYMBOL DESCRIPTION ## Plant Number AAA Tag Prefix; Equipment/Device Number $$$ Process Area %%% Equipment Number _ Underscore Character for iFIX VBA scripting BB Tag Suffix; Measurement, Status, Action, etc. EXAMPLE DESCRIPTION 01RWP101001_SI Lewisville Raw Water Pump Station #1, Pump #1 Speed Indication 01PMP803004_MM Lewisville Remote Site #3 Pump #4 Running 01FIT513001_FI Lewisville Filter #13 Influent Flow Indication TABLE 6.3.2 PLANT NUMBERS NUMBER PLANT 01 Lake Lewisville Water Production Plant 02 Lake Ray Roberts Water Production Plant TABLE 6.3.3 TAG PREFIXES PREFIX DESCRIPTION AC Air Compressor ACP Access Control Panel AFP Ammonia Feed Pump AMBST Ammonia Bulk Storage Tank AR Air Receiver ATC Automatic Temperature Controller AER Dissolved Oxygen Indication Transmitter AGV Automatic Gate Valve AIT Analyzer Indication Transmitter BFV Butterfly Valve BL Blower Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-3 TABLE 6.3.3 TAG PREFIXES PREFIX DESCRIPTION BV Ball Valve BWP Backwash Pump CAUBST Caustic Bulk Storage Tank CRP Caustic Recirculation Pump CFP Caustic Feed Pump CFP Centrifuge Feed Pump CNV Conveyor CTF Centrifuge DP Drain Pump DPT Differential Pressure Transmitter DRM Drive Motor DSU Destruct Unit EST Elevated Storage Tank EXF Exhaust Fan FACP Fire Alarm Control Panel FAN FAN FBST Fluoride Bulk Storage Tank FDST Fluoride Day Storage Tank FFP Fluoride Feed Pump FDR Power Feeder FIT Flow Indication Transmitter FLOC Flocculator FLT Filter FM Floating Mixer FS Fine Screen FSBST Ferric Sulfate Bulk Storage Tank FSC Fine Screen Compactor GC Grit Classifier GEN Ozone Generator GP Grit Pump GRU Grit Removal Unit Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-4 TABLE 6.3.3 TAG PREFIXES PREFIX DESCRIPTION HX Heat Exchanger JMP Jet Mixing Pump LIT Level Indication Transmitter LLP Low Lift Pump LOX Liquid Oxygen MPM Alum Pump MXR Mixer NET Network Switch OF Oxygen Filter ORP Oxygen Reduction Potential Transmitter PBU Polymer Blend Unit PBST Polymer Bulk Storage Tank PCS Plant Control System PFP Permanganate Feed Pump PIT Pressure Indication Transmitter PLC Programmable Logic Controller PMP Pump PSU Power Supply Unit PV Plug Valve PWP Plant Water Pump RCP Recirculation Pump RM Rapid Mixer RSP Return Sludge Pump/Recycle Sample Pump RWP Raw Water Pump SC Sludge Collector SHBST Sodium Hydroxide Bulk Storage Tank SHFP Sodium Hydroxide Feed Pump SLG Slide Gate SG Sluice Gate SM Submerged Mixer SP Sump Pump Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-5 TABLE 6.3.3 TAG PREFIXES PREFIX DESCRIPTION SMP Sample Pump SRP Sludge Return Pump TIT Temperature Indication Transmitter UGV Underground Gate Valve UVB Ultraviolet Unit VAP Vaporizer VLV Valve WG Weir Gate WSP Waste Sludge Pump WP Water Pump WWP Washwater Pump TABLE 6.3.4 PROCESS AREAS PROCESS AREA NOS. EQUIPMENT NOS. INSTRUMENT NOS. DESCRIPTION 101 - 1XXX Raw Water Supply & Collection 201 - 2XXX Rapid Mix System 301 - 3XXX Flocculation/Sedimentation 400 - - Ozone System 401 40X 40XX LOX Storage and Feed System 410 41X 41XX Ozone Generator 1 420 42X 42XX Ozone Generator 2 430 43X 43XX Ozone Generator 3 440 44X 44XX Ozone Nitrogen Boost System 450 45X 45XX Ozone Monitoring System 460 46X 46XX Not Used/Future 470 47X 47XX Ozone Contactor 1 480 48X 48XX Ozone Contactor 2 490 49X 49XX Ozone Destruct System 500 5XX 5XXX Filtration 600 6XX 6XXX Washwater Equalization Basin Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-6 TABLE 6.3.4 PROCESS AREAS PROCESS AREA NOS. EQUIPMENT NOS. INSTRUMENT NOS. DESCRIPTION 700 - - Remote Sites 710 71X 71XX McKenna Park Booster Pump Station 720 72X 72XX Southwest Booster Pump Station 730 73X 73XX Northwest Tank 740 74X 74XX Roselawn Tank 750 75X 75XX Riney Road Tank 760 76X 76XX Not Used/Future 770 77X 77XX Not Used/Future 780 78X 78XX Not Used/Future 790 79X 79XX Not Used/Future 800 - - Chemical System I 801 80X 80XX Fluoride System 810 81X 81XX 820 82X 82XX Liquid Ammonium Sulfate System 830 83X 83XX Caustic System 840 84X 84XX Ferric Sulfate System 850 85X 85XX Permanganate System 860 86X 86XX Not Used/Future 870 87X 87XX Not Used/Future 880 88X 88XX Not Used/Future 890 89X 89XX Not Used/Future 900 - - Chemical System II 901 90X 90XX Polymer System 910 91X 91XX Not Used/Future 920 92X 92XX Sodium Hypochlorite 930 93X 93XX Sodium Hydroxide 940 94X 94XX Not Used/Future 950 95X 95XX Not Used/Future 960 96X 96XX Not Used/Future 970 97X 97XX Not Used/Future 980 98X 98XX Not Used/Future Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-7 TABLE 6.3.4 PROCESS AREAS PROCESS AREA NOS. EQUIPMENT NOS. INSTRUMENT NOS. DESCRIPTION 990 99X 99XX Support Equipment & Systems TABLE 6.3.5 TAG SUFFIX SUFFIX DESCRIPTION* _ENG_HI Engineering High Scale (append to Analog tag suffix) _ENG_LO Engineering Low Scale (append to Analog tag suffix) AI Analyzer Indication ANY_FAULT Common Fault (HMI animation fault tag) AUTO_MAX Auto Mode Maximum PID output AUTO_MIN Auto Mode Minimum PID output BAD Bad reading - AI card trouble, appended to Analog Indication Suffix BL Broken Loop indication - appended to Analog Indication Suffix CLOSE_REQ Operator Closed Request DATE_TIME_DD Calendar Day DATE_TIME_DW Day of the Week DATE_TIME_HH Hour DATE_TIME_MM Month DATE_TIME_MN Minute DATE_TIME_SS Second DATE_TIME_YY Year DEVIATION Deviation – un-commanded action or deviate out of range DISCREPANCY Discrepancy - failed to start/stop or move to position EQUIP_SP Equipment Setpoint (Manual or Auto) FAIL_STPT Fail Timer Setpoint (Discrepancy Alarm) FAULT_RESET Deviation & Discrepancy Reset FH Flow High FI Flow Indication FI_PREV Yesterday's Total Flow Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-8 TABLE 6.3.5 TAG SUFFIX SUFFIX DESCRIPTION* FI_TODAY Today's Total Flow HW_FAULT Hardware Fault II Current (amp) Indication INFORM Equipment Information Tag JBL Low Battery JBN Loss of Power JF Power Factor JI Power Indication LAST_RUN_DD Last Run Calendar Day LAST_RUN_DW Last Run Day of the week LAST_RUN_HH Last Run Hour LAST_RUN_MM Last Run Month LAST_RUN_MN Last Run Minute LAST_RUN_SS Last Run Second LAST_RUN_YY Last Run Year LEAD_LAG Lead-Lag Indication/Setting LH Level High LI Level Indication LL Level Low LO_LOCKOUT Low Level Lockout MAN_OVR Manual Override - appended to Analog Indication Suffix MM Running Status MOD_FAIL I/O Module Fail OPEN_REQ Operator Open Request OR Over Range - appended to Analog Indication Suffix ORP Oxidation Reduction Potential PH Pressure High Switch PHY pH PI Pressure Indication PID_AUTO_MAN PID control block auto/manual mode (used for tuning only) Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-9 TABLE 6.3.5 TAG SUFFIX SUFFIX DESCRIPTION* PID_DB PID block deadband PID_GAIN PID block gain (proportional) PID_RESET_TIME PID block reset time (integral) PID_SP Auto Mode Setpoint PID_SP_HIGH Auto Mode High Control Limit PID_SP_LOW Auto Mode Low Control Limit PL Pressure Low Switch POS_DB Position Deadband POS_MAX Position Maximum Setpoint POS_STPT Position Setpoint PREV_RUNTIME Yesterday's Runtime PREV_RUNTIME Yesterday's Runtime PREV_STARTS Yesterday's Starts RT_RESET Resettable Runtime and Starts Reset Request RT_RESET_DD Runtime/Starts Reset On Calendar Day RT_RESET_DW Runtime/Starts Reset On Day of the week RT_RESET_HH Runtime/Starts Reset On Hour RT_RESET_MM Runtime/Starts Reset On Month RT_RESET_MN Runtime/Starts Reset On Minute RT_RESET_SS Runtime/Starts Reset On Second RT_RESET_YY Runtime/Starts Reset On Year RUNT_FIXSEQ Runtime vs. Fixed Sequence Lead/Lag control RUNTIME Resettable Runtime SI Speed Indication SPEED_DB Speed Deadband SPEED_MAX Maximum Speed Setpoint SPEED_MIN Minimum Speed Setpoint SPEED_OUT PID block speed output START_REQ Operator Start Request STARTS Resettable Starts STARTS_HOUR # of Starts in the Last Hr. Section 6 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 6-10 TABLE 6.3.5 TAG SUFFIX SUFFIX DESCRIPTION* STARTS_STPT Starts allowed per hour STARTS_TIME_REM Time Remaining Until Start Allowed STOP_REQ Operator Stop Request TAGOUT Out of Service Tag TH Temperature High TIME_REM Time Remaining Until Fault (Discrepancy Alarm) TL Temperature Low TODAY_RUNTIME Today's Runtime TODAY_STARTS Today's Starts TOTAL_RUNTIME Today's Runtime TOTAL_STARTS Total Starts UR Under Range - appended to Analog Indication Suffix VI Voltage Indication YA Alarm Condition YCA Auto Mode =1, Manual Mode = 0 YF Generic Equipment Fault YJ Power Available YLA Overload Trip YLS Overload Alarm YS Remote Mode ZH Position Open Switch ZI Position Indication ZL Position Closed Switch * Fault/Alarm condition may be either Normally Open or Normally Closed in the field. However, all tags at the HMI are "true" for alarm or fault. All Normally Closed I/O for fault/alarm conditions are inverted in the PLC Logic. Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-1 7 7. HMI ANIMATIONS 7.1. Overview The HMI’s primary purpose is to convey real time process information and control to the plant staff. Animations of static symbols convey this information to the plant. The use of only color changes to indicate device state change is not permitted on process level graphics. Devices will have a text status indication in addition to the color animations. Text status may be removed from overview graphics to allow for condense representation of the process only if a detail process graphic exists that has both the color and text animations. Overview graphics should display color animations for every device shown that has live data. Do not use unanimated overview graphics and animated detailed graphics. 7.2. Animation States & Methods The color of each piece of equipment should be GREEN for running and RED for stopped. GRAY should be used for place holding (no computer monitoring available). Failures and faults should be indicated by a square background directly behind the component. An active, unacknowledged alarm should be indicated by a BLINKING YELLOW background. An active, acknowledged alarm should have a solid YELLOW background. An inactive or resolved but unacknowledged alarm should have a BLINKING WHITE background. Device status text terms OPENED/CLOSED should be used to indicate position status whereas terms OPEN/CLOSE should be used to indicate a command. OPENING and CLOSING should be used to indicate that a state transition is occurring. Terminology for STOP/START follows a similar pattern. Liquid level in tanks and wet wells should be indicated by dynamic level change in the body of the symbol representing level. The dynamic fill color should be the same as the process flow line. The current level value should also be indicated digitally above the animated level. Animations are accomplished by changing the color properties of the symbol not by layering many symbols of different colors on top of each other and controlling visibility. The PLC or HMI will calculate an integer value that represents all of the possible states of the device through different values of the integer. The color property of the symbol and associated status text will change values based on this integer. The use of global look up tables in iFIX has been used extensively for color animation reference. Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-2 7.3. Valve Animations 7.3.1. Opened/Closed Motorized Valve y The valve body in closed state should be solid RED symbol with “CLOSED” status text. y The valve body in opened state should be solid GREEN symbol with “OPENED” status text. y Intermediate state is when neither the opened nor closed limit is made. The valve body in intermediate state should be CYAN and either RED or GREEN with “CLOSING” or “OPENING” status text, respectively. y Failed state should be when both closed and opened limits are made, through a common failed status bit from the actuator, from logic within the PLC, or loss of communications to with the PLC. The background behind the valve body in failure state should BLINK YELLOW. The text box should read as follows: o The status text should read “FAIL” if both closed and opened limits are active or a fail bit is active from the actuator. o If the valve failed and the opened bit is still made then the status text should alternate between “FAIL” and “OPENED”. o If the valve failed and the closed bit is still made then the status text should alternate between “FAIL” and “CLOSED”. o If the HMI loses communications with the PLC or if a smart actuator loses communication with the PLC, the status text should alternate between “COMM” and “FAIL”. The standard valve symbols should be animated to show opened, closed, intermediate, and fail. The database tags with the following signal codes used in the animation are as follows: y ##AAA$$$%%%_ZH – Open tag y ##AAA$$$%%%_ZL – Closed tag y ##AAA$$$%%%_ANY_FAULT – Common Alarm (Fail) y ##AAA$$$%%%_BAD – Bad communication Figure - Opened/Closed Motorized Valve Animations Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-3 These tags are used in a calculation block for the overall status of the valve. Below the valve symbol is a white box with a black border. It should show the status of the valve with black text. The text should be animated with the STATUS tag as indicated in the table below. The box foreground color should also be animated to reflect the status of the valve as indicated in the figure above. TABLE 7.3.1 VALVE TEXT LOW HIGH STRING BLINK TO 0 8 FAIL COMM 9 9 FAIL 10 10 FAIL CLOSED 11 11 FAIL OPENED 12 12 FAIL INTER 13 13 FAIL 14 14 CLOSED 15 15 OPENED 16 16 INTER 7.3.2. Valve with Limit Switches Only y The valve body in closed state should be solid RED symbol with “CLOSED” status text. y The valve body in opened state should be solid GREEN symbol with “OPENED” status text. y Intermediate state is when neither the opened nor closed limit is made. The valve body in intermediate state should be CYAN with “INTER” status text. y Failed state should be when both closed and opened limits are made, through a common failed status bit from the actuator, or loss of communications to with the PLC. The background behind the valve body in failure state should be YELLOW. The text box should read as follows: o The status text should read “FAIL” if both closed and opened limits are active or a fail bit is active from the actuator. o If the HMI loses communications with the PLC or if a smart actuator loses communication with the PLC, the status text should alternate between “COMM” and “FAIL”. Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-4 7.3.3. Modulating Motorized Valve y The valve body in closed state should be solid RED symbol with “0 %” status text. y The valve body in opened state should be solid GREEN symbol with “100%” status text. y Intermediate state is when neither the opened nor closed limit is made. The valve body in intermediate state should be CYAN with “XX%” status text, where XX is the current percentage the valve is opened. y Failed state should be when both closed and opened limits are made, through a common failed status bit from the actuator, from logic within the PLC, or loss of communications to with the PLC. The background behind the valve body in failure state should be YELLOW. The text box should read as follows: o The status text should read “FAIL” if both closed and opened limits are active or a fail bit is active from the actuator. o If the valve failed and the opened bit is still made then the status text should alternate between “FAIL” and “OPENED”. o If the valve failed and the closed bit is still made then the status text should alternate between “FAIL” and “CLOSED”. o If the HMI loses communications with the PLC or if a smart actuator loses communication with the PLC, the status text should alternate between “COMM” and “FAIL”. Figure - Modulating Motorized Valve Animations Figure - Valve with Limit Switches Only Animations Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-5 The standard valve symbols should be animated to show opened, closed, intermediate, and fail. The database tags with the following signal codes used in the animation are as follows: y ##AAA$$$%%%_ZH – Open tag y ##AAA$$$%%%_ZL – Closed tag y ##AAA$$$%%%_ANY_FAULT – Common Alarm (Fail) y ##AAA$$$%%%_BAD – Bad communication These tags are used in a calculation block for the overall status of the valve. The position of the valve should be shown in the white boxes with a black border below the valve body. It should be animated with the tag ##AAA$$$%%%_ZI. TABLE 7.3.2 VALVE_OC_TEXT LOW HIGH STRING BLINK TO 0 8 FAIL COMM 9 9 FAIL 10 10 FAIL CLOSED 11 11 FAIL OPENED 12 12 FAIL INTER 13 13 FAIL 14 14 CLOSED 15 15 OPENED 16 16 INTER 7.4. Gate Animations 7.4.1. Opened/Closed Motorized Gate y The gate body in closed state should be solid RED symbol, appear closed with “CLOSED” status text. y The gate body in opened state should be solid GREEN symbol, appear opened with “OPENED” status text. y Intermediate state is when neither the opened nor closed limit is made. The gate body in intermediate state should be CYAN and either RED (Closing) or GREEN (Opening) with “INTER” status text. y Failed state should be when both closed and opened limits are made, through a common failed status bit from the actuator, from logic within the PLC, or loss of Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-6 communications to with the PLC. The background behind the gate body in failure state should be YELLOW. The text box should read as follows: o The status text should read “FAIL” if both closed and opened limits are active or a fail bit is active from the actuator. o If the gate failed and the opened bit is still made then the status text should alternate between “FAIL” and “OPENED”. o If the gate failed and the closed bit is still made then the status text should alternate between “FAIL” and “CLOSED”. o If the HMI loses communications with the PLC or if a smart actuator loses communication with the PLC, the status text should alternate between “COMM” and “FAIL”. 7.4.2. Gate with Limit Switches Only y The gate body in closed state should be solid RED symbol with “CLOSED” status text. y The gate body in opened state should be solid GREEN symbol with “OPENED” status text. y Intermediate state is when neither the opened nor closed limit is made. The gate body in intermediate state should be CYAN with “INTER” status text. y Failed state should be when both closed and opened limits are made, through a common failed status bit from the actuator, from logic within the PLC, or loss of communications to with the PLC. The background behind the gate body in failure state should be YELLOW. The text box should read as follows: o The status text should read “FAIL” if both closed and opened limits are active or a fail bit is active from the actuator. o If the gate failed and the opened bit is still made then the status text should alternate between “FAIL” and “OPENED”. o If the gate failed and the closed bit is still made then the status text should alternate between “FAIL” and “CLOSED”. o If the HMI loses communications with the PLC or if a smart actuator loses communication with the PLC, the status text should alternate between “COMM” and “FAIL”. Figure - Motorized Gate Animations Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-7 Figure - Gate with Limit Switches Only Animations 7.4.3. Modulating Gate y The gate body in closed state should be solid RED symbol, appear closed with “0%” status text. The gate body in opened state should be solid GREEN symbol, appear opened with “100%” status text. y Intermediate state is when neither the opened nor closed limit is made. The gate body in intermediate state should be CYAN with “XX%” status text, where XX is the percentage that the gate is opened. y Failed state should be when both closed and opened limits are made, through a common failed status bit from the actuator, from logic within the PLC, or loss of communications to with the PLC. The background behind the gate body in failure state should be YELLOW. The text box should read as follows: o The status text should read “FAIL” if both closed and opened limits are active or a fail bit is active from the actuator. o If the gate failed and the opened bit is still made then the status text should alternate between “FAIL” and “OPENED”. o If the gate failed and the closed bit is still made then the status text should alternate between “FAIL” and “CLOSED”. o If the HMI loses communications with the PLC or if a smart actuator loses communication with the PLC, the status text should alternate between “COMM” and “FAIL”. Figure - Modulating Gate Animations 7.5. Motor & Pump Animations The end equipment driven by the motor will be animated along with the motor. Some examples: blower and gearbox is animated with its motor, pump is animated with it Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-8 motor (if the static symbol includes a motor part), clarifier flights are animated with their drive motor, etc. 7.5.1. On/Off Motor y The motor body in stopped state should be solid RED symbol with “STOPPED” status text. y The motor body in running state should be solid GREEN symbol with “RUNNING” status text. y Intermediate state is when neither the stopped nor running feedback for the motor is received following a stop or start command, respectively. The motor body in stopping intermediate state should be RED on the interior and GREEN on the exterior with “STOPPING” status text. The motor body in starting intermediate state should be GREEN on the interior and RED on the exterior with “STARTING” status text. Intermediate state will not apply to monitor only motors. y Failed state should be through a common failed status bit from the motor starter, from logic within the PLC, or loss of communications to with the PLC. The background behind the motor body in failure state should be YELLOW. The text box should read as follows: o The status text should read “FAIL” if only a fail bit is active from the motor starter. o If the motor failed to start when given a start command then the status text should alternate between “FAIL” and “START”. o If the motor failed to stop when given a stop command then the status text should alternate between “FAIL” and “STOP”. o If the HMI loses communications with the PLC or if a smart starter loses communication with the PLC, the status text should alternate between “COMM” and “FAIL”. Figure - On/Off Motor and Pump Animations 7.5.2. Variable Speed Motor y The motor body in stopped state should be solid RED symbol with “0%” status text. Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-9 y The motor body in running state should be solid GREEN symbol with “XX%” status text, where XX is the percentage of full speed. y Intermediate state is when neither the stopped nor running feedback for the motor is received following a stop or start command, respectively. The motor body in stopping intermediate state should be RED on the interior and GREEN on the exterior with “XX%” status text. The motor body in starting intermediate state should be GREEN on the interior and RED on the exterior with “XX%” status text. y Failed state should be through a common failed status bit from the motor starter, from logic within the PLC, or loss of communications to with the PLC. The background behind the motor body in failure state should be YELLOW. The text box should read as follows: o The status text should read “FAIL” if only a fail bit is active from the motor starter. o If the motor failed to start when given a start command then the status text should alternate between “FAIL” and “START”. o If the motor failed to stop when given a stop command then the status text should alternate between “FAIL” and “STOP”. o If the motor failed to stop when given a stop command then the status text should alternate between “FAIL” and “STOP”. o If the HMI loses communications with the PLC or if a smart VFD loses communication with the PLC, the status text should alternate between “COMM” and “FAIL”. Figure - Variable Speed Motor Animations 7.6. Control Mode Animations A controllable device may be in one of three modes from the HMI, local, manual or automatic. y Local mode is when the device is being controlled by hard wired means or through a local OIT. Local mode is any mode where the HMI does not have any control of the device (if control exists). Example: pump L/O/R switch is in local and the plant staff is controlling the pump through the hard wired switches on the LCP. y Manual Mode is when the device can be controlled through the HMI but the operator provides all control inputs. The PLC in this mode may only change the Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-10 device commands due to interlocks. Example: Pump L/O/R switch is in remote and the plant is using the HMI to control the start/stop and speed of the pump. y Automatic mode is when the device can be controlled through the HMI and PLC to automatically maintain process variables. Example: Pump L/O/R switch is in remote and the PLC is issuing start/stop and speed control commands to the pump automatically to maintain a flow set point. Local, Manual or Automatic status for a controllable device should be indicated on the process graphic through the symbols shown in figure. y Local mode is represented by a yellow circle with a black “L” in it next to the device. y Manual mode is represented by a black circle with a white “M” in it next to the device. y Automatic mode is represented by a white circle with a black “A” in it next to the device. Local, Manual, Automatic status for a controllable valve requires a calculation block. The valve should have a symbol indicating the status of the control as shown in figure. 7.7. Control Mode Configuration The tags from the database have the following signal codes: y ##AAA$$$%%%_YS – Local\Remote y ##AAA$$$%%%_YCA – Manual\Auto The calculation block for the Local, Manual, and Automatic control is named with AML as the signal code. The foreground color of the circle should be animated with the AML tag and color as indicated in the figure above. Figure - HMI Local, Manual and Automatic Indication Section 7 HMI Animations Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 7-11 The text inside the circle should be animated with the AML tag and the text as indicated in the table below. The background and foreground color of the text should be animated with the AML tag. TABLE 7.7.1 AML_TEXT VALUE STRING BLINK TO 0 L 1 M 2 L 3 A 7.8. Alarm Summary Animations Alarm summary colors should be as detailed earlier in this section and configured as DA type database blocks in the iFIX process database with the following features: y Each alarm should have the security area configured for the plant and process area that the alarm originates from. y Each alarm should have the alarm area configured for the plant and process area that the alarm originates from. y Each loop should have one acknowledge tag for resetting alarms for that loop. Acknowledging the alarm in the iFIX alarm summary object should fire the acknowledge tag. Refer to PLC logic documentation details of alarm generation and handling in the PLC. Use of the threshold alarm features in the any of the analog iFIX database blocks is prohibited. Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 8-1 8 8. CONTROL POP-UPS AND METHODS 8.1. Overview Equipment controlled from the computer on the graphic display is highlighted (by a thin black line box surrounding the equipment symbol) when the user passes the cursor over the equipment symbol. Clicking on the highlighted equipment symbol pulls up a small "Control" window. The window allows the Operator to control the operation of the equipment. When an Operator selects a particular piece of equipment such as a pump or a valve, the window will include START/STOP or OPEN/CLOSE pushbuttons. Speed and position controls for variable speed drives or modulating valves, respectively, may also be provided in the window when appropriate. A RESET pushbutton should be provided to reset interlocks for the selected component, when appropriate, and an ACKNOWLEDGE pushbutton to acknowledge component-specific alarms. The process graphics screen is for monitoring the process and not for direct commands (set point entry, start/stop buttons, open/close buttons, etc.). The use of pop-ups is intended to avoid accidently initiating commands on a process graphic, even if the pop up is full-screen size. The security implementation also relies on all control being in pop-ups and not directly on the process graphics. For added security after submitting critical set points or changes, a popup should display for the operator to confirm these changes where possible. All PID control loops, sequential and discrete logic is executed in the PLC, not the HMI. Any computational algorithms or logic incorporated into the HMI is only used to perform screen animations. Section 8 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 8-2 8.2. Open/Close Control The same open/close control pop-up is used for all valves regardless of actuation method. The left pop-up below is used for hard wired valves and the detailed status button is invisible. When an actuator communicates to the PLC via Modbus or another protocol, additional monitoring can be done (i.e. “smart valve”). When a smart valve is clicked, the left pop- up below appears with the detailed status button visible. 8.3. On/Off Control The same on/off control pop up is used for all start/stop or on/off applications regardless of equipment type. The pop-up below is used for hard wired control. At this point, no motor starters using a communication protocol to the PLC have been used. In the future, when a starter communicates to the PLC via Modbus or another protocol, additional monitoring will be available (i.e. “smart starter”). When a smart item is selected, the pop-up appears and a detailed status button will be visible. Figure - Open/Close Control Pop-Up Section 8 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 8-3 8.4. Modulating Control The same modulating control pop up is used for all valves regardless of actuation method. The left pop-up below is used for hard wired valves and the detailed status button is invisible. When an actuator communicates to the PLC via Modbus or another protocol, additional monitoring can be done (i.e. “smart valve”). When a smart valve is selected, the left pop- up below appears and the detailed status button is visible. Figure - Modulating Control Pop-Up Section 8 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 8-4 8.5. Variable Speed Control The same variable speed control pop-up is used for all applications regardless of equipment type. The pop-up below is used for hard wired control. At this point, no motor VFD’s using a communication protocol to the PLC have been used. In the future, when a starter communicates to the PLC via Modbus or another protocol, additional monitoring will be available (i.e. “smart VFD”). When a smart item is selected, the pop-up appears and a detailed status button will be visible. Figure - Variable Speed Control Pop-Up Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 9-1 9 9. SECURITY 9.1. Overview In general, system security must be provided at each individual workstation or server. Different levels of access for user entry are divided into two groups, Operators and Administrators. Refer to Table 9.1.1 below for a list functions available to either group. Changes made to the security levels should go through a City approval process. For added security, actions of the logged-in operator will also be tracked in a text file for future reference. TABLE 9.1.1 SECURITY ACCESS GROUP CATEGORY FUNCTION AVAILIBLE Operators Security Areas None Application Features Database Reloader Historical Trend Collection iFIX System Shutdown Manual Failover Recipe Downloader from Recipe Builder Recipe Load Recipe Save Recipe Upload from Recipe Builder Runtime Visual Basic Editor System User Login System User Logout Tag Status Workspace Runtime Workspace Runtime Exit Administrators Security Areas Set Points Application Features Background Block Add-Delete Database Manager Database Loader Database Reloader Database Saver EDA Feature 1-54 Enable Ctrl-Alt-Delete Enable Task Switching Section 9 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 9-2 TABLE 9.1.1 SECURITY ACCESS GROUP CATEGORY FUNCTION AVAILIBLE Historical Trend Assign Historical Trend Collection Historical Trend Export iFIX System Shutdown Manual Failover Project Backup-Restore Recipe Builder Development Recipe Builder Operations Recipe Downloader from Recipe Recipe Load Recipe Save Recipe Save from Recipe Builder Recipe Text Output from Recipe Recipe Upload from Recipe Builder Runtime Visual Basic Editor Security Configuration System Configuration System User Login System User Logout Tag Group Editor Tag Status Workspace Configuration Workspace Runtime Workspace Runtime Exit Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 10-1 10 10. FILE NAMING CONVENTIONS 10.1. Process Graphics All of the HMI graphics files follow a naming convention to ensure ease of finding process graphics. PPBBB_X.GRF PP = Plant Code (e.g. LL or RR) BBB = Building/Area Code. Should match building/area where the process data originates from. X = user defined field can be anything the developer needs to use to convey what is on the graphic. 10.2. Control Pop-ups Universal Pop-ups are used across multiple unit processes to accomplish similar functions such as controlling process equipment. POP_X.GRF POP = fixed field designating a universal pop up. X = user defined field can be anything the developer needs to use to convey what the pop up is for. Point Specific Pop-ups are used only one time for very unique control items. PPBBB_POP_X.GRF PP = Plant Code (e.g. LL or RR) BBB = Building/Area Code. Should match building/area where the process data originates from. POP = fixed code for identifying the graphic as a pop up. X = user defined field can be anything the developer needs to use to convey what is on the pop up. 10.3. Menus In order to navigate throughout the HMI graphics, a series of menus are used. There are overall plant menus and menus specific to each unit process. Section 10 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 10-2 Plant Wide Menus are named given the function of the HMI that they help organize. Using Plant Code “PP” for an example: PPMENU_MAIN.GRF – menu of all the other menus. PPMENU_PLANT_OVERVIEW.GRF – menu in the form of a map of the plant. PPMENU_HIST.GRF – menu of all trend menus for each unit process. PPMENU_RUNTIMES.GRF – menu of all runtime menus for each unit process. Unit Process Menus provide links to all of the available screens that deal with a unit process. PPMENU_BBB.GRF PP = Plant Code (e.g. LL or RR) MENU = fixed field designating a menu. BBB = Building/Area Code. Should match building/area where the process data originates from. 10.4. Alarm Graphics There are several graphics that list all the alarms for the entire plant. Each unit process also has an alarm screen that displays the alarms just for that unit process. Plant Wide Alarm graphics, using Plant Code “PP” for an example: PPALARM_SUMMARY.GRF – all Plant alarms. PPALARM_FILTER – all Plant filter alarms. PPALARM_FWPUMP – all Plant finished water pumping alarms. Unit Process Alarm graphics: PPALARM_BBB.GRF PP = Plant Code (e.g. LL or RR) ALARM = fixed field designating an alarm. BBB = Building/Area Code. Should match building/area where the process data originates from. 10.5. Historical Trend Graphics All historical trends are associated with the PLC where the process data originates from. Section 10 Issues, Drivers and Needs Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 10-3 PPHIST_BBB_X.GRF PP = Plant Code (e.g. LL or RR) HIST = fixed field designating a trend. BBB = Building/Area Code. Should match building/area where the process data originates from. X = user defined field can be anything the developer needs to use to convey what is being trended. Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 11-1 11 11. HMI GRAPHIC SAMPLES 11.1. Overview The following are sample HMI graphics for comparison. Sample Graphic 1 – Overview Section 11 HMI Graphic Samples Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 11-2 Sample Graphic 2 – Main Menu Sample Graphic 3 – Subsystem Overview 1 Section 11 HMI Graphic Samples Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 11-3 Sample Graphic 4 – Subsystem Overview 2 Sample Graphic 5 – Subsystem Overview 3 Section 11 HMI Graphic Samples Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 11-4 Sample Graphic 6 – Equipment Status 1 Sample Graphic 7 – Equipment Status 2 Section 11 HMI Graphic Samples Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 11-5 Sample Graphic 8 – Flow Status Sample Graphic 9 – Equipment Runtime Section 11 HMI Graphic Samples Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 11-6 Sample Graphic 10 – Set Points Sample Graphic 11 – Alarm Summary Section 11 HMI Graphic Samples Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards 11-7 Sample Graphic 12 – Trends Sample Graphic 13 – Communication Status Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-1 Appendix A PLC Common Instructions Common instructions are used to define your most frequently used logic. These instructions will allow programmers to easily reuse sets of instructions and promote consistency throughout the PLC program. By defining these common elements, changes can be made in one place and they will be automatically updated wherever the instruction is used. Each instruction will have a set input and output parameters as described below. Note: The tag names used below are for reference only. Refer to Section 6.3 for tag naming conventions. 1.1. Background Components The background instructions are often used within more complex instructions and normally pass parameters to the containing or parent instruction. This section will describe these instructions and define commonly used parameters associated with the more complex instructions. 1.1.1. Runtime The Runtime instruction calculates the number of minutes a device has run over a period of time. It also counts the number of times the device has started over the same period of time. The input parameters include: x Running – When this input is active, the logic increments the runtime minutes and logs a start. x Totals_Reset – Resets the runtime minutes and number of starts. This is typically triggered from the PLC time clock on a daily basis. The output parameters include x Runtime_Mins_Current – The number of incremented minutes since the logic was last reset. x Runtime_Mins_Last – The number of minutes elapsed when the logic was last reset. x Starts_Current – The number of times the device has started since the logic was last reset. x Starts_Last – The number of times the device had started when the logic was last reset. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-2 LOGIC Running Totals_Reset Runtime_Mins_Current Inputs Outputs Runtime_Mins_Last Starts_Current Starts_Last Figure 1.1.1. Runtime Instructions Diagram 1.1.2. 2-Wire Motor Start/Stop The 2-wire motor start and stop instruction (SS2Wire) controls the start and stop function, start delays, and run failure alarms for each motor. The new input parameters include: x Remote – Field input indicating the device is in the Remote mode. The device is not allowed to run from the PLC if it is not in Remote mode. x Manual – When the parameter is active, the device is in Manual mode. When it is not active, the device is in Automatic mode. This parameter is typically manipulated by a toggle on the HMI. x Running – Field input indicating the device is running. x Fail1-6 – Field inputs indicating the device has failed. If the device has failed, the PLC will not attempt to start it, thus avoiding nuisance run failure alarms. x Start_PB – When this parameter is activated, the device will start if it is in Manual mode. This parameter is typically pulsed by a pushbutton on the HMI. This parameter has no effect when the device is in Automatic mode. x Stop_PB – When this parameter is activated, the device will stop if it is in Manual mode. This parameter is typically pulsed by a pushbutton on the HMI. This parameter has no effect when the device is in Automatic mode. x Auto_Call – When this parameter is activated, the device will start if it is in Automatic mode. Logic to define when a device will start automatically is defined elsewhere. This parameter has no effect when the device is in Manual mode. x Alarm_Reset – Resets Fail-to-Start and Fail-to-Stop alarms. This parameter is typically pulsed by a pushbutton on the HMI. x Fail_Time – Defines the amount of time that must elapse between when the PLC commands the device to start or stop and the correct feedback is detected. x StartDelay_SP – Defines the amount of time that must elapse after stopping a device before it can be restarting. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-3 The new output parameters include: x Run_Cmd – Output to start the device when the parameter is active. A 2-wire controller will start the device when the output is active and stop the device when the output is not active. x Starting – Parameter is activated when the device has been commanded to start, but a running feedback has not yet been received. x Stopping – Parameter is activated when the device has been commanded to stop, but a running feedback is still being received. x Failed – Parameter is activated when any of the following is active: o Fail1-6 field inputs o Fail-to-Start o Fail-to-Stop x Fail_Start – Parameter is activated when the device is in Starting state for longer than the Fail Time. x Fail_Stop – Parameter is activated when the device is in Stopping state for longer than the Fail Time. x StartDelay – Parameter is activated when the device is in Start Delay. x StartDelay_Countdown – Defines the amount of time remaining during a Start Delay. LOGIC Running Remote Starting Stopping Inputs Outputs Manual Start_PB Stop_PB Auto_Call Fail1 Fail2 Fail3 Fail4 Fail5 Fail6 Fail_Time Alarm_Reset Failed Fail_Start Fail_Stop Run_Cmd StartDelay StartDelay_SP StartDelay_Countdown Figure 1.1.2. – 2-Wire Motor Start/Stop Instructions Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-4 1.1.3. 3-Wire Motor Start/Stop The 3-wire start and stop instruction (SS3Wire) controls the start and stop function, start delays, and run failure alarms for each motor. The input parameters for this instruction are previously defined in Appendix A, Section 1.1.2. The output parameters differ from the 2-wire start/stop instruction as the Run Command is replaced by Start and Stop commands. A 3-wire controller will start the device when the Start Command is active and continue to run until the Stop Command is activated. The new output parameters include: x Start_Cmd – Output to start the device when the parameter is active. x Stop_Cmd – Output to stop the device when the parameter is active. The remaining output parameters for this instruction are previously defined in Appendix A, Section 1.1.2. LOGIC Starting Stopping Inputs Outputs Failed Fail_Start Fail_Stop Start_Cmd StartDelay StartDelay_Countdown Stop_Cmd Running Remote Manual Start_PB Stop_PB Auto_Call Fail1 Fail2 Fail3 Fail4 Fail5 Fail6 Fail_Time Alarm_Reset StartDelay_SP Figure 1.1.3. – 3-Wire Motor Start/Stop Instructions Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-5 Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-6 1.1.4. Discrepancy Alarm The discrepancy instruction (DiscrepAlarm) compares an analog command with its feedback and generates an alarm if there is a discrepancy. The input parameters include: x Command – Value of the analog command being sent to the device. x Remote – Field input indicating the device is in the Remote mode. Discrepancy alarms are not generated for devices in Local mode. x Failed – Input indicating the device has failed. Discrepancy alarms are not generated for devices that have failed. x Feedback – Analog feedback value from the device. x Alarm_Reset – Resets discrepancy alarm. This parameter is typically pulsed by a pushbutton on the HMI. x Deadband – The minimum amount the Feedback must be above or below the Command to generate a Discrepancy alarm. x Fail_Time – Defines the amount of time that must elapse before the alarm is active. The output parameters include: x Discrepancy_Fail – Parameter is activated when the Feedback is above or below the Command (+/- deadband) for longer than the Fail Time. x Increasing – Parameter is activated when the Feedback is less than the command (minus deadband). x Decreasing – Parameter is activated when the Feedback is more than the command (plus deadband). LOGIC Failed Remote Decreasing Inputs Outputs Command Feedback Deadband Fail_Time Increasing Discrepancy_Fail Alarm_Reset Figure 1.1.4. – Discrepancy Alarm Instructions Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-7 1.2. Motor Controllers Motor controller instructions use many of the background instructions and associated input and output parameters listed in Appendix A, Section 1.1. New parameters not defined in Section 1.1 are defined in each instruction below. 1.2.1. 2-Wire Constant Speed Motor The 2-wire constant speed motor instruction (CnstSpd2Wire) is the simplest motor controller and contains the SS2Wire and Runtime instructions. The input and output parameters for this instruction are previously defined. LOGIC Running Remote Starting Stopping Inputs Outputs Manual Start_PB Stop_PB Auto_Call Fail1 Fail2 Fail3 Fail4 Fail5 Fail6 Fail_Time Failed Fail_Start Fail_Stop Run_Cmd StartDelay StartDelay_SP StartDelay_Countdown Alarm_Reset Totals_Reset Runtime_Mins_Current Runtime_Mins_Last Starts_Current Starts_Last Figure 1.2.1. 2-Wire Constant Speed Motor Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-8 1.2.2. 3-Wire Constant Speed Motor The 3-wire constant speed motor instruction (CnstSpd3Wire) contains the SS3Wire and Runtime instructions. The input and output parameters for this instruction are previously defined. LOGIC Running Remote Inputs Outputs Manual Start_PB Stop_PB Auto_Call Fail1 Fail2 Fail3 Fail4 Fail5 Fail6 Fail_Time Start_Cmd StartDelay_SP Alarm_Reset Stop_Cmd Totals_Reset Starting Stopping Failed Fail_Start Fail_Stop StartDelay StartDelay_Countdown Runtime_Mins_Current Runtime_Mins_Last Starts_Current Starts_Last Figure 1.2.2. 3-Wire Constant Speed Motor Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-9 1.2.3. 2-Wire VFD Motor The 2-wire VFD motor instruction (VFD2Wire) contains the SS2Wire, Runtime, and DiscrepAlarm instructions. The instruction provides additional logic for speed control. The new input parameters include: x Speed_Ind – Analog feedback value from the VFD. x Man_SP – Manual Speed setpoint that the VFD will operate at when in the Manual mode. This parameter is typically entered at the HMI. This parameter has no effect when the device is in Automatic mode. x Auto_SP – Auto Speed setpoint that the VFD will operate at when in the Automatic mode. Logic to define the automatic speed of the device is defined elsewhere. This parameter has no effect when the device is in Manual mode. The new output parameters include: x Speed_Cmd – Value of the analog command being sent to the VFD. LOGIC Running Remote Inputs Outputs Manual Start_PB Stop_PB Auto_Call Fail1 Fail2 Fail3 Fail4 Fail5 Fail6 Fail_Time StartDelay_SP Speed_Ind Auto_SP Alarm_Reset Discrepancy_Deadband Starting Stopping Failed Fail_Start Fail_Stop Speed_Cmd StartDelay StartDelay_Countdown Totals_Reset Runtime_Mins_Current Runtime_Mins_Last Starts_Current Starts_Last Discrepancy_Fail Run_Cmd Man_SP Figure 1.2.3. 2-Wire VFD Motor Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-10 1.2.4. 3-Wire VFD Motor The 3-wire VFD motor instruction (VFD3Wire) contains the SS3Wire, Runtime, and DiscrepAlarm instructions. The input and output parameters for this instruction are previously defined. LOGIC Running Remote Inputs Outputs Manual Start_PB Stop_PB Auto_Call Fail1 Fail2 Fail3 Fail4 Fail5 Fail6 Fail_Time StartDelay_SP Speed_Ind Man_SP Alarm_Reset Discrepancy_Deadband Starting Stopping Failed Fail_Start Fail_Stop Speed_Cmd StartDelay StartDelay_Countdown Totals_Reset Runtime_Mins_Current Runtime_Mins_Last Starts_Current Starts_Last Discrepancy_Fail Start_Cmd Stop_Cmd Auto_SP Figure 1.2.4. 3-Wire VFD Motor Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-11 1.2.5. 2-Wire Chemical Metering Pump The 2-wire motor chemical pump instruction (ChemPump2Wire) contains the SS2Wire, Runtime, and DiscrepAlarm instructions. The instruction provides additional logic for speed and stroke control. The new input parameters include: x Speed_Ind – Analog speed feedback value from the device. x Stroke_Ind – Analog stroke feedback value from the device. x Man_ Speed_ SP – Manual Speed setpoint that the device will operate at when in the Manual mode. This parameter is typically entered at the HMI. This parameter has no effect when the device is in Automatic mode. x Man_Stroke_SP – Manual Stroke setpoint that the device will operate at when in the Manual mode. This parameter is typically entered at the HMI. This parameter has no effect when the device is in Automatic mode. x Auto_Speed_ SP – Auto Speed setpoint that the device will operate at when in the Automatic mode. Logic to define the automatic speed of the device is defined elsewhere. This parameter has no effect when the device is in Manual mode. x Max_Speed_SP – Maximum speed the pump will run at in Automatic mode before the stroke is automatically increased. x Min_Speed_SP – Minimum speed the pump will run at in Automatic mode before the stroke is automatically decreased. x Stroke_Change_Delay_SP – Amount of time the pump speed must be above/below the min/max before the stroke is automatically adjusted. x Stroke_Change_Amount_SP – Amount the stroke is automatically adjusted when the pump speed is above/below the min/max. x Discrepancy_Deadband_Speed – Discrepancy deadband for the speed circuit. x Discrepancy_Deadband_Stroke – Discrepancy deadband for the stroke circuit. The new output parameters include: x Speed_Cmd – Value of the analog Speed command being sent to the device. x Stroke_Cmd – Value of the analog Stroke command being sent to the device.. x Discrepancy_Fail_Speed – Discrepancy alarm for the speed circuit. x Discrepancy_Fail_Stroke – Discrepancy alarm for the stroke circuit. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-12 LOGIC Running Remote Inputs Outputs Manual Start_PB Stop_PB Auto_Call Fail1 Fail2 Fail3 Fail4 Fail5 Fail6 Fail_Time StartDelay_SP Stroke_Ind Speed_Ind Man_Speed_SP Man_Stroke_SP Auto_Speed_SP Max_Speed_SP Min_Speed_SP Stroke_Change_Delay_SP Stroke_Change_Amount_SP Alarm_Reset Discrepancy_Deadband_Speed Discrepancy_Deadband_Stroke Discrepancy_Fail_Speed Discrepancy_Fail_Stroke Totals_Reset Starting Stopping Failed Fail_Start Fail_Stop StartDelay StartDelay_Countdown Starts Runtime_Mins Runtime_Mins_Current Runtime_Mins_Last Starts_Current Starts_Last Stroke_Cmd Speed_Cmd Run_Cmd Figure 1.2.5. 2-Wire Chemical Metering Pump Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-13 1.2.6. 3-Wire Chemical Metering Pump The 3-wire motor chemical pump instruction (ChemPump3Wire) contains the SS3Wire, Runtime, and DiscrepAlarm instructions. The input and output parameters for this instruction are previously defined. LOGIC Running Remote Inputs Outputs Manual Start_PB Stop_PB Auto_Call Fail1 Fail2 Fail3 Fail4 Fail5 Fail6 Fail_Time StartDelay_SP Stroke_Ind Speed_Ind Man_Speed_SP Man_Stroke_SP Auto_Speed_SP Max_Speed_SP Min_Speed_SP Stroke_Change_Delay_SP Stroke_Change_Amount_SP Alarm_Reset Discrepancy_Deadband_Speed Discrepancy_Deadband_Stroke Discrepancy_Fail_Speed Discrepancy_Fail_Stroke Totals_Reset Starting Stopping Failed Fail_Start Fail_Stop StartDelay StartDelay_Countdown Starts Runtime_Mins Runtime_Mins_Current Runtime_Mins_Last Starts_Current Starts_Last Stroke_Cmd Speed_Cmd Start_Cmd Stop_Cmd Figure 1.2.6. 3-Wire Chemical Metering Pump Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-14 1.3. Valve Controllers 1.3.1. Maintain Contact Valve The maintain contact (isolation) valve instruction (ValveControlMaint) is used for a valve or gate with maintained Open and Closed contacts. The input parameters include: x Remote – Field input indicating the device is in the Remote mode. The device is not allowed to run from the PLC if it is not in Remote mode. x Manual – When the parameter is active, the device is in Manual mode. When it is not active, the device is in Automatic mode. This parameter is typically manipulated by a toggle on the HMI. x Open_LS – Field input indicating the Open limit switch is active. x Closed_LS – Field input indicating the Closed limit switch is active. x Fail – Input indicating the device has failed. If the device has failed, the PLC will not attempt to move it, thus avoiding nuisance travel fail alarms. x Open_PB – When this parameter is activated, the device will open if it is in Manual mode. This parameter is typically pulsed by a pushbutton on the HMI. This parameter has no effect when the device is in Automatic mode. x Close_PB – When this parameter is activated, the device will close if it is in Manual mode. This parameter is typically pulsed by a pushbutton on the HMI. This parameter has no effect when the device is in Automatic mode. x Auto_Call – When this parameter is activated, the device will open if it is in Automatic mode. Logic to define when a device will open automatically is defined elsewhere. This parameter has no effect when the device is in Manual mode. x Alarm_Reset – Resets Open and Close Fail alarms. This parameter is typically pulsed by a pushbutton on the HMI. x Fail_Time – Defines the amount of time that must elapse between when the PLC commands the device to open or close and the correct feedback is detected. x Totals_Reset – Resets the Moves totalizer. This is typically triggered from the PLC time clock on a daily basis. The output parameters include: x Open_Cmd – Output to open the device when the parameter is active. The contacts will stay energized until the device has reached its open limit switch. x Close_Cmd – Output to close the device when the parameter is active. The contacts will stay energized until the device has reached its closed limit switch. x Opening – Parameter is activated when the device has been commanded to open, but an opened feedback has not yet been received. x Closing – Parameter is activated when the device has been commanded to close, but a closed feedback has not yet been received. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-15 x Failed – Parameter is activated when any of the following is active: o Fail field input o Open_Fail o Closed_Fail x Open_Fail – Parameter is activated when the device is in Opening state for longer than the Fail Time. x Close_Fail – Parameter is activated when the device is in Closing state for longer than the Fail Time. x Moves_Current – The number of times the device has moved since the logic was last reset. x Moves_Last – The number of times the device had moved when the logic was last reset. LOGIC Open_LS Manual Inputs Outputs Remote OpeningClosed_LS Close_PB Open_PB Fail Fail_Time Alarm_Reset Auto_Call Closing Failed Open_Fail Close_Fail Open_Cmd Close_Cmd Totals_Reset Moves_Current Moves_Last Figure 1.3.1. Maintain Contact Valve Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-16 1.3.2. Analog Valve The analog valve instruction (ValveControlAnalog) is used for a valve or gate with an analog positioner. It contains the DiscrepAlarm instruction and provides additional logic for position control. Some of the input and output parameters for this instruction are previously defined in Appendix A, Section 1.3.1. The new input parameters include: x Enable_LS – When this parameter is active, physical limit switches are used as Open/Closed signals. If the parameter is inactive, the Position Indication is used instead. x Open_LS – Field input from the Open limit switch. If the actuator is not equipped with limit switches, set the Enable_LS parameter inactive and the Position Indication will be used instead. When the actuator is greater than 97% open, it is assumed it is fully open. x Closed_LS – Field input from the Closed limit switch. If the actuator is not equipped with limit switches, set the Enable_LS parameter inactive and the Position Indication will be used instead. When the actuator is less than 3% open, it is assumed it is fully closed. x Pos_Ind – Analog position feedback from the device. x Man_SP – Manual Position setpoint that the device will operate when in the Manual mode. This parameter is typically entered at the HMI. This parameter has no effect when the device is in Automatic mode. x Auto_SP – Auto Position setpoint that the device will operate at when in the Automatic mode. Logic to define the automatic position of the device is defined elsewhere. This parameter has no effect when the device is in Manual mode. x Max_Moves – Defines the maximum number of times the device may be commanded to change position per hour while in Automatic mode. As an example, if the parameter is set to “60,” then the device would only be allowed to change position once per minute; it would not move 60 times then be locked out for the rest of the hour. The new output parameters include: x Pos_Cmd – Position Command sent to the device. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-17 Close_Cmd LOGIC Open_LS Manual Inputs Outputs Remote Opening Closed_LS Man_SP Pos_Ind Fail Auto_SP Fail_Time Alarm_Reset MaxMoves Closing Failed Discrepancy_Fail Enable_LS Discrepancy_Deadband Totals_Reset Moves_Current Moves_Last Open_Cmd Pos_Cmd Figure 1.3.2. Analog Valve Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-18 1.4. Instrumentation 1.4.1. Analog Input The analog input instruction (AnalogInput) spans a raw analog input to engineering units and contains a number of configurable alarms. The input parameters include: x Input – Raw input from the I/O module A/D converter. x InMin – Minimum scaling value of the I/O module A/D converter. Note that this parameter is hidden from view, as it should not need to be adjusted under normal circumstances. x InMax – Maximum scaling value of the I/O module A/D converter. x Note that this parameter is hidden from view, as it should not need to be adjusted under normal circumstances. x OutMin – Minimum engineering units of the signal. x OutMax – Maximum engineering units of the signal. x Enable_Clamp – When this parameter is active, the output will not be permitted to go above or below its OutMin or OutMax values. This prevents the HMI display and logic from reporting negative numbers when the signal is near zero. x LowLow_Alarm_SP – Low-Low Alarm setpoint. The scaled value must be below this setpoint for longer than the Alarm_Time to activate the alarm. x Low_Alarm_SP – Low Alarm setpoint. The scaled value must be below this setpoint for longer than the Alarm_Time to activate the alarm. x High_Alarm_SP – High Alarm setpoint. The scaled value must be above this setpoint for longer than the Alarm_Time to activate the alarm. x HighHigh_Alarm_SP – High-High Alarm setpoint. The scaled value must be above this setpoint for longer than the Alarm_Time to activate the alarm. x Alarm_Reset – This parameter resets the alarms if Enable_AutoReset is not active. This parameter is typically activated by a pushbutton on the HMI. x Enable_Alarms – This parameter enables the alarms when active. The alarms maybe disabled in logic when the alarm does not apply. For example, a Low Flow alarm should only be enabled when a pump is running to avoid nuisance alarms when the pump is stopped. x Inhibit_Alarms – This parameter disables the alarms when active. This parameter is typically activated from a toggle on the HMI. The difference between this parameter and Enable_Alarms is that this parameter takes priority, regardless of PLC logic enabling/disabling alarms. x Alarm_Time – Amount of time the value must be outside of the alarm setpoints before an alarm is generated. x Enable_AutoReset – If this parameter is active, alarms will automatically reset themselves when the value returns to acceptable range for longer than the Alarm Time. If this parameter is not active, the alarms can only be reset by activating the Alarm Reset parameter. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-19 The output parameters include: x Value – Scaled output in engineering units. x Value_mA – Scaled output in milliamps for troubleshooting purposes. x Range_Alarm – This parameter will activate if the raw input is greater than 10% outside the InMin/InMax values. It can detect if a field device is “underdriving” or “overdriving” the I/O module. x LowLow_Alarm – This parameter activates when the scaled value is less than the Low-Low Alarm setpoint for longer than the Alarm Time. The Enable Alarms parameter must be active and the Inhibit Alarms parameter must be inactive. x Low_Alarm – This parameter activates when the scaled value is less than the Low Alarm setpoint for longer than the Alarm Time. The Enable Alarms parameter must be active and the Inhibit Alarms parameter must be inactive. This alarm is disabled if the Low-Low alarm is activated. x High_Alarm – This parameter activates when the scaled value is greater than the High Alarm setpoint for longer than the Alarm Time. The Enable Alarms parameter must be active and the Inhibit Alarms parameter must be inactive. This alarm is disabled if the High-High alarm is activated. x HighHigh_Alarm – This parameter activates when the scaled value is greater than the High-High Alarm setpoint for longer than the Alarm Time. The Enable Alarms parameter must be active and the Inhibit Alarms parameter must be inactive. x ChannelFault – This parameter will activate if the unit experiences a connection failure. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-20 LOGIC OutMax OutMin Inputs Outputs Input RangeAlarm Enable_Clamp High_Alarm_SP Low_Alarm_SP LowLow_Alarm_SP HighHigh_Alarm_SP Alarm_Time Enable_Alarms Alarm_Reset Enable_AutoReset LowLow_Alarm Low_Alarm High_Alarm HighHigh_Alarm ChannelFault Value Value_mAInMax InMin Inhibit_Alarms Figure 1.4.1. Analog Input Instruction Diagram 1.4.2. Analog Output The analog output instruction (AnalogOutput) spans an input before it is sent to analog output I/O. The input parameters include: x Input – Raw input from control logic. Typically in engineering units. x InMin – Minimum engineering units of raw input used to span analog signal. x InMax – Maximum engineering units of raw input used to span analog signal. x OutMin – Minimum scaling value of the I/O module D/A converter. Note that this parameter is hidden from view, as it should not need to be adjusted under normal circumstances. x OutMax – Maximum scaling value of the I/O module D/A converter. Note that this parameter is hidden from view, as it should not need to be adjusted under normal circumstances. x Enable_Clamp – When this parameter is active, the output will not be permitted to go above or below its OutMin or OutMax values. This prevents the I/O module from “underdriving” or “overdriving” the field device. The output parameters include: Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-21 x Output – The scaled output value sent to the I/O module D/A converter. x Output_mA – This output is scaled in milliamps for troubleshooting purposes. LOGICInMax InMin Inputs Outputs Input Output_mA Output OutMax OutMin Enable_Clamp Figure 1.4.2. Analog Output Instruction Diagram 1.4.3. Totalizer Count The totalize count instruction (TotalizeCount) calculates totalized flow based on pulse outputs from a flow meter. The input parameters include: x Flow_Pulse – Field input from the flow meter’s totalizer pulse. Each time the parameter activates, the totalizer accumulates. x Multiplier – This parameter defines the number of gallons per pulse from the flow meter. x Totals_Reset – Resets the logic. This is typically triggered from the PLC time clock on a daily basis. The output parameters include: x Total_Gals_Current – The number of totalized gallons since the logic was last reset. x Total_Gals_Last – The number of totalized gallons when the logic was last reset. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-22 LOGIC Inputs Outputs Flow_Pulse Multiplier Totals_Reset Total_Gals_Current Total_Gals_Last Figure 1.4.3. Totalizer Count Instruction Diagram 1.4.4. Totalizer Calculation The totalize calculation instruction (TotalizeCalc) calculates totalized flow based on the analog value from a flow meter. Most of the input and output parameters for this instruction are previously defined in Appendix A, Section 1.4.3. The new input parameters include: x Flow – This parameter is the scaled flow in gallons from the flow meter. The output parameters for this instruction are previously defined in Section 1.4.3. LOGIC Inputs Outputs Flow Total_Gals_Current Totals_Reset Total_Gals_Last Figure 1.4.4. Totalizer Calculation Instruction Diagram Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-23 1.5. Miscellaneous Functions 1.5.1. PLC Status The PLC status instruction (PLCStat) extracts processor status values and diagnostics. The input parameters include: x Year – The PLC time clock current year. Note that all other parameters follow the same format. x Month – The PLC time clock current year. x Day – The PLC time clock current day. x Hour – The PLC time clock current hour. x Minute – The PLC time clock current minute. x Second – The PLC time clock current second. The output parameters include: x Run – This parameter is active when the processor is in the Run mode. x Program – This parameter is active when the processor is in the Program mode. x Fault – This parameter is active when the processor has faulted and is no longer running. x KeyRemote – This parameter is active when the processor key switch is in the Remote position. x KeyRun – This parameter is active when the processor key switch is in the Run position. x KeyProgram – This parameter is active when the processor key switch is in the Program position. x BatteryLow – This parameter is active when the processor’s internal battery is low. x Midnight – This parameter activates for one scan at midnight. This is commonly used to reset certain parameters in other logic. x Scantime – Displays the current scantime of the processor in milliseconds. Note that this parameter is hidden from view. Appendix A Project No. 18088080 Lake Lewisville WTP Dewatering Improvements Section 26 90 35.1 PLC and HMI Programming - City Standards A-24 Day Month Year Hour Second Program Run Minute KeyRemote Fault KeyRun KeyProgram BatteryLow LOGIC Inputs Outputs Midnight Scantime Figure 1.5.1. PLC Status Instruction Diagram 1.5.2. Rotation The rotation instruction (Rotator) is used to rotate equipment duty status. The input parameters include: x Quantity – This parameter defines the number of devices to rotate. x Trigger – The devices will automatically rotate when this input is activated. x Rotate_Enable – The devices will not automatically rotate if this parameter is not active. The output parameters include: x Lead_Assignment – This parameter outputs the device number currently in Lead or Duty status. LOGIC Rotate_Enable Trigger Inputs Outputs Quanity Lead_Assignment Figure 1.5.2. Rotation Instruction Diagram 12 Project No. 18088080 1 Section 26 90 40 Lake Lewisville WTP Dewatering Improvements Process Control Descriptions SECTION 26 90 40 – PROCESS CONTROL DESCRIPTIONS PART 1 - GENERAL 1.1 SUMMARY A. The control descriptions described herein are intended to convey the functionality of system equipment and processes in conjunction with the SCADA system. B. Related Sections: 1. 26 90 00 General Instrumentation and Control 2. 26 90 10 Process and Analytical Instruments 3. 26 90 20 PLC Control Panels 4. 26 90 35 PLC and HMI Programming 5. 41 12 13 Dumpster-Veyor Patented Container Handling System 6. 44 42 56.23 Vertical Turbine Pumps 7. 44 42 56.23.1 DS – Vertical Turbine Pump (Low Lift Pumps) Supplement 8. 44 42 56.29 Wet-Pit Submersible Pumps 9. 44 42 56.29.1 DS – Wet-Pit Submersible Pumps Supplement 10. 44 42 56.53 Progressive Cavity Pumps 11. 44 42 56.53.1 DS – Thickened Residuals Transfer Pumps 12. 44 44 63 Liquid Polymer Feed System 13. 44 46 26.13 Gravity Thickener Mechanisms 14. 44 46 26.13.1 DS – Gravity Thickener Mechanisms Supplement 15. 46 07 53 Plant Booster Pump Station 16. 46 21 75 Shaftless Screw Conveyors 17. 46 21 75.1 DS – Shaftless Screw Conveyors From BFPs 18. 46 21 75.1 DS – Shaftless Screw Conveyors Inclined 19. 46 21 75.1 DS – Shaftless Screw Conveyors To Bins 20. 46 76 21 Belt Filter Press System 1.2 REFERENCES A. Definitions: Symbols, Definitions, and Abbreviations: All symbols, definitions, and engineering unit abbreviations utilized shall conform to IEEE 100-84, S50.1, and S51.1, where applicable. 1. SCADA – Supervisory Control and Data Acquisition 2. HMI – Human Machine Interface 3. HOA – Hand/Off/Auto 4. OIT – Operator Interface Terminal 5. PLC – Programmable Logic Controller 6. I/O – Input/Output 7. VFD – Variable Frequency Drive 8. SSRVS – Solid State Reduced Voltage Starter (“Soft Starter”) 9. RTU – Remote Telemetry Unit 10. MTU – Master Telemetry Unit 11. MCC – Motor Control Center 12. Operating Program – Operating system, SCADA or other core software 13. Integrated Operating Platform – System of installed, connected, and configured hardware, operating programs, and networking equipment 14. PLC and HMI Programming – Software configuration of operating programs to implement plant control strategies Project No. 18088080 2 Section 26 90 40 Lake Lewisville WTP Dewatering Improvements Process Control Descriptions PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 FUNCTIONAL CONTROL DESCRIPTION The following control descriptions provide basic functionality for the system equipment and processes. This description shall be used as a guide for controlling various items by location and is expected to be continually refined throughout the execution of the project. The descriptions are not intended to identify every status or alarm indication required on the plant SCADA HMI. Refer to contract drawings and related specification sections for additional requirements. Automated operations require a successful permissive check in order to begin operation. If manual operation is selected, permissive requirements are no longer required for operation of the equipment system. Under manual conditions, hardwired faults for pumps, valves, belt filter presses, booster pump system, polymer feed system, screw conveyor system, and the dumpster- veyor system should be taken into account before operating the system. A. Facility 68 – Washwater Equalization Basin 1. General Information a. The primary functionality of the washwater equalization basin pumps is to pump flows from the flocculation/sedimentation basins and filter backwash to the gravity thickener. Drawing 08-I681 details the process and instrumentation diagram, and highlights the process control components. b. The washwater equalization basin consists of a concrete-formed basin with four (4) submersible centrifugal pumps, two (2) existing and two (2) new, with associated piping and valve vaults. c. An existing ultrasonic level transmitter is installed that transmits WWEQ basin level to the existing SCADA system for monitoring. No changes to SCADA functionality are expected. d. The existing pumps operate automatically with the use of existing float switches. No changes to the operation of the existing pumps is expected. e. The new submersible pumps are controlled by local control panel 68EQCP02 for local automatic and manual control. The local panel includes HAND/OFF/AUTO (HOA) modes of operation for each pump. f. Five new float switches will be installed in the basin for control of the new pumps in a duty/standby mode of control. 2. Local Manual Control: The pumps will be turned on locally at the local control panels by placing the HOA selector switch to the HAND position. 3. Local Automatic Control: The pumps will be controlled in automatic by placing the HOA selector switch in the AUTO position. The pumps will alternate in a duty/standby mode of operational based on the installed float switches. 4. Refer to specification Section 44 42 56.29 Wet-Pit Submersible Pumps for additional control system requirements and description. B. Facility 69 – Washwater Recovery Basin 1. General Information a. The primary functionality of the washwater recovery basin pumps is to pump decanted flow from the gravity thickener and belt filter press filtrate to the rapid mix process. Drawing 08-I691 details the process and instrumentation diagram, and highlights the process control components. b. The washwater recovery basin consists of a concrete formed basin with two (2) new vertical turbine pumps with associated piping. c. New vertical turbine pumps are controlled by a local control panel (69VTCP01) interfaced to PLC-BB via hardwired signals for automatic remote control. The local Project No. 18088080 3 Section 26 90 40 Lake Lewisville WTP Dewatering Improvements Process Control Descriptions control panel will include HAND/OFF/AUTO (HOA) modes of operation for each pump. d. The pumps will operate on an ON/OFF basis. e. Control of the pumps will be implemented with programming of PLC-BB and configuration of the SCADA system. f. A new low-level-float switch (69LSLL01) and high-level-float switch (69LSHH02) will be installed in the basin. g. An existing ultrasonic level transmitter is installed that transmits WWRB basin level to the existing SCADA system for monitoring and control. No changes to SCADA functionality are expected. h. Under normal operating conditions, pumping will be automatically initiated by the SCADA system using feedback from the ultrasonic level transmitter. 2. Local Control: The pumps will have the ability to be turned on manually at the local control panel by placing the HOA selector switch to the HAND position. 3. Automatic Control: The new pumps will be controlled automatically or manually from the SCADA system. With the HOA selector switch in the AUTO position, each pump will have an operator adjustable MANUAL-AUTO selector on the HMI. a. MANUAL Mode: 1) When MANUAL is selected, each pump will be stopped and started with START-STOP buttons on the HMI. b. AUTO Mode: 1) The operator will set the desired pump on level and pump off level setpoints from the SCADA system. When the pump on level is reached, the control system will run the pump until the water level in the washwater recovery basin reaches the low-level setpoint. 2) The operator will have the ability to assign Duty/Standby status for the pumps. The Duty/Standby status of the pumps will be rotated between each cycle. 4. Refer to specification Section 44 42 56.23 Vertical Turbine Pumps for additional control system requirements and description. C. Facility 70 - Gravity Thickener 1. The primary functionality of the gravity thickener is to: a. Receive flow from the washwater equalization basin. b. Settle out solids in the water to be sent to the thickened residuals pump station c. Decant settled water to the washwater recovery basin. 2. The gravity thickener will be controlled via individual vendor supplied local control panel, 70TCP01, interfaced to 77PLC01 via hardwired signals for automatic remote control with HAND/OFF/AUTO (HOA) modes of operation. 3. Local Control: The thickener motor will run when the HOA switch is placed in the HAND position. 4. Remote Control: The thickener drive motor will be controlled from the plant SCADA HMI START/STOP buttons when the local HOA switch is in the AUTO position. 5. Status and alarm indications will be provided on the plant SCADA HMI. 6. The primary process control of the gravity thickener after the influent and effluent flows are balanced is the residuals blanket level. The residuals blanket level will be a function of the influent flow solids loading rate. The process objectives are to maximize the thickened residuals underflow concentration while maintaining the residuals blanket depth at an acceptable level. 7. Residuals withdrawal will be controlled via the metered pumping rates by the thickened residuals pumps. 8. Refer to specification Section 44 46 26.13 Gravity Thickener Mechanisms for specific control system requirements and description. 9. Drawing 08-I701 details the process and instrumentation diagram and highlights the process control components. Project No. 18088080 4 Section 26 90 40 Lake Lewisville WTP Dewatering Improvements Process Control Descriptions D. Facilities 75 and 77 – Thickened Residuals Pump Station and Dewatering Systems 1. General Information a. The complete dewatering system consists of three (3) new progressive cavity thickened residuals pumps, electrically actuated control valves, two (2) thickened residuals flowmeters, two (2) polymer feed systems, two (2) belt filter presses, discharge screw conveyors, dumpster-veyor system, and water booster pump skid. b. The system is designed such that both belt filter presses are capable of operating simultaneously. c. In normal automatic operation, the thickened residual pumps will pump thickened residuals to the belt filter press(es) at an operator-adjustable flow rate setpoint. d. Automatic control of the belt filter press feed system will be implemented with programming of 77PLC01 and the SCADA system. e. Automatic control of the belt filter presses will be implemented as part of the belt press control panels provided by the manufacturer, and programming of 77PLC01 and the SCADA system. f. Automatic control of the discharge conveyor system will be implemented as part of the control panel provided by the conveyor manufacturer, and programming of 77PLC01 and the SCADA system. g. The SCADA system will be configured to provide the operator with the ability to remotely start and stop the dewatering unit processes from the SCADA screens. h. The system is designed such that multiple pair combinations of thickened residual pump and belt filter press can be operated together. The operator will select which pump to associate with which belt filter press from the SCADA HMI screens. Based on this selection, and with control valves in AUTO on the SCADA HMI, the control valves will automatically actuate on/off to enable the correct pumping path. By default, pump 1 will pump to belt press 1 and pump 2 will pump to belt press 2. See table below. Pump and BFP Pair Combinations Pump to BFP Valves Open Valves Closed 1 to 1 75CV01, 75CV04 75CV07 2 75CV01, 75CV06, 75CV07, 75CV08 75CV02, 75CV05, 75CV04 3 75CV01, 75CV05, 75CV06, 75CV07, 75CV09, 75CV11 75CV02, 75CV03, 75CV04, 75CV08, 75CV10 2 to 1 75CV02, 75CV04, 75CV07 75CV01, 75CV06 2 75CV02, 75CV06, 75CV08 75CV05, 75CV07 3 75CV02, 75CV05, 75CV06, 75CV09, 75CV11 75CV03, 75CV07, 75CV08, 75CV10 3 to 1 75CV03, 75CV04, 75CV05, 75CV06, 75CV07 75CV01, 75CV02, 75CV08, 75CV09 2 75CV03, 75CV05, 75CV08 75CV06, 75CV09 3 75CV03, 75CV09, 75CV11 75CV05, 75CV10 4 to 1 75CV04, 75CV05, 75CV06, 75CV07, 75CV09, 75CV10 75CV01, 75CV02, 75CV03, 75CV08, 75CV11 2 75CV05, 75CV08, 75CV09, 75CV10 75CV03, 75CV06, 75CV11 3 75CV10, 75CV11 75CV09 1) Changes to pump/belt press association can only be made when the systems are stopped. Project No. 18088080 5 Section 26 90 40 Lake Lewisville WTP Dewatering Improvements Process Control Descriptions 2) The operator will maintain the ability to override a programmed scenario and assign valve status when required by placing the valve in MANUAL from the SCADA HMI. 3) Display a warning when manual inputs for valve status change resulting in a conflict with a programmed scenario operation. 4) When operating multiple pumps and BFPs, display a warning when equipment inputs have conflicting valve statuses. Current selections have priority when assigning an additional pump/BFP pair. 2. Thickened Residuals Pumps a. The thickened residuals pump (TRP) station consists of three (3) new progressive cavity pumps for residuals pumping with one (1) future installation. The pumps draw from the gravity thickener and pump the residuals through a piping network to feed the dewatering equipment. b. The new pumps will be controlled by VFD pump control panels 75PCP01-75PCP03, and integrated with SCADA through 77PLC01. The VFD control panels will include HAND-OFF-REMOTE selector switches for selection of local or remote control. c. The SCADA system will provide monitoring of key status and alarm indicators for the thickened residuals pumping system such as running, speed indication, and faults. d. For remote control from SCADA, each pump will have an operator adjustable MANUAL-AUTO selector on the HMI. a) When MANUAL is selected, each pump will be stopped and started with START and STOP buttons on the HMI. Pump speed will be set with an operator adjustable manual speed set-point on the HMI. e. When AUTO is selected, the pump will be started according to the status of a “start belt press feed” command from the associated belt press. Pump speeds will be modulated to maintain a flow rate at the operator adjustable flow rate set-point. f. The VFD speed operating ranges will be based on the following: 1) The minimum speed recommended by the VFD manufacturer. 2) The minimum motor speed to cool the motor as recommended by the pump manufacturer. 3) The minimum motor speed for minimum pump flow rate as recommended by the pump manufacturer. 4) The minimum speed for the pump to begin pumping as determined in the field by operating the pumps. 5) The maximum speed for the pump to prevent the pump from running off its curve 6) Changes in operational speed will be governed by a maximum ramp up/down time as determined in the field to prevent system shocks. g. Permissive for operation: 1) No internal faults 2) BFP normal status which includes wash water pressure and no faults on control panel 3) No valve faults from selected TRP to selected BFP 4) Polymer feed with normal status, coordinated in SCADA to which BFP is receiving the feed 5) Booster pump system with normal status, coordinated in SCADA to which BRP is receiving pressurized flow 6) Gravity thickener with normal status h. Refer to specification Section 44 42 56.53 Progressive Cavity Pumps for additional information. 3. Belt Filter Presses Project No. 18088080 6 Section 26 90 40 Lake Lewisville WTP Dewatering Improvements Process Control Descriptions a. The primary function of the belt filter press (BFP) is to increase the solids concentration of the thickened residuals flow by applying pressure to filter out water. The solids discharge to a screw conveyor system that brings the residuals to the dumpster-veyor system for disposal. The effluent from the BFPs flows back to the washwater EQ basin. b. The BFP system will be controlled by a manufacturer supplied control panel (77BPPLC1 and 77BPPLC2) that is integrated with the plant SCADA HMI. Refer to specification Section 46 76 21 Belt Filter Press System for control descriptions and details. c. The BFP system will be integrated with the thickened residual pumps, polymer feed system, booster pump system, screw conveyor system, and dumpster-veyor system. d. The operator will start a BFP through a start button on the SCADA HMI or through a start button on the belt press control panel HMI. The BFP will begin an automated startup process and provide signals to 77PLC01 for starting the thickened residual pump, the polymer system, and discharge screw conveyors. e. Permissive for operation: 1) No internal faults 2) 77PLC01 will provide a “system ready” indication to the BFP when the following conditions are met: a) Clear path with no valve faults to BFP from the assigned TRP b) Available dumpster volume with feedback from the dumpster-veyor system c) Functioning gates with a path to available dumpster volume d) Conveyors with normal status, which includes a check on each conveyor as running within a set timeframe not to exceed 10 seconds and to be coordinated with equipment manufacturer, speed sensor, and conveyor control panels e) Booster pump system with normal status f. The SCADA system HMI shall display key status and alarm indicators for the belt filter press system. g. Drawing 08-I771 details the process and instrumentation diagrams and highlights the process control components. 4. Screw Conveyors a. The primary function of the screw conveyor system is to transport thickened residuals from the BFPs to the dumpster-veyor system for disposal. b. The screw conveyor system will be controlled by a main manufacturer supplied control panel (77SCCP01) that is integrated with the plant SCADA HMI. A secondary control panel (77SCCP02) will control the conveyor to the bins and the associated gate. The screw conveyor control panel will receive run signals from 77PLC01 when all permissives have been met and the BFP has initiated a conveyor run command. Refer to specification Section 46 21 75 Shaftless Screw Conveyors for control descriptions and details. c. Permissive for operation: 1) No internal faults 2) Available dumpster volume with feedback from the dumpster-veyor system 3) Functioning gates to an available dumpster-veyor system. 4) Successful check of outside bin conveyor (77SC03) operation for a minimum of 10 seconds. 5) Successful check of incline conveyor (77SC02) operation for a minimum of 10 seconds. 6) Successful check of BFP conveyor (77SC01) operation for a minimum of 10 seconds. 7) BFPs with normal status Project No. 18088080 7 Section 26 90 40 Lake Lewisville WTP Dewatering Improvements Process Control Descriptions d. The screw conveyors will begin operation starting with the outside bin conveyor, then the inclined conveyor, and finishing with the BFP conveyor. e. The conveyor control panel will receive open/close commands for the gate based on the availability of the dumpsters controlled by the dumpster-veyor system. f. The SCADA system will display key status and alarm indicators for the screw conveyor system including start/stop, running, and fault. 5. Dumpster-Veyor System a. The primary function of the dumpster-veyor system is to collect the residuals from the screw conveyors for disposal. Dewatering facility operations require available dumpster volume, which will be integrated within upstream processes/permissive details. b. The dumpster-veyor system will be controlled by a manufacturer provided local control panel (77DCP01 and 77DCP02) that is integrated into the plant SCADA HMI. c. Permissive for operation: 1) No internal faults 2) Dumpster in place 3) Available dumpster volume 4) Screw conveyor system with normal status d. Dumpster volume availability is determined by a sensing tree located on the sides of the conveyor platforms. As thickened residuals drop into the dumpster, the sensing tree will monitor the height of the residuals using a laser positioned above the dumpster. When the height of the residuals reaches a defined maximum level and impedes the laser, positioning devices will move the dumpster down the guide rails at a defined distance, clearing the interruption and continuing the process. Operations will repeat until the dumpster position has reached its maximum traveling distance, indicating no available volume for that dumpster. Flow will be diverted to the second dumpster by changing the position of the conveyor #3 gate. If both dumpsters have reached their maximum capacity, the dewatering facility will shut off by first shutting down the feed pumps and polymer system, clearing conveyors, and entering standby status. 1) Dumpster positioning will be reset manually after a new dumpster has been positioned in place properly. 2) Dumpster is unavailable if no dumpster is in place. e. From the SCADA HMI, operators will have the ability to select a preferred dumpster to fill (when both dumpster have available volume). 1) If manual operations interfere with permissive details, show a warning in the HMI or OIT. f. The SCADA system will display key status and alarm indicators for the dumpster- veyor system such as start/stop, forward/reverse operation, and fault. 6. Plant Water Booster Pump System: a. The primary function of the plant water booster pump station is to add pressure to the flow of water being received by the BFPs or hose bibs. b. The plant water booster pump station will be controlled by a manufacturer supplied control panel and interface to the dewatering PLC control panel (77PLC01). Refer to specification Section 46 07 53 Plant Booster Pump Station for additional information. c. Operators will set a target system pressure and an acceptable range for fluctuation. The booster pump station will automatically turn on or off to maintain the target pressure selection. d. Permissive for operation: 1) No internal faults e. The SCADA system will display key status and alarm indicators for the plant water booster pump station such as on/off and fault. Project No. 18088080 8 Section 26 90 40 Lake Lewisville WTP Dewatering Improvements Process Control Descriptions f. Drawing 08-I772 details the process and instrumentation diagrams and highlights the process control components. 7. Polymer Feed System a. The primary function of the polymer feed system is to mix neat liquid polymer with makedown water to feed the BFPs during operation. The addition of polymer to the thickened residuals aids in filtering out water to increase the solids concentration before disposal. b. The polymer feed system is controlled by local polymer system controllers and hard- wired interface to 77PLC01. c. The polymer feed system will provide a polymer solution to the belt filter presses using a flow pacing signal from the thickened residual flow meters. d. The polymer totes will be installed on weight scales for monitoring the polymer usage from SCADA. e. Permissive for operation: 1) No internal faults 2) Available polymer volume in storage totes selected as the feed for the system 3) TRP and BFP systems with normal status f. The polymer system will start automatically based on the TRP and BFP running status. g. The SCADA HMI shall provide the ability for the operator to select which BFP each polymer system is connected to. The valves along the path between the polymer system and BFP will be manually adjusted. The system will automatically provide the appropriate flow pace signal to the polymer controller based on the operator selection. Physical connection of the polymer system piping to the correct BFP based on the operator SCADA selection will be a manual operation. h. The SCADA system will display key status and alarm indicators for the polymer feed system such as start/stop, flow pace, and pressure. i. Refer to specification Section 44 44 63 Liquid Polymer Feed System for control descriptions. Drawing 08-I773 shows the process and instrumentation diagrams and highlights for process control components. END OF SECTION DIVISION 31 EARTHWORK Project No. 18088080 1 Section 31 05 19 Lake Lewisville WTP Dewatering Improvements Geotextile Filter Fabric SECTION 31 05 19 – GEOTEXTILE FILTER FABRIC PART 1 - GENERAL 1.1 SUMMARY A. Section includes the installation of a non-woven geotextile fabric below the riprap. B. Related sections: 1. Section 31 37 00 – Rip Rap. 2. Section 01 33 00 – Submittal Procedures. 1.2 REFERENCE STANDARDS A. ASTM D3786 – Standard Test Method for Bursting Strength of Textile Fabrics – Diaphragm Bursting Strength Tester Method B. ASTM D4355 – Standard Test Method for Deterioration of Geotextiles by Exposure to Light, Moisture and Heat in a Xenon Arc Type Apparatus C. ASTM D4491 – Standard Test Methods for Water Permeability of Geotextiles by Permittivity D. ASTM D4632 – Standard Test Method for Grab Breaking Load and Elongation of Geotextiles E. ASTM D4833 – Standard Test Method for Index Puncture Resistance of Geomembranes and Related Products F. ASTM D4751 – Standard Test Method for Determining Apparent Opening Size of a Geotextile G. ASTM D4886 – Standard Test Method for Abrasion Resistance of Geotextiles (Sand Paper/Sliding block Method) H. ASTM D4533 – Standard Test Method for Trapezoid Tearing Strength of Geotextiles I. ASTM D6241 – Standard Test Method for Static Puncture Strength of Geotextiles and Related Products Using a 50mm Probe 1.3 QUALITY ASSURANCE A. The installation shall be performed in accordance with the manufacturer's recommendations and as directed by Engineer. 1.4 SUBMITTALS A. See Section 01 33 00, SUBMITTAL PROCEDURES. B. Certificates: Certify that products meet or exceed specified requirements. PART 2 - PRODUCTS 2.1 MATERIAL A. The non-woven geotextile fabric shall be an 8-ounce fabric, US Fabrics US 205NW or equal. The fabric shall be of non-woven needle punched construction and consist of long-chain polymeric filaments or fibers composed of polypropylene, polyethylene or polyamide. The Project No. 18088080 2 Section 31 05 19 Lake Lewisville WTP Dewatering Improvements Geotextile Filter Fabric filaments and fibers shall be oriented whereby they retain their relative positions with each other and allow the passage of water as specified. B. The fabric shall be mildew, insect and rodent resistant and shall be inert to chemicals commonly found in soil. The non-woven fabric shall conform to the physical property requirements below: Physical Property Test Method Test Results Weight ASTM D 5261 8 oz/sy Tensile Strength, wet, lbs ASTM D 4632 205 lbs Elongation, wet, % ASTM D 4632 50% Permittivity ASTM D 4491 1.35 sec-1 Puncture Strength, lbs ASTM D 4833 130 lbs CBR Puncture ASTM D 6241 535 lbs Mullen Burst Strength, psi ASTM D 3786 350 psi Abrasion Resistance, % Strength Retained ASTM D 4886 90 Apparent Opening Size (AOS) ASTM D 4751 80 US Sieve Ultraviolet Resistance, % Strength Retention ASTM D 4355 (After 500 70% Xenon Weatherometer hrs.) Trapezoidal Tear ASTM D 4533 85 lbs Water Flow Rate ASTM D 4491 90 gal/min/sf C. The non-woven geotextile fabric shall be furnished in a protective wrapping which shall protect the fabric from ultraviolet radiation and from abrasion due to shipping and handling. PART 3 - EXECUTION 3.1 INSTALLATION A. Fabric Exposure Following Placement - Exposure of the geotextile filter fabric to the elements, particularly the sun, between lay down and cover shall be a maximum of 7 days. B. The non-woven geotextile fabric shall be placed in the manner and at the locations shown on the drawings or as directed by the Engineer. The surface to receive the fabric shall be prepared to a smooth condition free of obstructions, depressions and debris. The fabric shall be placed loosely, not in a stretched condition. C. The Contractor shall anchor the geotextile fabric at outer edges of the riprap courses by embedding the fabric down, across, and up a 1-foot deep by 1-feet wide trench. The fabric shall be centered on the pipe. The anchoring trench shall be backfilled with rock material approved by Engineer. There will be no separate payment for Geotextile Fabric; it shall be subsidiary to other items. D. Where necessary, the fabric shall be placed so as to provide a minimum 24-inch overlap. The fabric shall be placed transverse to the direction of the flow with the upstream panel overlapping the downstream panel. All installations shall be subject to approval by Engineer. E. Repairs - A geotextile patch, of the same material, shall be placed over any damaged area and shall extend 12-inches beyond the perimeter of the tear or damaged area. Patch shall be either glued or sewn to the mother fabric or as approved by Engineer. END OF SECTION Project No. 18088080 1 Section 31 11 00 Lake Lewisville WTP Dewatering Improvements Site Preparation SECTION 31 11 00 - SITE PREPARATION PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Clearing, grubbing, scalping, stripping, and disposal of waste debris. 1.2 DEFINITIONS A. Interfering or Objectionable Material: Trash, rubbish, and junk; vegetation and other organic matter, whether alive, dead, or decaying; topsoil. B. Clearing: Removal of interfering or objectionable material lying on or protruding above ground surface. C. Grubbing: Removal of vegetation and other organic matter including stumps, buried logs, and roots greater than 2 inches caliper to a depth of 12 inches below subgrade. D. Scalping: Removal of sod without removing more than upper 3 inches of topsoil. E. Stripping: Removal of topsoil remaining after applicable scalping is completed. F. Project Limits: Areas, as shown or specified, within which Work is to be performed. 1.3 SUBMITTALS A. Shop Drawings: Drawings clearly showing clearing, grubbing, and stripping limits. B. See Section 01 33 00, SUBMITTAL PROCEDURES. 1.4 QUALITY ASSURANCE A. Obtain Engineer’s approval of staked clearing, grubbing, and stripping limits, prior to commencing clearing, grubbing, and stripping. 1.5 SCHEDULING AND SEQUENCING A. Prepare site only after adequate erosion and sediment controls are in place. Limit areas exposed uncontrolled to erosion during installation of temporary erosion and sediment controls to maximum of 5 acres. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 GENERAL A. Clear, grub, and strip areas actually needed for waste disposal, borrow, or site improvements within limits shown or specified. B. Do not injure or deface vegetation that is not designated for removal. Project No. 18088080 2 Section 31 11 00 Lake Lewisville WTP Dewatering Improvements Site Preparation 3.2 LIMITS A. As follows, but not to extend beyond Project limits. 1. Excavation, including trenches, 5 feet beyond top of cut slopes or shored walls. 2. Fill: a. Clearing and Grubbing: 5 feet beyond toe of permanent fill. b. Stripping and Scalping: 2 feet beyond toe of permanent fill. 3. Structures: 15 feet outside of new structures. 4. Roadways: Clearing, grubbing, scalping, and stripping 15 feet from centerline. 5. Other Areas: As shown. B. Remove rubbish, trash, and junk from entire area within Project limits. 3.3 CLEARING A. Clear areas within limits shown or specified. B. Fell trees so that they fall away from facilities and vegetation not designated for removal. C. Cut stumps not designated for grubbing to within 6 inches of ground surface. D. Cut off shrubs, brush, weeds, and grasses to within 2 inches of ground surface. 3.4 GRUBBING A. Grub areas within limits shown or specified. 3.5 SCALPING A. Do not remove sod until after clearing and grubbing is completed and resulting debris is removed. B. Scalp areas within limits shown or specified. 3.6 STRIPPING A. Do not remove topsoil until after scalping is completed. B. Strip areas within limits to minimum depths shown or specified. Do not remove subsoil with topsoil. C. Stockpile strippings, meeting requirements for topsoil, separately from other excavated material. 3.7 TOPSOIL A. Natural, friable, sandy loam, obtained from well-drained areas, free from objects larger than 1-1/2 inches maximum dimension, and free of subsoil, roots, grass, other foreign matter, hazardous or toxic substances, and deleterious material that may be harmful to plant growth or may hinder grading, planting, or maintenance. 3.8 DISPOSAL A. Clearing and Grubbing Debris: 1. Dispose of debris. 2. Burning of debris will not be allowed. 3. Woody debris may be chipped. Chips may be sold to CONTRACTOR'S benefit or used for landscaping as mulch or uniformly mixed with topsoil, provided that resulting mix will be Project No. 18088080 3 Section 31 11 00 Lake Lewisville WTP Dewatering Improvements Site Preparation fertile and not support combustion. Maximum dimensions of chipped material used shall be 1/4-inch by 2 inch. Dispose of chips that are unsaleable or unsuitable for landscaping or other uses with unchipped debris. 4. Limit disposal of clearing and grubbing debris to locations that are approved by federal, state, and local authorities, and that will not be visible from Project. B. Scalpings: As specified for clearing and grubbing debris. C. Strippings: 1. Dispose of strippings that are unsuitable for topsoil or that exceed quantity required for topsoil 2. Stockpile topsoil in sufficient quantity to meet Project needs. Dispose of excess strippings as specified for clearing and grubbing. END OF SECTION Project No. 18088080 1 Section 31 22 13 Lake Lewisville WTP Dewatering Improvements Subgrade Preparation SECTION 31 22 13 - SUBGRADE PREPARATION PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work and testing required for preparing subgrade. B. Related sections: 1. Section 02 41 00 – Demolition. 2. Section 31 11 00 – Site Preparation. 3. Section 31 23 16 – Excavation. 4. Section 31 23 23.13 – Fill and Backfill. 1.2 REFERENCE STANDARDS A. ASTM D1557 – Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3) B. ASTM D698 - Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3) 1.3 DEFINITIONS A. Optimum Moisture Content: As defined in Section 31 23 23.13, FILL AND BACKFILL. B. Prepared Ground Surface: Ground surface after completion of clearing and grubbing, scalping of sod, stripping of topsoil, excavation to grade, and scarification and compaction of subgrade. C. Relative Compaction: As defined in Section 31 23 23.13, FILL AND BACKFILL. D. Relative Density: As defined in Section 31 23 23.13, FILL AND BACKFILL. E. Subgrade: Layer of existing soil after completion of clearing, grubbing, scalping of topsoil prior to placement of fill, roadway structure or base for floor slab. F. Standard Specifications: The latest edition, including supplements of the Texas Department of Transportation Standard Specifications for Construction and Maintenance of Highways, Streets, and Bridges. 1.4 SEQUENCING AND SCHEDULING A. Complete applicable Work specified in Sections 02 41 00, DEMOLITION; 31 11 00, SITE PREPARATION; and 31 23 16, EXCAVATION, prior to preparation. 1.5 QUALITY ASSURANCE A. Notify Engineer when subgrade is ready for compaction or whenever compaction is resumed after a period of extended inactivity. 1.6 ENVIRONMENTAL REQUIREMENTS A. Prepare subgrade when unfrozen and free of ice and snow. Project No. 18088080 2 Section 31 22 13 Lake Lewisville WTP Dewatering Improvements Subgrade Preparation PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 GENERAL A. Keep subgrade free of water, debris, and foreign matter during compaction or proof-rolling. B. Bring subgrade to proper grade and cross-section and uniformly compact surface. C. Do not use sections of prepared ground surface as haul roads. Protect prepared from traffic. D. Maintain prepared ground surface in finished condition until next course is placed. 3.2 MOISTURE CONDITIONING A. Dry Subgrade: Add water, then mix to make moisture content uniform throughout. B. Wet Subgrade: Aerate material by blading, discing, harrowing, or other methods, to hasten drying process. 3.3 TESTING A. Test roll subgrade as specified in Standard Specifications to detect soft or loose subgrade or unsuitable material, as determined by Engineer. 3.4 CORRECTION A. Soft or Loose Subgrade: 1. Adjust moisture content and recompact, or 2. Over excavate as specified in Section 31 23 16, EXCAVATION, and replace with suitable material from the excavation, as specified in Section 31 23 23.13, FILL AND BACKFILL. END OF SECTION Project No. 18088080 1 Section 31 22 19 Lake Lewisville WTP Dewatering Improvements Grading SECTION 31 22 19 - GRADING PART 1 - GENERAL 1.1 SUMMARY A. Section includes: 1. Removal and storage of topsoil. 2. Rough grading the site for site structures, building pads, and drive and parking isles. 3. Finish grading for planting. B. Related sections: 1. Section 31 23 16 – Excavation. 2. Section 31 23 23.13 – Fill and Backfill. 3. Section 31 23 16.13 – Trenching for Site Utilities. 1.2 SUBMITTALS A. Project Record Documents: Accurately record actual locations of utilities remaining by horizontal dimensions, elevations or inverts, and slope gradients. 1.3 QUALITY ASSURANCE A. Perform Work in accordance with Texas Department of Transportation standards. 1. Maintain one copy on site. 1.4 PROJECT CONDITIONS A. Protect above – and below – grade utilities that remain. B. Protect plants, lawns, rock outcroppings, and other features to remain as a portion of final landscaping. C. Protect bench marks, survey control points, existing structures, fences, sidewalks, paving and curbs from grading equipment and vehicular traffic. PART 2 - PRODUCTS 2.1 MATERIALS. A. Topsoil: Shall be soil suitable for sustaining grass and vegetation and shall not have any particles larger than ¾” in diameter and shall be free of any trash, debris, or deleterious material. B. Other Fill Materials: See Section 31 23 23.13, FILL AND BACKFILL. PART 3 - EXECUTIONS 3.1 EXAMINATION A. Verify that survey bench mark and intended elevations for the Work are as indicated. 3.2 PREPARATION A. Identify required lines, levels, contours, and datum. Project No. 18088080 2 Section 31 22 19 Lake Lewisville WTP Dewatering Improvements Grading B. Stake and flag locations of known utilities. C. Locate, identify, and protect utilities that remain from damage. D. Notify utility company to remove and relocate utilities. 3.3 ROUGH GRADING A. Remove topsoil from areas to be further excavated, re-landscaped, or re-graded without mixing with foreign materials. B. Do not remove topsoil when wet. C. Remove subsoil from areas to be further excavated, re-landscaped, or re-graded. D. Do not remove wet subsoil, unless it is subsequently processed to obtain optimum moisture content. E. When excavating through roots, perform work by hand and cut roots with sharp axe. F. Stability: Replace damaged or displaced subsoil to same requirements as for specified fill. 3.4 SOIL REMOVAL A. Stockpile excavated topsoil on site. B. Stockpile excavated subsoil on site. C. Stockpiles: Use areas designated on site; pile depth not to exceed 8 feet; protect from erosion. 3.5 FINISH GRADING A. Before Finish Grading: 1. Verify building and trench backfilling have been inspected. 2. Verify subgrade has been contoured and compacted. B. Remove debris, roots, branches, stones, in excess of ½ inch in size. Remove soil contaminated with petroleum products. C. In areas where vehicles or equipment have compacted soil, scarify surface to depth of 3 inches. D. Place topsoil in areas where seeding are indicated. E. Place topsoil to the following compacted thicknesses: 1. Areas to be Seeded with Grass: 6 inches. 2. Areas to be Sodded: 4 inches. 3. Shrub Beds: 18 inches. 4. Flower Beds: 12 inches 5. Planter Boxes: To within 3 inches of box rim. F. Place topsoil during dry weather. G. Remove roots, weeds, rocks, and foreign material while spreading. H. Near plants spread topsoil manually to prevent damage. Project No. 18088080 3 Section 31 22 19 Lake Lewisville WTP Dewatering Improvements Grading I. Fine grade topsoil to eliminate uneven areas and low spots. Maintain profiles and contour of subgrade. J. Lightly compact placed topsoil. 3.6 TOLERANCES A. Top Surface of Subgrade: Plus or minus 1/10 foot from required elevation. B. Top Surface of Finish Grade: Plus or minus ½ inch. 3.7 FIELD QUALITY CONTROL A. See Section 31 23 23.13, FILL AND BACKFILL for compaction density testing. 3.8 CLEANING AND PROTECTION A. Remove unused stockpiled topsoil and subsoil. Grade stockpile area to prevent standing water. B. Leave site clean and raked, ready to receive landscaping. END OF SECTION Project No. 18088080 1 Section 31 23 16 Lake Lewisville WTP Dewatering Improvements Excavation SECTION 31 23 16 - EXCAVATION PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work and materials associated with excavation. B. Related sections: 1. Section 01 50 00 – Temporary Facilities and Controls. 2. Section 02 41 00 – Demolition. 3. Section 31 11 00 – Site Preparation. 4. Section 31 23 19 – Dewatering. 5. Section 31 50 00 – Excavation Support Systems. 1.2 SUBMITTALS A. Shop Drawings: 1. Excavation Plan, Detailing: a. Methods and sequencing of excavation. b. Proposed locations of stockpiled excavated material. c. Proposed and spoil disposal sites. d. Numbers, types, and sizes of equipment proposed to perform excavations. 1.3 QUALITY ASSURANCE A. Provide adequate survey control to avoid unauthorized over-excavation. 1.4 WEATHER LIMITATIONS A. Material excavated when frozen or when air temperature is less than 32 degrees F shall not be used as fill or backfill until material completely thaws. B. Material excavated during inclement weather shall not be used as fill or backfill until after material drains and dries sufficiently for proper compaction. 1.5 SEQUENCING AND SCHEDULING A. Demolition: Complete applicable Work specified in Section 02 41 00, DEMOLITION, prior to excavating. B. Clearing, Grubbing, and Stripping: Complete applicable Work specified in Section 31 11 00, SITE PREPARATION, prior to excavating. C. Dewatering: Conform to applicable requirements of Section 31 23 19, DEWATERING, prior to initiating excavation. D. Excavation Support: Install and maintain, as specified in Section 31 50 00, EXCAVATION SUPPORT SYSTEMS, as necessary to support sides of excavations and prevent detrimental settlement and lateral movement of existing facilities, adjacent property, and completed Work. Project No. 18088080 2 Section 31 23 16 Lake Lewisville WTP Dewatering Improvements Excavation PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 GENERAL A. Excavate to lines, grades, and dimensions shown and as necessary to accomplish Work. Excavate to within tolerance of plus or minus 0.1-foot except where dimensions or grades are shown or specified as maximum or minimum. Allow for forms, working space, granular base, topsoil, and similar items, wherever applicable. Trim to neat lines where concrete is to be deposited against earth. B. Do not over excavate without written authorization of Engineer. C. Remove or protect obstructions as shown and as specified in Section 01 50 00, TEMPORARY FACILITIES AND CONTROLS. 3.2 UNCLASSIFIED EXCAVATION A. Excavation is unclassified. Complete all excavation regardless of the type, nature, or condition of the materials encountered. 3.3 TRENCH WIDTH A. Minimum Width of Trenches: 1. Single Pipes, Conduits, Direct-Buried Cables, and Duct Banks: a. Less than 4-inch Outside Diameter or Width: 18 inches. b. Greater than 4-inch and up to 18-inch Outside Diameter or Width: 12 inches greater than outside diameter or width of pipe, conduit, direct-buried cable, or duct bank. c. Greater than 18-inch Diameter or Width: 24-inches greater than outside diameter or width of pipe, conduit, direct-buried cable, or duct bank. 2. Multiple Pipes, Conduits, Cables, or Duct Banks in Single Trench: 18 inches greater than aggregate width of pipes, conduits, cables, duct banks, plus space between. 3. Increase trench widths by thicknesses of sheeting. B. Maximum Trench Width: Unlimited, unless otherwise shown or specified, or unless excess width will cause damage to existing facilities, adjacent property, or completed Work. 3.4 PIPE BEDDING GROOVES FOR NONPERFORATED DRAIN LINES A. Semicircular, trapezoidal, or 90-degree-V. B. Excavated or plowed into trench bottom. Forming groove by compaction will not be acceptable. 3.5 STOCKPILING EXCAVATED MATERIAL A. Stockpile excavated material that is suitable for use as fill or backfill until material is needed. B. Post signs indicating proposed use of material stockpiled. Post signs that are readable from all directions of approach to each stockpile. Signs should be clearly worded and readable by equipment operators from their normal seated position. C. Confine stockpiles to within easements, rights-of-way, and approved work areas. Do not obstruct roads or streets. Project No. 18088080 3 Section 31 23 16 Lake Lewisville WTP Dewatering Improvements Excavation D. Do not stockpile excavated material adjacent to trenches and other excavations unless excavation side slopes and excavation support systems are designed, constructed, and maintained for stockpile loads. E. Do not stockpile excavated materials near or over existing facilities, adjacent property, or completed Work, if weight of stockpiled material could induce excessive settlement. 3.6 DISPOSAL OF SPOIL A. Dispose of excavated materials, which are unsuitable or exceed quantity needed for fill or backfill, B. Dispose of debris resulting from removal of underground facilities as specified in Section 02 41 00, DEMOLITION, for demolition debris. C. Dispose of debris resulting from removal of organic matter, trash, refuse, and junk as specified in Section 31 11 00, SITE PREPARATION, for clearing and grubbing debris. 3.7 EXCAVATION SAFETY A. Conform to all applicable federal, state, and local regulations. 3.8 SUBGRADE PREPARATION A. The excavation for all structures and facilities shall be in dewatered, firm, undisturbed earth. Excavation shall extend down to the levels required to construct the facilities. B. The subgrade soils at the base of the excavations shall be proofrolled to detect any areas of weakness. Proofrolling shall be performed in accordance with the Texas Department of Transportation Standard Specifications for Construction and Maintenance of Highways, Streets and Bridges, 2014 Edition, Item 216, Proofrolling. C. Proofrolling operations will be observed by a Professional Geotechnical Engineer or Professional Geologist licensed in the State of Texas and retained by the Owner. D. Any soft or compressible areas detected during proofrolling shall be over-excavated until firm soil is exposed. Low areas resulting from over-excavation shall be filled select fill in compacted lifts. The select fill is to be placed in lifts not to exceed 8 inches in uncompacted depth. Each lift is to be compacted to a minimum of 95% of maximum density in accordance with ASTM D698 at a moisture content within three percentage points (±3%) of optimum moisture content. E. Once all low areas are filled in, the exposed subgrade is to be scarified to a depth of 8 inches and have its moisture content adjusted and be recompacted to the limits listed below. 1. For soils having a plasticity index (PI) of 15 or less, recompact to a minimum of 95% of maximum density as defined by ASTM D698 at a moisture content within ±3% of the optimum moisture content. 2. For soils having a PI between 16 and 25, recompact to a minimum of 95% of maximum density as defined by ASTM D698 at a moisture content ranging from -1% to 5% of the optimum moisture content. 3. For soils having a PI greater than 25, recompact to between 95% and 100% of maximum density as defined by ASTM D698 at a moisture content ranging from 1% to 6% above the optimum moisture content. F. After an acceptable subbase has been prepared, it is to be covered by a 3 inch concrete mud slab within 24 hours of establishing the acceptable subbase. If rain occurs prior to the mud slab Project No. 18088080 4 Section 31 23 16 Lake Lewisville WTP Dewatering Improvements Excavation being placed, the subbase shall be dried to the moisture contents listed above and recompacted as required. G. The mud slab is to be constructed of minimum f’c = 3000 psi concrete. The mud slab is to be sloped at a minimum grade of 1% to one or more collection points where rainwater runoff is to be collected and pumped out of the excavation. H. Any disturbance of the accepted subbase prior to the installation of the mud slab must be remediated by removing the disturbed area and filling with select fill as described in this section. I. If the source of the disturbance is determined to be the result of the actions, or inactions of the Contractor, (for example, inadequate dewatering, disturbance by excavating or hauling equipment) the cost of additional subgrade preparation will be at the Contractor’s expense. END OF SECTION Project No. 18088080 1 Section 31 23 16.13 Lake Lewisville WTP Dewatering Improvements Trenching for Site Utilities SECTION 31 23 16.13 - TRENCHING FOR SITE UTILITIES PART 1 - GENERAL 1.1 SUMMARY A. Section includes: 1. Backfilling and compacting for utilities outside the building to utility main connections. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 31 05 19 – Geotextile Filter Fabric. 3. Section 31 22 19 – Grading. 4. Section 31 23 16 – Excavation. 5. Section 31 23 23.13 – Fill and Backfill. 6. Section 31 23 23.16 – Trench Backfill. 1.2 DEFINITIONS A. Subgrade Elevations: 4 inches below finish grade elevations indicated on drawings, unless otherwise indicated. B. Finish Grade Elevations: 4 inches above subgrade elevations indicated on drawings, unless otherwise indicated. 1.3 SUBMITTALS A. See Section 01 33 00, SUBMITTAL PROCEDURES, for submittal procedures. B. Compaction Density Test Reports. 1.4 PROJECT CONDITIONS A. Provide sufficient quantities of fill to meet project schedule and requirements. When necessary, store materials on site in advance of need. B. Verify that survey bench marks and intended elevations for the work are as indicated. PART 2 - PRODUCTS 2.1 FILL MATERIALS A. As specified in Section 31 23 23.16, TRENCH BACKFILL. PART 3 - EXECUTION 3.1 EXAMINATION A. Identify required lines, levels, contours, and datum locations. B. Locate, identify, and protect utilities that remain and protect from damage. C. Notify utility company to remove and relocate utilities. D. See Section 31 22 19, GRADING, for additional requirements. Project No. 18088080 2 Section 31 23 16.13 Lake Lewisville WTP Dewatering Improvements Trenching for Site Utilities 3.2 TRENCHING A. Notify Owner’s Representative of unexpected subsurface conditions and discontinue affected Work in areas until notified to resume work. B. Slope banks of excavations deeper than 4 feet to angle of repose or less until shored. C. Do not interfere with 45 degree bearing splay of foundations. D. Cut trenches wide enough to allow inspection of installed utilities. E. Hand trim excavations. Remove loose matter. F. Remove excavated material that is unsuitable for re-use from site. G. Remove excess excavated material from site. 3.3 PREPARATION FOR UTILITY PLACEMENT A. Cut out soft areas of subgrade not capable of compaction in place. Backfill with general fill. B. Compact subgrade to density equal to or greater than requirements for subsequent fill material. C. Until ready to backfill, maintain excavations and prevent loose soil from falling into excavation. 3.4 BACKFILLING A. Backfill to contours and elevations indicated using unfrozen materials. B. Employ a placement method that does not disturb or damage other work. C. Systematically fill to allow maximum lime for natural settlement. Do not fill over porous, wet, frozen or spongy subgrade surfaces. D. Maintain optimum moisture content of fill materials to attain required compaction density. E. Slope grade away from building minimum 2 inches in 10 ft. unless noted otherwise. Make gradual grade changes. Blend slope into level areas. F. Correct areas that are over-excavated. 1. Thrust bearing surfaces: Fill with concrete. 2. Other areas: Use general fill, flush to required elevation, compacted to minimum 98 percent of maximum dry density. G. Compaction Density Unless Otherwise Specified or Indicated. 1. Under paving, slabs-on-grade, and similar construction: 98 percent of maximum dry density. 2. All other locations: 95 percent of maximum dry density. H. Reshape and re-compact fills subjected to vehicular traffic. 3.5 BEDDING AND FILL AT SPECIFIC LOCATIONS A. At Pipe Culverts: 1. Bedding: use general fill. Project No. 18088080 3 Section 31 23 16.13 Lake Lewisville WTP Dewatering Improvements Trenching for Site Utilities 2. Place filter fabric specified in Section 31 05 19, GEOTEXTILE FILTER FABRIC, over compacted bedding. 3. Cover with general fill. 4. Fill up to subgrade elevation. 5. Compact in maximum 8 inch lifts to 95 percent of maximum dry density. 3.6 TOLERANCES A. Top Surface of General Backfilling: Plus or minus 1 inch from required elevations. 3.7 FIELD QUALITY CONTROL A. Perform compaction density testing on compacted fill in accordance with ASTM D1556, ASTM D2167, ASTM D6938, or ASTM D3017. B. Evaluate results in relation to compaction curve determined by testing uncompacted material in accordance with ASTM D1557 (“Modified Proctor”). C. If tests indicate work does not meet specified requirements, remove work, replace and retest. D. Frequency of Tests; One test per every other lift per 200 lineal feet of trench. 3.8 CLEAN-UP A. Leave unused materials in a neat compact stockpile. B. Remove unused stockpiled material, leave area in a clean and neat condition. Grade stockpile areas to prevent standing surface water. C. Leave borrow areas in a clean and neat condition. Grade to prevent standing surface water. END OF SECTION Project No. 18088080 1 Section 31 23 19 Lake Lewisville WTP Dewatering Improvements Dewatering SECTION 31 23 19 – DEWATERING PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work required to dewater excavations. B. Related sections: 1. Section 01 50 00 – Temporary Facilities and Controls. 1.2 WATER CONTROL PLAN A. As a minimum, include: 1. Descriptions of proposed groundwater and surface water control facilities including, but not limited to, equipment; methods; standby equipment and power supply, pollution control facilities, discharge locations to be utilized, and provisions for immediate temporary water supply as required by this section. 2. Drawings showing locations, dimensions, and relationships of elements of dewatering system. B. If system is modified during installation or operation revise or amend and resubmit Water Control Plan. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 GENERAL A. Remove and control surface and subsurface water during periods when necessary to properly accomplish Work. 3.2 SURFACE WATER CONTROL A. See Section 01 50 00, TEMPORARY FACILITIES AND CONTROLS. B. Remove surface runoff controls when no longer needed. 3.3 DEWATERING SYSTEMS A. Provide, operate, and maintain dewatering systems of sufficient size and capacity to permit excavation and subsequent construction in dry conditions and to lower and maintain groundwater level a minimum of 2 feet below the lowest point of excavation. Continuously maintain excavations free of water, regardless of source, and until backfilled to final grade. B. Design and Operate Dewatering Systems: 1. To prevent loss of ground as water is removed. 2. To avoid inducing settlement or damage to existing facilities, completed Work, or adjacent property. 3. To relieve artesian pressures and resultant uplift of excavation bottom. 4. Prevent softening, loosening or otherwise disturbing the excavation subgrade. C. Provide sufficient redundancy in each system to keep excavation free of water in event of component failure. Project No. 18088080 2 Section 31 23 19 Lake Lewisville WTP Dewatering Improvements Dewatering D. Provide supplemental ditches and sumps only as necessary to collect water from local seeps. 3.4 DISPOSAL OF WATER A. Obtain discharge permit for water disposal from authorities having jurisdiction. B. Treat water collected by dewatering operations, as required by regulatory agencies, prior to discharge. C. Discharge water as required by discharge permit and in a manner that will not cause erosion or flooding, or otherwise damage existing facilities, completed Work, or adjacent property. D. The discharge of ground water into treatment facilities will not be permitted unless specifically authorized by the Owner. Remove solids from treatment facilities and perform other maintenance of treatment facilities as necessary to maintain their efficiency, if Owner allows groundwater discharge into facilities. 3.5 PROTECTION OF PROPERTY A. Make assessment of potential for dewatering induced settlement. Provide and operate devices or systems, including but not limited to reinjection wells, infiltration trenches and cutoff walls, necessary to prevent damage to existing facilities, completed Work, and adjacent property. B. Securely support existing facilities, completed Work, and adjacent property vulnerable to settlement due to dewatering operations. Support shall include, but not be limited to, sheeting bracing, underpinning, or compaction grouting. 3.6 REMEDIATION OF GROUNDWATER AFTER DEPLETION A. If dewatering reduces quantity or quality of water produced by existing wells, temporarily supply water to affected well owners from other sources. Furnish water of a quality and quantity equal to or exceeding the quality and quantity available to the well owner prior to beginning Work or as satisfactory to each well owner. END OF SECTION Project No. 18088080 1 Section 31 23 23.13 Lake Lewisville WTP Dewatering Improvements Fill and Backfill SECTION 31 23 23.13 - FILL AND BACKFILL PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work and materials required for fill and backfill for all excavations other than trench type excavations. B. Related sections: 1. Section 02 41 00 – Demolition. 2. Section 03 30 00 – Cast-In-Place Concrete. 3. Section 31 11 00 – Site Preparation. 4. Section 31 22 13 – Subgrade Preparation. 5. Section 31 23 16 – Excavation. 6. Section 31 23 23.16 – Trench Backfill. 7. Section 32 11 00 – Base Course. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American Society for Testing and Materials (ASTM): a. ASTM C117, Standard Test Method for Materials Finer Than 75-μm (No. 200) Sieve in Mineral Aggregates by Washing. b. ASTM C136, Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates. c. ASTM D75, Standard Practice for Sampling Aggregates. d. ASTM D698, Standard Test Methods for Laboratory Characteristics of Soil Using Modified Effort (12,400 ft-lbf/ft3). e. ASTM D1556, Standard Test Method for Density of Soil in Place by the Sand Cone Method. f. ASTM D1557, Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3). g. ASTM D6938, Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth). h. ASTM D4253, Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table. i. ASTM D4254, Standard Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density. 1.3 DEFINITIONS A. Relative Compaction: 1. Ratio, in percent, of as-compacted field dry density to laboratory maximum dry density as determined in accordance with ASTM D698. 2. Apply corrections for oversize material to either as-compacted field dry density or maximum dry density, as determined by Engineer. B. Optimum Moisture Content: 1. Determined in accordance with ASTM D698 specified to maximum dry density for relative compaction. 2. Determine field moisture content on basis of fraction passing 3/4-inch sieve. Project No. 18088080 2 Section 31 23 23.13 Lake Lewisville WTP Dewatering Improvements Fill and Backfill C. Relative Density: Calculated in accordance with ASTM D4254 based on maximum index density determined in accordance with ASTM D4253 and minimum index density determined in accordance with ASTM D4254. D. Prepared Ground Surface: Ground surface after completion of required demolition, clearing and grubbing, scalping of sod, stripping of topsoil, excavation to grade, and preparation. E. Completed Course: A course or layer that is ready for next layer or next phase of Work. F. Lift: Loose (uncompacted) layer of material. G. Geosynthetics: Geotextiles, geogrids, or geomembranes. H. Well-Graded: 1. A mixture of particle sizes with no specific concentration or lack thereof of one or more sizes. 2. Does not define numerical value that must be placed on coefficient of uniformity, coefficient of curvature, or other specific grain size distribution parameters. 3. Used to define material type that, when compacted, produces a strong and relatively incompressible soil mass free from detrimental voids. I. Influence Area: Area within planes sloped downward and outward at 60-degree angle from horizontal measured from: 1. 1-foot outside outermost edge at base of foundations or slabs. 2. 1-foot outside outermost edge at surface of roadways or shoulder. 3. 0.5-foot outside exterior at spring line of pipes or culverts. J. Borrow Material: Material from required excavations or from designated borrow areas on or near site. K. Selected Backfill Material/Earthfill: Materials available onsite that Engineer determines to be suitable for specific use. L. Imported Material: Materials obtained from sources suitable for specified use. M. Structural Fill: Fill materials as required under structures, pavements, and other facilities. N. Embankment Material: Fill materials required to raise existing grade in areas other than under structures. O. Standard Specification: The latest edition, including supplements of the Texas Department of Transportation Standard Specifications for Construction and Maintenance of Highways, Streets, and Bridges. 1.4 SUBMITTALS A. Quality Control Submittals: 1. Catalog and manufacturer's data sheets for compaction equipment. 2. Certified test results from independent testing agency. 1.5 QUALITY ASSURANCE A. Notify Engineer when: 1. Structure is ready for backfilling, and whenever backfilling operations are resumed after a period of inactivity. Project No. 18088080 3 Section 31 23 23.13 Lake Lewisville WTP Dewatering Improvements Fill and Backfill 2. Soft or loose subgrade materials are encountered wherever embankment or site fill is to be placed. 3. Fill material appears to be deviating from Specifications. 1.6 SEQUENCING AND SCHEDULING A. Complete applicable Work specified in Sections 02 41 00, DEMOLITION; 31 11 00, SITE PREPARATION; 31 23 16, EXCAVATION; and 31 22 13, SUBGRADE PREPARATION, prior to placing fill or backfill. B. Backfill against concrete structures only after concrete has attained compressive strength, specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. Obtain acceptance of concrete work and attained strength prior to placing backfill. C. Backfill around water-holding structures only after completion of satisfactory leakage tests as specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. D. Do not place granular base, subbase, or surfacing until after subgrade has been prepared as specified in Section 31 22 13, SUBGRADE PREPARATION. PART 2 - PRODUCTS 2.1 SOURCE QUALITY CONTROL A. Gradation Tests: It will be the Contractor’s responsibility to conduct testing as necessary to locate acceptable sources of imported material. 2.2 EARTHFILL A. Excavated material from required excavations, free from rocks larger than 3 inches, from roots and other organic matter, ashes, cinders, trash, debris, and other deleterious materials. 2.3 GRANULAR FILL A. Type A or D, Grade 1 or 2 aggregate meeting all the requirements of Section 247 of the Standard Specifications. 2.4 SELECT FILL A. Homogenous soils (i.e. not sand with clay lumps) free of organic matter and rocks larger than 6 inches in diameter and possessing an Atterberg PI of 8 to 18, with a liquid limit of 40 or less. 2.5 WATER FOR MOISTURE CONDITIONING A. Free of hazardous or toxic contaminates, or contaminants deleterious to proper compaction. 2.6 BASE COURSE ROCK A. As specified in Section 32 11 00, BASE COURSE. 2.7 FOUNDATION STABILIZATION ROCK A. Crushed rock or pit run rock. B. Uniformly graded from coarse to fine. Project No. 18088080 4 Section 31 23 23.13 Lake Lewisville WTP Dewatering Improvements Fill and Backfill C. Free from excessive dirt and other organic material. D. Maximum 2-1/2 inches particle size. PART 3 - EXECUTION 3.1 GENERAL A. Keep placement surfaces free of water, debris, and foreign material during placement and compaction of fill and backfill materials. B. Place and spread fill and backfill materials in horizontal lifts of uniform thickness, in a manner that avoids segregation, and compact each lift to specified densities prior to placing succeeding lifts. Slope lifts only where necessary to conform to final grades or as necessary to keep placement surfaces drained of water. C. During filling and backfilling, keep level of fill and backfill around each structure and buried tank even. D. Do not place fill or backfill, if fill or backfill material is frozen, or if surface upon which fill or backfill is to be placed is frozen. E. If pipe, conduit, duct bank, or cable is to be laid within fill or backfill: 1. Fill or backfill to an elevation 2 feet above top of item to be laid. 2. Excavate trench for installation of item. 3. Install bedding, if applicable, as specified in Section 31 23 23.16, TRENCH BACKFILL. 4. Install item. 5. Backfill envelope zone and remaining trench, as specified in Section 31 23 23.16, TRENCH BACKFILL, before resuming filling or backfilling specified in this section. F. Tolerances: 1. Final Lines and Grades: Within a tolerance of 0.1-foot unless dimensions or grades are shown or specified otherwise. 2. Grade to establish and maintain slopes and drainage as shown. Reverse slopes are not permitted. G. Settlement: Correct and repair any subsequent damage to structures, pavements, curbs, slabs, piping, and other facilities, caused by settlement of fill or backfill material. H. Fill and backfill materials shall be conditioned to a water content that is within 2 percentage points (plus or minus) of the optimum required for compaction as determined by ASTM D698. 3.2 BACKFILL UNDER AND AROUND STRUCTURES A. Under Facilities: Within influence area beneath structures, slabs, pavements, curbs, piping, conduits, duct banks, and other facilities, backfill with granular fill or select fill, unless otherwise shown. Place granular fill or select fill in lifts of 6-inch maximum thickness and compact each lift to minimum of 95 percent relative compaction as determined in accordance with ASTM D698, Method C. B. Subsurface Drainage: Backfill with granular drain material, where shown. Place granular drain material in lifts of 6-inch maximum thickness and compact each lift to minimum of 90 percent relative density. Project No. 18088080 5 Section 31 23 23.13 Lake Lewisville WTP Dewatering Improvements Fill and Backfill C. Other Areas: Backfill with earthfill to lines and grades shown, with proper allowance for topsoil thickness where shown. Place in lifts of 6-inch maximum thickness and compact each lift to minimum 95 percent relative compaction as determined in accordance with ASTM D698, Method C. 3.3 FILL A. Outside Influence Areas Beneath Structures, Tanks, Pavements, Curbs, Slabs, Piping, and Other Facilities: Unless otherwise shown, place earthfill as follows: 1. Allow for 6-inch thickness of topsoil where required. 2. Maximum 9-inch thick lifts. 3. Place and compact fill across full width of embankment. 4. Compact to minimum 95 percent relative compaction as determined in accordance with ASTM D698, Method C. 5. Dress completed embankment with allowance for topsoil, crest surfacing, and slope protection, where applicable. 3.4 SITE TESTING A. Gradation: 1. One sample from each 400 tons of finished product or more often as determined by Engineer, if variation in gradation is occurring, or if material appears to depart from Specifications. 2. If test results indicate material does not meet Specification requirements, terminate material placement until corrective measures are taken. 3. Remove material placed in Work that does not meet Specification requirements. B. In-Place Density Tests: In accordance with ASTM. During placement of materials, test as follows: 1. One test per every other lift per 200 lineal feet of roadway or trench. 2. A minimum of two tests on granular fill beneath structures. 3. Conduct one test per 3,000 square feet for every lift with a minimum of 2 tests per lift. 4. A minimum of two test per 300 cubic yards during backfilling of walls. C. Testing shall be the Contractor’s responsibility and conducted by persons experienced in such work. 3.5 GRANULAR BASE, SUBBASE, AND SURFACING A. Place and Compact as specified in Section 32 11 00, BASE COURSE. 3.6 REPLACING OVEREXCAVATED MATERIAL, A. Replace excavation carried below grade lines shown or established by Engineer as follows: 1. Beneath Footings: Concrete of strength equal to that of respective footing. 2. Beneath Fill or Backfill: Same material as specified for overlying fill or backfill. 3. Beneath Slabs-On-Grade: Granular fill or select fill. 4. Trenches: a. Unauthorized Overexcavation: Either trench stabilization material or granular pipe base material, as specified in Section 31 23 23.16, TRENCH BACKFILL. b. Authorized Overexcavation: Trench stabilization material, as specified in Section 31 23 23.16, TRENCH BACKFILL. 5. Permanent Cut Slopes (Where Overlying Area is Not to Receive Fill or Backfill): a. Flat to Moderate Steep Slopes (3: 1, Horizontal Run: Vertical Rise or Flatter): Earthfill. b. Steep Slopes (Steeper than 3: 1): Project No. 18088080 6 Section 31 23 23.13 Lake Lewisville WTP Dewatering Improvements Fill and Backfill 1) Correct overexcavation by transitioning between areas and designed slope adjoining areas, provided such cutting does not extend offsite or outside easements and right-of-ways, or adversely impacts existing facilities, adjacent property, or completed Work. 2) Backfilling overexcavated areas is prohibited unless, in opinion, back- fill will remain stable, and overexcavated material is replaced as com- pacted earth fill. END OF SECTION Project No. 18088080 1 Section 31 23 23.16 Lake Lewisville WTP Dewatering Improvements Trench Backfill SECTION 31 23 23.16 - TRENCH BACKFILL PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Bedding, backfill, and other related materials required to install a buried pipe or conduit. B. Related sections: 1. Section 03 30 00 – Cast-In-Place Concrete. 2. Section 31 23 19 – Dewatering. 3. Section 31 23 23.13 – Fill and Backfill. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American National Standards Institute (ANSI): 253.1, Safety Color Code. 2. American Public Works Association (APWA): Uniform Color Code for Temporary Marking of Underground Utility Locations. 3. American Society for Testing and Materials (ASTM): a. ASTM D448, Standard Classification for Sizes of Aggregate for Road and Bridge Construction. b. ASTM C94, Specification for Ready-Mixed Concrete. c. ASTM C117, Standard Test Method for Materials Finer than 75 micrometer (No. 200) Sieve in Mineral Aggregates by Washing. d. ASTM C136, Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates. e. ASTM C150, Standard Specification for Portland Cement. f. ASTM C618, Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete. g. ASTM D422, Standard Test Method for Particle-Size Analysis of Soils. h. ASTM D698, Standard Test Methods for Laboratory Compaction Characteristics of Soil using Standard Effort (12,400 ft-lbf/cubic ft). i. ASTM D1140, Standard Test Methods for Amount of Material in Soils Finer than the No. 200 (75 micrometer) Sieve. j. ASTM D1557, Standard Test Methods for Laboratory Compaction Characteristics of Soil using Modified Effort (56,000 ft-lbf). k. ASTM D3776, Standard Test Methods for Mass per Unit Area (Weight) of Fabric. l. ASTM D3786, Standard Test Method for Bursting Strength of Textile Fabrics: Diaphragm Bursting Strength Tester Method. m. ASTM D4253, Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table. n. ASTM D4254, Standard Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density. o. ASTM D4318, Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils. p. ASTM D4533, Standard Test Method for Trapezoid Tearing Strength of Geotextiles. q. ASTM D4832, Standard Test Method for Preparation and Testing of Controlled Low Strength Material (CLSM) Test Cylinders. r. ASTM D4991, Standard Test Method for Leakage Testing of Empty Rigid Containers by Vacuum Method. s. ASTM D5034, Standard Test Method for Breaking Strength and Elongation of Textile Fabrics (Grab Test). Project No. 18088080 2 Section 31 23 23.16 Lake Lewisville WTP Dewatering Improvements Trench Backfill 1.3 DEFINITIONS A. Base Rock: Granular material upon which manhole bases and other structures are placed. B. Bedding Material: Granular material upon which pipes, conduits, cables, or duct banks are placed. C. Imported Material: Material obtained by the Contractor from source(s) offsite. D. Lift: Loose (uncompacted) layer of material. E. Pipe Zone: Backfill zone that includes full trench width and extends from prepared trench bottom to an upper limit above top outside surface of pipe, conduit, cable or duct bank. F. Prepared Trench Bottom: Graded trench bottom after stabilization and installation of bedding material. G. Relative Compaction: The ratio, in percent, of the as-compacted field dry density to the laboratory maximum dry density as determined by ASTM D1557. Corrections for oversize material may be applied to either the as-compacted field dry density or the maximum dry density, as determined by the Engineer. H. Relative Density: As defined by ASTM D4253 and ASTM D4254. I. Selected Backfill Material: Material available that the Engineer determines to be suitable for a specific use. J. Well-Graded: A mixture of particle sizes that has no specific concentration or lack thereof of one or more sizes producing a material type that, when compacted, produces a strong and relatively incompressible soil mass free from detrimental voids. Well-Graded does not define any numerical value that must be placed on the coefficient of uniformity, coefficient of curvature, or other specific grain size distribution parameters. 1.4 SUBMITTALS A. Shop Drawings: Manufacturer's descriptive literature for marking tapes. B. Samples: 1. Trench stabilization material. 2. Bedding and pipe zone material. 3. Granular drain. 4. Granular backfill. 5. Earth backfill. 6. Sand(s). 7. Geotextile. C. Quality Control Submittals: Catalog and manufacturer's data sheets for compaction equipment. D. Certified Gradation Analysis: Submit not less than 30 days prior to delivery for imported materials or anticipated use for excavated materials, except for trench stabilization material that will be submitted prior to material delivery to site. E. Controlled Low Strength Material: Certified mix design and test results. Include material types and weight per cubic yard for each component of mix. Project No. 18088080 3 Section 31 23 23.16 Lake Lewisville WTP Dewatering Improvements Trench Backfill PART 2 - PRODUCTS 2.1 MARKING TAPE A. Plastic: 1. Inert polyethylene, impervious to known alkalis, acids, chemical reagents, and solvents likely to be encountered in soil. 2. Thickness: Minimum 4 mils. 3. Width: 12 inches. 4. Identifying Lettering: Minimum 1-inch high, permanent black lettering imprinted continuously over entire length. 5. Manufacturers and Products: a. Reef Industries; Terra Tape. b. Allen; Markline. B. Metallic: 1. Solid aluminum foil, visible on unprinted side, encased in a protective high visibility, inert polyethylene plastic jacket. 2. Thickness: Minimum 5 mils. 3. Width: 12 inches. 4. Identifying Lettering: Minimum 1-inch high, permanent black lettering imprinted continuously over entire length. 5. Joining Clips: Tin or nickel-coated, furnished by tape manufacturer. 6. Manufacturers and Products: a. Reef Industries; Terra Tape Sentry Line. b. Allen; Detectatape. C. Color: In accordance with APWA Uniform Color Code for Temporary Marking of Underground Facilities. Colora Facility Red Electric power lines, cables, conduit, and lightning cables Orange Communicating alarm or signal lines, cables, or conduit Yellow Gas, oil, steam, petroleum, or gaseous materials Green Sewers and drain lines Blue Water, irrigation, and slurry lines aAs specified in ANSI Z53.1, Safety Color Code. 2.2 TRENCH STABILIZATION MATERIAL A. Clean, hard, durable 3-inch minus crushed rock gravel, or pit run, free from clay balls, other organic materials, or debris. B. Uniformly graded from coarse to fine, less than 8 percent by weight passing the 1/4-inch sieve. 2.3 BEDDING MATERIAL AND PIPE ZONE MATERIAL A. Unfrozen, friable, and no clay balls, roots, or other organic material. Project No. 18088080 4 Section 31 23 23.16 Lake Lewisville WTP Dewatering Improvements Trench Backfill B. Clean or gravelly sand with less than 5 percent passing No. 200 sieve, as determined in accordance with ASTM D1140, or gravel or crushed rock within maximum particle size and other requirements as follows unless otherwise specified. 1. Duct Banks: 3/4-inch maximum particle size. 2. PVC Irrigation System Piping: 3/8-inch maximum particle size. 3. Pipe Under 18 Inches Diameter: 3/4-inch maximum particle size, except 1/4-inch for stainless steel pipe, copper pipe, tubing, and plastic pipe under 3 inches diameter. 4. Pipe Greater than 18 Inches Diameter: 1-1/2-inch maximum particle size for ductile iron pipe, concrete pipe, welded steel pipe, and pretensioned or prestressed concrete cylinder pipe. 3/4-inch maximum particle size for PVC, FRP, or HDPE Pipe. 5. Perforated Pipe: Granular drain material. 6. Conduit and Direct-Buried Cable: a. Sand, clean or clean to silty, less than 12 percent passing the No. 200 sieve. b. Individual Particles: Free of sharp edges. c. Maximum Size Particle: Pass a No. 4 sieve. d. If more than 5 percent passes No. 200 sieve, the fraction that passes No. 40 sieve shall be nonplastic as determined in accordance with ASTM D4318. 2.4 EARTH FILL A. As specified in Section 31 23 23.13, FILL AND BACKFILL. 2.5 CONTROLLED LOW STRENGTH FILL A. As specified in Section 31 23 23.33, FLOWABLE FILL. 2.6 CONCRETE BACKFILL A. Provide as specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. 2.7 TOPSOIL A. Topsoil removed and stockpiled from onsite excavation. 2.8 SOURCE QUALITY CONTROL A. Perform gradation analysis in accordance with ASTM C136 for: 1. Earth backfill, including specified class(es). 2. Trench stabilization material. 3. Bedding and pipe zone material. B. Certify Laboratory Performance of Mix Designs: 1. Controlled low strength fill. 2. Concrete. PART 3 - EXECUTION 3.1 TRENCH PREPARATION A. Water Control: Conform to Section 31 23 19, DEWATERING. 1. Promptly remove and dispose of water entering trench as necessary to grade trench bottom and to compact backfill and install manholes, pipe, conduit, direct-buried cable, or duct bank. Do not place concrete, lay pipe, conduit, direct-buried cable, or duct bank in water. 2. Remove water in a manner that minimizes soil erosion from trench sides and bottom. Project No. 18088080 5 Section 31 23 23.16 Lake Lewisville WTP Dewatering Improvements Trench Backfill 3. Provide continuous water control until trench backfill is complete. B. Remove foreign material and backfill contaminated with foreign material that falls into trench. 3.2 TRENCH BOTTOM A. Firm Subgrade: Grade with hand tools, remove loose and disturbed material, and trim off high areas and ridges left by excavating bucket teeth. Allow space for bedding material if shown or specified. B. Soft Subgrade: If it is encountered that it may require removal to prevent pipe settlement, notify Engineer. Engineer will determine the depth of overexcavation, if any, required. 3.3 TRENCH STABILIZATION MATERIAL INSTALLATION A. Rebuild trench bottom with trench stabilization material. B. Place material over full width of trench in 6-inch lifts to required grade, providing allowance for bedding thickness. C. Compact each lift so as to provide a firm, unyielding support for the bedding material prior to placing succeeding lifts. 3.4 BEDDING A. Furnish imported bedding material where, in the opinion of the Engineer, excavated material unsuitable for bedding or insufficient in quantity. B. Place over the full width of the prepared trench bottom in two equal lifts when the required depth exceeds 8 inches. C. Hand grade and compact each lift to provide a firm, unyielding surface. D. Minimum Thickness: 1. Pipe, 15-inch and Smaller: 4 inches. 2. Pipe, 18-inch to 36 inch: 6 inches. 3. Pipe, 42-inch and Larger: 12 inches. 4. Conduit: 3 inches. 5. Direct-Buried Cable: 3 inches. 6. Duct Banks: 3 inches. E. Check grade and correct irregularities in bedding material. Loosen top 1 to 2 inches of compacted bedding material with a rake or by other means to provide a cushion before laying each section of pipe, conduit, direct-buried cable, or duct bank. F. Install to form continuous and uniform support except at bell holes, if applicable, or minor disturbances resulting from removal of lifting tackle. G. Bell or Coupling Holes: Excavate in bedding at each joint to permit proper assembly and inspection of joint and to provide uniform bearing along barrel of pipe or conduit. 3.5 BACKFILL PIPE ZONE A. Upper limit of pipe zone shall not be less than following: 1. Pipe: 12 inches above top of pipe, unless shown otherwise. Project No. 18088080 6 Section 31 23 23.16 Lake Lewisville WTP Dewatering Improvements Trench Backfill 2. Conduit: 3 inches above top of conduit, unless shown otherwise. 3. Direct-Buried Cable: 3 inches above top of cable, unless shown otherwise. 4. Duct Bank: 3 inches above top of duct bank, unless shown otherwise. B. Restrain pipe, conduit, cables, and duct banks as necessary to prevent their movement during backfill operations. C. Place material simultaneously in lifts on both sides of pipe and, if applicable, between pipes, conduit, cables, and duct banks installed in same trench. 1. Pipes 10 Inches and Smaller Diameter: First lift less than or equal to pipe-diameter. 2. Pipes Over 10 Inches Diameter: Maximum 6-inch lifts. D. Thoroughly tamp each lift, including area under haunches, with handheld tamping bars supplemented by "walking in" and slicing material under haunches with a shovel to ensure that voids are completely filled before placing each succeeding lift. E. After the full depth of the pipe zone material has been placed as specified, compact the material by a minimum of three passes with a vibratory plate compactor only over the area between the sides of the pipe and the trench walls. F. Do not use power-driven impact compactors to compact pipe zone material. 3.6 MARKING TAPE INSTALLATION A. Continuously install marking tape along centerline of all buried piping, at depth of 2 feet. Coordinate with piping installation drawings. 1. Metallic Marking Tape: Install with nonmetallic piping 2. Plastic Marking Tape: Install with metallic piping. 3.7 BACKFILL ABOVE PIPE ZONE A. General: 1. Process excavated material to meet specified gradation requirements. 2. Adjust moisture content as necessary to obtain specified compaction. 3. Do not allow backfill to free fall into the trench or allow heavy, sharp pieces of material to be placed as backfill until after at least 2 feet of backfill has been provided over the top of pipe. 4. Do not use power driven impact type compactors for compaction until at least 4 feet of backfill is placed over top of pipe. 5. Backfill to grade with proper allowances for topsoil, crushed rock surfacing, and pavement thicknesses, wherever applicable. 6. Backfill around structures with same class backfill as specified for adjacent trench unless otherwise shown or specified. B. Select Excavated Backfill: 1. Place in lifts not exceeding 9-inch thickness. 2. Mechanically compact each lift to a minimum of 95 percent relative compaction prior to placing succeeding lifts. C. Excavated Backfill: Backfill trench above the pipe zone with granular backfill in lifts not exceeding 8 inches. Compact each lift to a minimum of 95 percent relative compaction prior to placing succeeding lifts. D. Concrete Backfill: 1. Place above bedding. Project No. 18088080 7 Section 31 23 23.16 Lake Lewisville WTP Dewatering Improvements Trench Backfill 2. Minimum Concrete Thickness: 6 inches on top and sides of pipe. 3. Do not allow dirt or foreign material to become mixed with concrete during placement. 4. Allow sufficient time for concrete to reach initial set before additional backfill material is placed in trench. 5. Prevent flotation of pipe. 6. Begin and end concrete backfill within 4 inches of a pipe joint on each end. 7. Do not encase pipe joints except within the limits of the concrete backfill. E. Controlled Low Strength Fill: 1. Discharge from truck mounted drum type mixer into trench. 2. Place in lifts as necessary to prevent uplift (flotation) of new and existing facilities. 3.8 REPLACEMENT OF TOPSOIL A. Replace topsoil in top 6 inches of backfilled trench. B. Maintain the finished grade of topsoil even with adjacent area and grade as necessary to restore drainage. 3.9 MAINTENANCE OF TRENCH BACKFILL A. After each section of trench is backfilled, maintain the surface of the backfilled trench even with the adjacent ground surface until final surface restoration is completed. B. Gravel Surfacing Rock: Add gravel surfacing rock where applicable and as necessary to keep the surface of the backfilled trench even with the adjacent ground surface, and grade and compact as necessary to keep the surface of backfilled trenches smooth, free from ruts and potholes, and suitable for normal traffic flow. C. Topsoil: Add topsoil where applicable and as necessary to maintain the surface of the backfilled trench level with the adjacent ground surface. D. Replace settled areas with cold mix asphalt as needed until final concrete pavement is placed. E. Other Areas: Add excavated material where applicable and keep the surface of the backfilled trench level with the adjacent ground surface. 3.10 SETTLEMENT OF BACKFILL A. Settlement of trench backfill, or of fill or facilities constructed over trench backfill, will be considered a result of defective compaction of trench backfill. END OF SECTION Project No. 18088080 1 Section 31 23 23.33 Lake Lewisville WTP Dewatering Improvements Flowable Fill SECTION 31 23 23.33 – FLOWABLE FILL PART 1 - GENERAL 1.1 SUMMARY A. This Section specifies controlled low strength concrete flowable fill. B. Comply with all requirements of Section 03 30 00 CAST-IN-PLACE CONCRETE except as specifically modified in this Section. C. Related sections: 1. Section 03 30 00 - Cast-In-Place Concrete. 1.2 DEFINITIONS A. Flowable Fill: Controlled low strength concrete ready mix. 1.3 SUBMITTALS A. Comply with the requirements of Section 03 30 00 CAST-IN-PLACE CONCRETE. 1.4 QUALITY ASSURANCE A. Comply with the requirements of Section 03 30 00 CAST-IN-PLACE CONCRETE. PART 2 - PRODUCTS 2.1 PRODUCTS A. Comply with the requirements of Section 03 30 00 CAST-IN-PLACE CONCRETE and as follows: 1. Concrete Mixture for Flowable Fill only: a. Compressive strength 75 to 100 psi. b. Cement 80-100 lbs per CY. c. Fly Ash 200-300 lbs per CY. d. Sand variable to equal one CY. e. Water 65 to 199 gallons per CY. f. Unit weight approximately 110 lbs/CY. PART 3 - EXECUTION 3.1 EXECUTION A. Comply with the requirements of Section 03 30 00 CAST-IN-PLACE CONCRETE. END OF SECTION Project No. 18088080 1 Section 31 32 00 Lake Lewisville WTP Dewatering Improvements Soil Erosion Stabilization SECTION 31 32 00 - SOIL EROSION STABILIZATION PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work and materials required to minimize erosion and comply with Storm Water Pollution Prevention Plan. 1.2 STABILIZATION A. Soil Erosion Stabilization: 1. Ground surfaces exposed during the wet weather conditions: 2. Areas which will not be subjected to heavy wear by ongoing construction traffic. 3. Temporary and long term stabilization of new or disturbed ditches, swales, detention ponds, or disturbed ground with intermittence construction traffic. B. Permanent Stabilization: 1. Permanently stabilize exposed soil surfaces at finished grades. 2. Permanent stabilization methods include, but are not limited to, seeding (permanent), mulching, and landscaping. 3. Immediately perform permanent stabilization at each completed excavation and areas except for areas that are scheduled to be redisturbed. 4. Incorporate all permanent erosion control features into the project at the earliest practical time. C. Buffer Zone: Undisturbed area or strip of natural vegetation or an established suitable planting adjacent to a disturbed area that reduces erosion and runoff. D. Standard Specifications: The latest edition, including supplements, of the Texas Department of Transportation Standard Specifications for Highway Construction. 1.3 SUBMITTALS A. Shop Drawings: Product Data for the following items: 1. Erosion control rock. 2. Fertilizer. 3. Seed. 4. Mulch. 5. Erosion control rock. 6. Soil tackifier 7. Reinforced plastic covering. 8. Silt fence. 9. Straw bales. 10. Posts for straw bales. 11. Dust controller. 12. Wire mesh. B. See Section 01 33 00, SUBMITTAL PROCEDURES. 1.4 DELIVERY, STORAGE, AND PROTECTION A. General: Prevent or reduce the discharge of pollutants to stormwater from all material delivery and storage by minimizing the storage of hazardous materials storing materials in a designated Project No. 18088080 2 Section 31 32 00 Lake Lewisville WTP Dewatering Improvements Soil Erosion Stabilization area, installing Secondary containment, conducting regular inspection, and training employees and subcontractors. B. Seed: 1. Furnish in standard containers with seed name, lot number, net weight, percentages of purity, germination, and hard seed and maximum weed seed content, clearly marked for each container of seed. 2. Keep dry during storage. C. Hydroseeding Mulch: Mark package of wood fiber mulch to show air dry weight. 1.5 SEQUENCING AND SCHEDULING A. Install erosion and sediment control devices before starting earth disturbance activities and as drainage facilities get constructed. B. Complete Soil Preparation: Seeding, fertilizing, mulching and matting on disturbed areas that will require stabilization either because the area has reached final grade (permanent landscaping) or because the area will remain unworked for over 14 days (temporary seeding) during the wet season. C. Notify Engineer at least 3 days in advance of: 1. Materials delivery. 2. Start of stabilization activity. D. Seeding: Perform between March 15 and September 15. 1.6 MAINTENANCE A. Operations: 1. Seeded Areas: Perform during maintenance period to include: a. Watering: Keep seeded surface moist. b. Washouts: Repair by filling with topsoil, fertilizing, seeding, and mulching. c. Mulch: Replace wherever and whenever washed or blown away. d. Reseed unsatisfactory areas or portions thereof immediately at the end of the maintenance period if a satisfactory stand has not been produced. e. Reseed during next planting season if scheduled end of maintenance period falls after September 15. f. Reseed entire area if satisfactory stand does not develop by July 1 of the following year. g. Mowing: Mow to 2 inches after grass height reaches 3 inches, and mow to maintain grass height from exceeding 3-1/2 inches. 2. Inspect, repair, and replace as necessary all erosion control measures during the time period from start of construction to completion of construction. 3. Inspect a minimum of at least once every 7 days or after a 1/2-inch storm event in a 24- hour period. 4. Furnish and install a rain gauge at the project site to monitor rainfall. At no time shall more than 1-foot depth of sediment be allowed to accumulate in any erosion control device. B. Sediment Removal: 1. Remove sediment from erosion control devices and work into the grading plan at least once a week as required to maintain proper operation of devices. The cleaning operation shall not dispose of sediment offsite. Project No. 18088080 3 Section 31 32 00 Lake Lewisville WTP Dewatering Improvements Soil Erosion Stabilization 2. Sediment shall be removed and the controls upgraded or repaired as needed as soon as practicable, but not later than 2 days after the surrounding exposed ground has dried sufficiently to prevent further damage from equipment needed for repair operations. 3. In the event of continuous rainfall over a 24 hour period, or other circumstances that preclude equipment operation in the area, hand carry and install additional sediment controls as approved by the Engineer. PART 2 - PRODUCTS 2.1 FERTILIZER A. Commercial, uniform in composition, free-flowing, suitable for application with equipment designed for that purpose. B. Fertilizer shall have the following minimum percentage of plant food by weight: 1. Summer Hydroseed Mix: a. Nitrogen: 20 percent. b. Phosphoric Acid: 10 percent. c. Potash: 10 percent. 2. Winter Hydroseed Mix: a. Nitrogen: 16 percent. b. Phosphoric Acid: 8 percent. c. Potash: 0 percent. 2.2 SEED A. Common bermudagrass meeting the requirements of Section 735 of the Texas Department of Transportation Standard Specifications for Highway Construction. 2.3 MULCH A. Wood Cellulose Fiber Mulch: 1. Specially processed wood fiber containing no growth or germination inhibiting factors. 2. Dyed a suitable color to facilitate inspection of material placement. 3. Manufactured such that after addition and agitation in slurry tanks with water, the material fibers will become uniformly suspended to form a homogenous slurry. 4. When hydraulically sprayed on ground, material will allow absorption and percolation of moisture. B. Straw: 1. Clean salt hay or threshed straw of oats, wheat, barley, or rye, free from seed of noxious weeds. Suitable for spreading with mulch blower equipment. 2. Average Stalk Length: 6 inches. 3. Seasoned before baling or loading. 2.4 EROSION CONTROL MATTING A. Excelsior mat or straw blanket; staples as recommended by matting manufacturer. B. Manufacturers and Products: 1. American Excelsior Company, Dallas, TX; Curlex Mat. 2. North American Green, Evansville, IN; S150 blanket. Project No. 18088080 4 Section 31 32 00 Lake Lewisville WTP Dewatering Improvements Soil Erosion Stabilization 2.5 REINFORCED PLASTIC COVERING A. Co-extruded, copolymer laminate reinforced with a nonwoven grid of high strength nylon cord submersed in a permanently flexible adhesive media allowing for equal tear resistance in all directions. B. Black in color and ultraviolet stabilized. C. Physical Requirement (Minimum Average Roll Values): 1. Tear Strength: 130 pounds. 2. Elongation: 620 percent. 3. Minimum Thickness: 6 mil. D. Manufacturers: 1. Reef Industries, Inc., Houston, TX. 2. Griffolyn Co., Houston, TX. 2.6 SILT FENCE A. Support Posts: As recommended by manufacturer of geotextile. B. Fasteners: Heavy-duty wire staples at least 1-inch long, tie wires, or hog rings, as recommended by manufacturer of geotextile. C. Filter Fabric: Polyester, polypropylene, or nylon filaments, woven into a uniform pattern, distinct and measurable openings. 1. Filaments: Resistant to damage from exposure to ultraviolet rays and heat. 2. Material Edges: Finish so that, filaments retain their relative positions under stress. D. In accordance with requirements of Table No. 1: Table No. 1 – Filter Fabric Physical Property Required Value Test Method Weight, pz/sq yd, min. 4 ASTM D3776 Equivalent Opening Size, max. 50-70 U.S. Standard Sieve Grab Tensile Strength, lb, min. ARV 160 ASTM D4632 Elongation, % max. 25 ASTM D1682 Mullen Burst Strength, psi, min. ARV 200 ASTM D3786 Ultraviolet Radiation Resistance, % Strength Retention 70 ASTM D4355 Flow Rate, gpm/sf, min. ARV 30 to 50 ASTM D4491 E. Manufacturers: 1. Polyfelt, Evergreen, AL. 2. Dupont Co., Wilmington, DE. Project No. 18088080 5 Section 31 32 00 Lake Lewisville WTP Dewatering Improvements Soil Erosion Stabilization 3. Mirafi, Inc., Charlotte, NC. 2.7 STRAW BALES A. Machine baled clean salt hay or straw of oats, wheat, barley, or rye, free from seed of noxious weeds, using standard baling wire or string. 2.8 POSTS FOR STRAW BALES A. 2-inch by 2-inch untreated wood or commercially manufactured metal. 2.9 DUST CONTROLLER A. Nontoxic materials that do not have an adverse effect on soil structure or establishment and growth of vegetation. PART 3 - EXECUTION 3.1 GENERAL A. Erosion control measures are required during all construction and site disturbance activity and shall remain until permanent site ground covers are in place. B. The implementation of the erosion control plan and the construction maintenance, replacement and upgrading the erosion control devices are the responsibility of the Contractor until all construction is completed and landscaping established and approved. During the construction period, the erosion control devices shall be upgraded for unexpected storm events and to ensure that sediment and sediment laden water do not leave the site. C. Maintain existing buffer zones adjacent to project limits. Keep all construction equipment, debris and soils out of the natural buffer zone. 3.2 GRAVEL CONSTRUCTION ENTRANCES A. Provide a graveled construction access at each access point between the site and any public or private road or other paved surface. B. Place subgrade geotextile, as specified, on the ground prior to erosion control rock placement. C. Place erosion control rock over the geotextile to a minimum thickness of 8 inches. D. Minimum dimensions for construction entrances are 50-foot in length by 16-foot width. E. Contractor shall provide a minimum of 4 inches of erosion control rock for each entrance 3 times during the project at times directed by the Engineer to maintain proper function. More frequent applications of rock may be required, and if so, shall be considered as incidental work. 3.3 SOIL PREPARATION A. Before start of hydroseeding, and after surface has been shaped and graded, and lightly compacted to uniform grade, scarify soil surface to minimum depth of 1 inch. 3.4 FERTILIZER A. Apply evenly over area in accordance with manufacturer's instructions. Mix into top 1-inch of soil. Project No. 18088080 6 Section 31 32 00 Lake Lewisville WTP Dewatering Improvements Soil Erosion Stabilization B. Application Rate: 5 pounds per 1,000 square foot over areas to be seeded. Use of approved hydraulic equipment to sow seed and distribute fertilizer at the same time will be acceptable. 3.5 SEEDING A. Prepare 1-inch depth seed bed; obtain Engineer’s acceptance prior to proceeding. B. Apply by hydroseeding method on moist soil, but only after free surface water has drained away. Prevent drift and displacement of mixture into other areas. C. Summer Application: 1. Prepare and apply slurry as follows: Item Rate Seed Mix 200 pounds per acre Fertilizer 750 pounds per acre Wood Cellulose Fiber Mulch As recommended by manufacturer Water As necessary 2. Irrigation: 1-inch per week to seeded areas. 3.6 MULCHING A. Apply uniformly on disturbed areas that will remain undisturbed for 7 days or more, as requested by Engineer, and on all seeded areas. B. Application: Sufficiently loose to permit penetration of sunlight and air circulation, and sufficiently dense to shade ground, reduce evaporation rate, and prevent or materially reduce erosion of underlying soil. 1. Straw: Apply by hand or mechanical means to minimum depth of 2 inches. 2. Wood Cellulose Fiber: 1,000 to 1,500 pounds per acre. 3.7 EROSION CONTROL MATTING A. Place on seeded slopes 4H:1V and steeper. B. Apply seed and fertilizer prior to matting. C. At top of slope, entrench material in a 6-inch by 6-inch trench and staple at 1-foot intervals. At the bottom of the slope, extend the mat 2 feet beyond the toe of slope, turn material under 4 inches and staple at 1-foot intervals. D. Mats shall be stapled in place as they are installed down the slope face. The mat shall have direct contact with the soil surface. E. Overlap: 1. Lengthwise: 1-foot minimum. 2. Crosswise: 6-inches minimum. Project No. 18088080 7 Section 31 32 00 Lake Lewisville WTP Dewatering Improvements Soil Erosion Stabilization 3.8 REINFORCED PLASTIC COVERING A. Place on areas where hydroseeding and erosion control matting have not controlled erosion and over all temporary stockpiles. B. Install in single thickness, strips parallel to direction of drainage. Anchor plastic in 6-inch by 6- inch trench backfilled with compacted native material. C. Maintain tightly in place by using sand bags on ropes with a maximum 10-foot grid spacing in all directions. D. Tape or weight down full length, overlap seams at least 12 inches. E. Remove at final acceptance unless notified otherwise by Engineer. 3.9 SILT FENCE A. Install prior to starting earth disturbing activities upslope of fence. B. One-piece filter fabric or continuously sewn to make one-piece filter fabric for full height of the fence, including portion buried in the toe trench. C. When joints are necessary, splice filter fabric together only at a support post, with a minimum 6- inch overlap, and securely fasten both ends to support post. D. Filter fabric shall not extend more than 24 inches above the ground surface. Securely fasten to upslope side of each support post using ties. Filter fabric shall not be stapled to existing trees. E. Fasten wire mesh material support fence securely to upslope side of post fasteners. Extend wire into the trench a minimum of 4 inches, and not more than 36 inches above the ground surface. F. Take precaution not to puncture filter fabric during installation. Repair or replace damaged area. G. Remove silt fence after upslope area has been permanently stabilized. Immediately dress sediment deposits remaining after the silt fence has been removed to conform to existing grade. Prepare and seed graded area. 3.10 TEMPORARY SOIL STOCKPILES A. Cover with reinforced plastic covering, as directed in Article REINFORCED PLASTIC COVERING. B. Protect perimeter of stockpile from erosion with ditches. 3.11 STRAW BALES A. Embed minimum of 4 inches in flat-bottomed trench. Place across swales or ditches to reduce velocities of concentrated flows. Space bales a minimum of 100-foot spacing. B. Place with ends tightly abutting or overlapped. Corner abutment is not acceptable. C. Install so that bale bindings are oriented around the sides and not over the top and bottom of the bale. D. Use two posts for each bale. Drive posts through the bale until top of post is flush with top of bale. Project No. 18088080 8 Section 31 32 00 Lake Lewisville WTP Dewatering Improvements Soil Erosion Stabilization E. Wedge loose straws in any gaps between bales. 3.12 DUST CONTROL A. Apply appropriate dust control measures on a continuous basis until permanent stabilization measures are in place. B. Apply on construction routes and other disturbed areas subject to surface dust movement and where off-site damage may occur if dust is not controlled. C. Avoid creating erosion when using water as a dust controller. 3.13 CLEAN-UP A. Sediment trapped in erosion control devices shall be regraded into the slopes on the site. Do not flush sediment-laden water into the drainage system. B. After site restoration is complete and when approved by the Engineer, all temporary erosion control measures shall be completely removed. Immediately shape and permanently stabilize areas affected by the removal process. C. Silt fence, straw bales, reinforced plastic covering, and any other erosion control devices shall be disposed off site to locations that are approved by federal, state, and local authorities. END OF SECTION Project No. 18088080 1 Section 31 37 00 Lake Lewisville WTP Dewatering Improvements Rip Rap SECTION 31 37 00 – RIP RAP PART 1 - GENERAL 1.1 SUMMARY A. Section includes the procurement and installation of riprap. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 31 23 16 – Excavation. 3. Section 31 23 23.16 – Trench and Backfill. 1.2 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM) latest edition. 1. ASTM C97 – Standard Test Methods for Absorption and Bulk Specific Gravity of Dimension Stone 2. ASTM D4992 – Standard Practice for Evaluation of Rock to Be Used for Erosion Control. 3. ASTM D5240 – Standard Test Method for Evaluation of Durability of Rock for Erosion Control Using Sodium Sulfate or Magnesium Sulfate. 4. ASTM D5312 – Standard Test Method for Evaluation of Durability of Rock for Erosion Control Under Freezing and Thawing Conditions. 5. ASTM D5313 – Standard Test Method for Evaluation of Durability of Rock for Erosion Control Under Wetting and Drying Conditions. 6. ASTM D5779 – Standard Test Method for Field Determination of Apparent Specific Gravity of Rock and Manmade Materials for Erosion Control. 1.3 SUBMITTALS A. Provide as specified in Section 01 33 00, SUBMITTAL PROCEDURES. B. Certificates: Certify that products meet or exceed specified requirements. PART 2 - PRODUCTS 2.1 MATERIALS A. The riprap shall be hard, sound, and durable. It shall be reasonably free of fines and shall be well graded between the maximum and minimum rock sizes so as to produce a minimum of voids. No riprap shall be placed on the project until it has been accepted by Engineer. B. The minimum density of stone shall be 130 pounds per cubic foot and the maximum absorption shall be 6 percent. C. The maximum size shall not be greater than 12-inches in any dimension and approximately 50 percent of the material shall consist of pieces weighing 20 pounds or more. The stones shall be predominantly angular in shape with not more than 25 percent having a length more than 2.5 times its breadth or thickness and none having a length exceeding 3.0 times its breadth or thickness. D. Contractor shall obtain and submit certification that the proposed rock meets density and absorption requirements specified herein. Testing for certification shall be in accordance with ASTM C97. Certified test results shall be submitted to Engineer prior to the use of the proposed material as riprap. Project No. 18088080 2 Section 31 37 00 Lake Lewisville WTP Dewatering Improvements Rip Rap PART 3 - EXECUTION 3.1 INSTALLATION A. The riprap layer shall be a minimum of 24-inches thick when placed over the geotextile fabric. B. When placed on the embankment, the smaller stones shall be well distributed throughout the mass. Hand placing may be required to obtain the results specified above. C. The areas to be protected with riprap shall be dressed to the lines and grades shown on the Drawings and covered with the geotextile fabric prior to placing the riprap. D. Riprap graded so that the smaller stones are uniformly distributed throughout the mass shall then be placed, starting at the toe of the slope, with a maximum vertical drop onto the geotextile fabric of 2 feet. In no case shall stones be allowed to roll down the fabric covered slope. Placement of the riprap over the fabric shall proceed so that the upper boundary of the riprap layer is at essentially the same level for the entire length of the fabric. END OF SECTION Project No. 18088080 1 Section 31 50 00 Lake Lewisville WTP Dewatering Improvements Excavation Support System SECTION 31 50 00 - EXCAVATION SUPPORT SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work required to install and remove excavation support systems. B. Related sections: 1. Section 31 23 23.13 – Fill and Backfill 1.2 SUBMITTALS A. Shop Drawings: 1. Excavation support plan. 2. Movement monitoring plan. B. Quality Control Submittals: Movement measurement and data and reduced results indicating movement trends. 1.3 QUALITY ASSURANCE A. Provide surveys to monitor movements of critical facilities. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 GENERAL A. Design, provide, and maintain shoring, sheeting, and bracing as necessary and where shown to support the sides of excavations and to prevent detrimental settlement and lateral movement of existing facilities, adjacent property, and completed Work. B. Minimum areas for sharing, sheeting and bracing are shown on the Drawings. It will be the Contractor’s responsibility to determine if areas will require excavation slope retention to protect existing structures and facilities from damage resulting from the Contractor’s excavation or excavation methods. C. The Contractor will also be responsible for providing shoring, sheeting and bracing of excavations as needed for worker safety and as may be required by federal, state, and local regulations. 3.2 EXCAVATION SUPPORT PLAN A. Prepare excavation support plan addressing following topics: 1. Details of shoring, bracing, sloping, or other provisions for worker protection of existing structures or facilities. 2. Design assumptions and calculations. 3. Methods and sequencing of installing excavation support. 4. Proposed locations of stockpiled excavated material. 5. Minimum lateral distance from the crest of slopes for vehicles and stockpiled excavated materials. Project No. 18088080 2 Section 31 50 00 Lake Lewisville WTP Dewatering Improvements Excavation Support System 3.3 MOVEMENT MONITORING PLAN A. Prepare movement monitoring plan addressing following topics: 1. Survey control. 2. Locations of monitoring points (at least one every 50 feet). 3. Plots of data trends. 4. Interval between surveys (not to exceed 5 working days). B. Movement monitoring shall be done on every existing structure that is adjacent to the Contractor’s excavations. C. Results of movement monitoring will be delivered for the Engineer at least once a week. 3.4 REMOVAL OF EXCAVATION SUPPORT A. Do not begin to remove excavation support until it can be removed without damage to existing facilities, completed Work, or adjacent property. B. Remove excavation support and protection systems when construction has progressed sufficiently to support excavation and earth and hydrostatic pressures. Remove in stages to avoid disturbing underlying soils and rock or damaging structures, pavements, facilities, and utilities. Maintain soil wall support as excavation is backfilled. C. Fill voids immediately with approved backfill compacted to density specified in Section 31 23 23.13, FILL AND BACKFILL. END OF SECTION Project No. 18088080 1 Section 31 63 30 Lake Lewisville WTP Dewatering Improvements Drilled Concrete Piers SECTION 31 63 30 – DRILLED CONCRETE PIERS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work and materials required for drilled concrete piers. B. Related sections: 1. Section 03 20 00 – Concrete Reinforcing. 2. Section 03 30 00 – Cast-In-Place Concrete. C. Payment Procedures: 1. Basis of payment: a. Payment for pier work: 1) Base lump sum bid price for pier work on the number and lengths of piers as indicated on the drawings. a) This price shall include all costs in connection with the Work, including pier material, installation, reinforcing, concrete, pier cutoff, and other related items for a complete installation. 2) In addition, quote a unit price per foot for additional pier length and reduction in pier length for changes in pier length made based on Geotechnical Engineer’s recommendations during installation. 3) Payment will be made only for the length of pier established by the Geotechnical Engineer’s recommendations during drilling operations. a) No payment will be made for any defective pier. b) Install piers to the elevations and lengths indicated on the drawings, unless otherwise indicated in writing by the Geotechnical Engineer. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American Concrete Institute (ACI) a. 211.1 - Standard Practice of Selecting Proportions for Normal, Heavyweight, and Mass Concrete. b. 350 - Code Requirement for Environmental Engineering Concrete Structures and Commentary. 2. American Society for Testing and Materials (ASTM): a. C 31 - Standard Practice for Making and Curing Concrete Test Specimens in the Field. b. C 39 - Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens. c. C 143 - Standard Test Method for Slump of Hydraulic-Cement Concrete. d. C 172 - Standard Practice for Sampling Freshly Mixed Concrete. e. C 192 - Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory 1.3 DEFINITIONS A. Cementitious Materials: Defined as Portland cement and pozzolans admixture. 1.4 SUBMITTALS A. Reinforcing bar placement drawings. Project No. 18088080 2 Section 31 63 30 Lake Lewisville WTP Dewatering Improvements Drilled Concrete Piers B. Bar lists and bending details. C. Concrete mix design report as specified in Section 03 30 00. D. Aggregate tests. E. Trial batch results. F. Concrete testing requirements as specified in Section 03 30 00. G. A list and description of proposed equipment to be used for the construction of piers such as cranes, drills, cleaning equipment, and tremie concrete pumps. H. Details of overall construction operation, sequence, and drilling construction methods. I. Qualifications of crew for review at bid time. Substitution of approved personnel will not be allowed without written authorization by the OWNER. J. Pier location plan and location information: 1. Pier layout plan: Pier plan showing location indicated on the Drawings, including: 2. Assigned number for each pier as identification for use in pier installation record. 3. Pier tip elevation. K. Pier location survey. 1.5 QUALITY ASSURANCE A. Contractor Qualifications: 1. The CONTRACTOR shall be regularly engaged in the installation of drilled piers foundation systems. 2. Have a minimum of 10 years previous experience on projects of similar or larger size, complexity, and subsurface conditions. 3. The job supervisor directly responsible for pier installation shall have continuous experience on drilled pier installation throughout the last 10 years. 4. The crane operators or “keymen” who give directions to the crane operators shall have at least 2 years of experience. 1.6 PROJECT CONDITIONS A. Project environmental requirements: 1. Sound control: a. Muffle equipment for pier installation as necessary to comply with federal, state, and local community noise regulations. b. Perform drilling and pier installation operations in manner such that noise levels do not exceed 55 db(A) at any residential property boundary except for short periods of time as provided by local ordinances. c. Monitor and record noise levels from pier installation operations, as required for compliance with worker safety regulations: 1) Monitoring costs and any costs associated with related construction and project shutdown delays necessitated while bringing noise levels in compliance with the preceding provisions shall be the responsibility of and be borne by the CONTRACTOR. Project No. 18088080 3 Section 31 63 30 Lake Lewisville WTP Dewatering Improvements Drilled Concrete Piers PART 2 - PRODUCTS 2.1 MATERIALS A. Reinforcing steel: Use reinforcing steel as specified in Section 03 11 00. B. Tie wire: Use Number 18 double annealed iron wire, tie wire. C. Concrete: Use concrete materials as specified in Section 03 30 00. PART 3 - EXECUTION 3.1 INSTALLATION A. General: 1. Install piers only in the presence of the ENGINEER. 2. Piers that fail to meet the requirements of these Specifications for alignment and piers which for other reasons are unacceptable will be rejected. B. C. Drilling: 1. Drill holes by means of a power driven, rotary bucket, rotary auger type, or core barrel foundation drilling machine designed to excavate a cylindrical shaft: a. Have sufficient power and cutting capacity to excavate the pier holes to the required depths into the soil or rock at the site. 2. Use drilling method which prevents the shaft sidewalls from caving in or sloughing into the excavated hole, except that dewatering will not be permitted. 3. Proceed with the work in the “wet” if the groundwater level is found above pier tip elevation. 4. Do not drill holes within 4 pier diameters (center-to-center) of a previously drilled hole until after the concrete in the previous hole has set up, but in no case until the concrete has been placed for at least 15 hours. 5. Do not drill holes until the excavation or fill in the area in which the shafts are to be located has been completed to the elevations indicated on the Drawings. 6. Clean out the hole until no more than 1/4 inch of loose or soft material is left in the bottom of the hole. 7. Clean and protect top of holes to prevent soil from falling into hole. 8. Drill piers from the ground surface to tip elevations as indicated on the Drawings. a. The Geotechnical Engineer will determine the final bottom of hole elevation and will keep a record of each drilled hole during installation. D. Reinforcing steel: 1. Upon completion of drilling, position the reinforcing steel cage in the pier shaft as indicated on the Drawings and suspend it above the bottom of excavation before any concrete is placed in the shaft. 2. Support the reinforcing steel cage so that it rotates freely just prior to final suspension. 3. If soil caving occurs after reinforcing steel is placed and before placement of concrete, remove the reinforcing steel and ream the hole to permit repositioning of the cage. 4. Support the cage in a manner that will assure that it remains centered in the pier shaft during placement of concrete. a. Use plastic roller type centering devices attached to spiral reinforcing bars. b. The centering devise shall position reinforcing cages in center of hole and provide proper cover for reinforcing bars. E. Concrete: Project No. 18088080 4 Section 31 63 30 Lake Lewisville WTP Dewatering Improvements Drilled Concrete Piers 1. Quality: a. Use concrete composed of portland cement, fly ash, natural or crushed aggregate, and water proportioned in accordance with ACI 211.1, and mixed as specified. b. Use proportions of portland cement, fly ash, and aggregate to produce a workable, strong, dense, and impermeable concrete having a consistency and strength as specified. c. Use concrete having a maximum water-to-cementitious materials ratio of 0.40. d. Do not exceed a maximum fly ash content of 125 pounds per cubic yard. e. Use an air content of concrete, in accordance with ACI 350 for severe exposure. f. Use a minimum cementitious materials content of 520 pounds per cubic yard of concrete. 2. Consistency: a. Determine the quantity of water required for the proper consistency of the concrete by using slump tests in accordance with ASTM C 143. b. Use 8- to 10-inch slump at point of deposit for concrete which contains super- plasticizer. 3. Admixtures: a. Accelerating or retarding admixtures may be used when ambient temperatures affect setting times. b. Use water-reducing admixtures in mix. c. Use super-plasticizer for drilled piers. 4. Aggregate tests: a. Take samples of fine and course aggregate at the concrete batch plant. b. Perform mechanical analysis and determine the specific gravity of one sample for each aggregate size. c. Perform all sampling and tests using an independent engineering testing laboratory acceptable to the ENGINEER. 5. Concrete strength: a. The specified 28-day compressive strength of a standard 6-inch diameter test cylinder shall not be less than 4,500 pounds per square inch. b. Determine compressive strength in accordance with ASTM C 39. c. Make and cure test cylinders in accordance with ASTM C 192 for laboratory testing and ASTM C 31 for field testing. d. Verify the concrete strength during placement of concrete by test cylinders of samples taken at the job site: e. Sample concrete in accordance with ASTM C 172 at the time the concrete is deposited to determine the strength of the castings at different areas. f. Make and cure test cylinders in accordance with ASTM C 31. g. Six cylinders shall be molded, cured, and tested for each day or for every 20 cubic yards of concrete placed, whichever is greater. h. Perform strength tests 28 days after molding the cylinders, except 2 cylinders of the set shall be tested at 7 days or 14 days. 6. Perform slump tests in accordance with ASTM C 143. F. Concrete placement: 1. Placement of concrete shall be as specified for dry or wet conditions as may be applicable for the conditions found at the time of the work. 2. During concrete placement, take care to prevent concrete from hitting the sides of the steel reinforcing bar cage which will cause segregation. 3. To prevent segregation, do not allow concrete to fall more than 5 feet. 4. Proceed with concrete placement that starts underwater, using underwater placement requirements until the hole is completely filled. a. Do not dewater the shaft after partial concrete placement. 5. Provide for a supply of concrete that is adequate to complete placement on any given drilled pier in one continuous uninterrupted operation without cold joints. Project No. 18088080 5 Section 31 63 30 Lake Lewisville WTP Dewatering Improvements Drilled Concrete Piers 6. Construct concrete work in a manner that dense, monolithic concrete is provided throughout the full length and diameter of the drilled pier. 7. Immediately after acceptance of the excavation, place the concrete. 8. Water in excavation: a. Excavations containing more than 3 inches of water shall be pumped dry prior to concrete placement. 1) Except for the bottom 3 inches, do not drop concrete through water: b. In a dry excavation, place concrete with a concrete chute or pumping method acceptable to the ENGINEER. c. Direct the flow of concrete down the center of the pier shaft in order to minimize sloughing of the sides of the hole and segregation of the concrete on the reinforcing steel. 9. Water seepage: a. If seepage occurs at such a rate that the concrete cannot be properly placed, even if the pier hole is cased, place concrete using the “tremie” method: b. Use a tremie pipe having a disposable plug that keeps the tremie free of fluid until the plug is blown out by the concrete pressure. c. Preferably, use a tremie pipe which is 12 inches, but not less than 8 inches in diameter. d. Alternatively, use pumped concrete discharging through a pipe at least 5 inches in diameter. e. Use a tremie or pump pipe having watertight joints. f. Provide for no more than 3 inches of height between the bottom of the tremie pipe and the bottom of excavation during initial concrete placement. g. Provide positive control to make certain that the bottom of the tremie or pump pipe is at all times below the concrete surface. h. At least a 1 foot head of concrete shall be maintained above the top of the water. G. Temporary casing: 1. Use temporary casing. a. Withdraw casing as the concrete is placed: 2. Provide steel casing onsite in various appropriate lengths. 3. Case the drilled pier holes through any fill and native soil or rock as required to maintain a stable excavation. 4. Withdrawn casing as concrete placement proceeds while maintaining at least 3 feet of concrete depth over the bottom of the casing pipe. 5. Use steel casing with an outside diameter at least as large as the design pier diameter. 6. Use a casing wall thickness such that it is not damaged by water or ground pressures or by the stresses of installation. 7. Attach cutting teeth to the casing, if required to penetrate to the planned depth. 8. Use casing length so that at the end of drilling, the top of the casing projects above the ground surface and any adjacent mound of drill cuttings. 9. Provide positive control to make certain that the bottom of the casing is at least 3 feet below the top of the concrete being placed to prevent a reduction in the diameter of the pier shaft due to earth pressure and to prevent insitu materials from falling into and mixing with the concrete. H. Cave-ins: 1. Remove soil which sloughs into the excavated pier shaft prior to concrete placement: 2. During concrete placement, if the ENGINEER has reasons to suspect that concrete was breached by the soil or that the pier, for any other reason, may contain extraneous material, or otherwise is not in conformance with Drawings and Specifications, the ENGINEER may order testing of the pier by coring or other methods: a. Pay for testing and additional construction as required by the ENGINEER, if the work is found defective. b. If work is found to be not defective, testing cost will be paid by the OWNER. Project No. 18088080 6 Section 31 63 30 Lake Lewisville WTP Dewatering Improvements Drilled Concrete Piers I. Where required due to pier being constructed too high, cut off piers to the top of pier elevations indicated on the Drawings. J. Site tolerances: 1. Pier installation tolerances: a. Deviation of center of pier butts: Not deviate from locations indicated on the Drawings more than 3 inches in any direction. b. Deviation of elevation of pier butts: Not more than 1 inch higher nor more than 3 inches lower than elevation indicated on the Drawings. c. Deviation of piers from vertical: Not more than 1/4 inch per foot of length. 3.2 FIELD QUALITY CONTROL A. Inspection of drilled hole: 1. If inspection of hole is required by ENGINEER, dewater holes to make the holes accessible to inspection and construction personnel. 2. Provide fresh air and adequate light for workmen and ENGINEER. 3. Provide lighting that will illuminate the bottom of the deepest drilled hole adequately to make visual inspection possible. B. Field measurements: 1. Pier location survey: a. After piers are installed and prior to placing reinforcing steel, formwork, or concrete for the structure, prepare pier location survey showing coordinates of final location of butt of piers and elevations of butt of piers to accuracy of plus or minus 0.01 feet. b. Pier location survey shall be performed by Surveyor licensed in the state where the Project is located. c. Provide survey that includes as minimum following information: 1) Location coordinates of: a) Location of pier butts as indicated on the Drawings. b) Location of pier butts as installed. c) Calculate distance between location coordinates of pier butts as indicated on the Drawings and actual location coordinates of pier butts as installed. 2) Elevation of pier butts: a) Elevation of pier butts as indicated on the Drawings. b) Elevation of pier butts as installed. c) Calculate difference in elevations of pier butts as indicated on the Drawings and actual elevation of pier butts as installed. 3) Highlight piers that are not within specified tolerances for location in plan and butt elevation. 4) Provide preceding information in tabular form and keyed to a pier plan by pier number: a) Submit pier plan that shows each pier for each structure. d. ENGINEER will utilize pier location survey information to evaluate acceptability of pier locations and elevations. 3.3 ADJUSTING A. Correction of defective pier work: 1. Pier work not in accordance with the requirements indicated on the Drawings and specified in the Specifications is considered defective. 2. Take corrective measures acceptable to the ENGINEER, if piers are damaged, out of tolerance, mislocated, or otherwise defective: a. Cost of redesign of foundation elements by the ENGINEER required by reason of defective pier work shall be paid by CONTRACTOR. Project No. 18088080 7 Section 31 63 30 Lake Lewisville WTP Dewatering Improvements Drilled Concrete Piers b. Allow 15 working days from submittal of pier location survey, for design of corrections for defective pier work. 3. Measures to be used to correct defective pier work will be selected by the ENGINEER. Corrective measures that may be acceptable to the ENGINEER include: a. Installing additional piers at locations selected by the ENGINEER. b. Pier caps will be redesigned by the ENGINEER and required details of modifications to pier caps will be given to the CONTRACTOR to accommodate piers that were installed out of tolerance. 4. Leave piers which are not accepted in the ground. Cut off such piers at least 2 feet below bottom of pier cap and fill such holes with compacted aggregate base course material. 5. Fill holes drilled for piers that are not used with concrete. END OF SECTION DIVISION 32 EXTERIOR IMPROVEMENTS Project No. 18088080 1 Section 32 10 00 Lake Lewisville WTP Dewatering Improvements Concrete Sidewalks SECTION 32 10 00 - CONCRETE SIDEWALKS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work and materials required to install concrete sidewalk. B. Related sections: 1. Section 03 30 00 – Cast-In-Place Concrete. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American Society for Testing and Materials (ASTM): a. ASTM C94, Standard Specification for Ready Mixed Concrete. b. ASTM C309, Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete. c. ASTM D994, Standard Specification for Preformed Expansion Joint Filler for Concrete (Bituminous Type). 2. American Association of State Highway and Transportation Officials (AASHTO): T99. 3. American Concrete Institute (ACI): ACI Guide for Measuring, Mixing, Transporting, and Placing Concrete. 4. Standard Specification: The latest edition, including supplements of the Texas Department of Transportation Standard Specifications for Highway Construction. 1.3 SUBMITTALS A. Shop Drawings: 1. Form Material: Information on metal forms, if used, including type, condition, surface finish, and intended function. 2. Complete data on concrete mix, including aggregate gradations and admixtures in accordance with requirements of ASTM C94. B. Quality Control Submittals: 1. Curing Compound: Manufacturer’s Certificate of Compliance and application instructions. 2. Ready-mix delivery ticket for each truck in accordance with ASTM C94. PART 2 - PRODUCTS 2.1 EXPANSION JOINT FILLER A. 1/2-inch thick, preformed asphalt-impregnated, expansion joint material meeting ASTM D994. 2.2 CONCRETE A. As specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. B. Maximum Aggregate Size: 1-1/2-inch. C. Slump: 2 to 4 inches. 2.3 CURING COMPOUND A. Liquid membrane-forming, clear or translucent, suitable for and meeting ASTM C309, Type 1. Project No. 18088080 2 Section 32 10 00 Lake Lewisville WTP Dewatering Improvements Concrete Sidewalks PART 3 - EXECUTION 3.1 FORMWORK A. Lumber Materials: 1. 2-inch dressed dimension lumber, or metal of equal strength, straight, free from defects that would impair appearance or structural quality of completed sidewalk. 2. 1-inch dressed lumber or plywood may be used where short-radius forms are required. B. Metals: Steel in new undamaged condition. C. Setting Forms: 1. Construct forms to shape, lines, grades, and dimensions. 2. Stake securely in place. D. Bracing: 1. Brace forms to prevent change of shape or movement resulting from placement. 2. Construct short-radius curved forms to exact radius. E. Tolerances: 1. Do not vary tops of forms from gradeline more than 1/8-inch when checked with 10-foot straightedge. 2. Do not vary alignment of straight sections more than 1/8-inch in 10 feet. 3.2 PLACING CONCRETE A. Prior to placing concrete, remove water from excavation and debris and foreign material from forms. B. Place concrete as soon as possible, and within 1-1/2 hours after adding cement to mix without segregation or loss of ingredients, and without splashing. C. Place, process, finish, and cure concrete in accordance with applicable requirements of ACI 304, and this section. Wherever requirements differ, the more stringent shall govern. D. To compact, vibrate until concrete becomes uniformly plastic. 3.3 SIDEWALK CONSTRUCTION A. Thickness: 1. 4 inches in walk areas. 2. 6 inches in driveway areas. B. Connection to Existing Sidewalk: 1. Remove old concrete back to an existing contraction joint. 2. Clean the surface. 3. Apply a neat cement paste immediately prior to placing new sidewalk. C. Expansion Joints: Place at building corners and changes in sidewalk width around posts, poles, or other objects penetrating sidewalk. Install expansion joint filler at each joint. D. Contraction Joints: 1. Provide transversely to walks at locations opposite contraction joints in curb. 2. Dimensions: 3/16-inch by 1-inch weakened plane joints. 3. Construct straight and at right angles to surface of walk. Project No. 18088080 3 Section 32 10 00 Lake Lewisville WTP Dewatering Improvements Concrete Sidewalks E. Finish: 1. Broom surface with fine-hair broom at right angles to length of walk and tool at edges, joints, and markings. 2. Mark walks transversely at 5-foot intervals with jointing tool; finish edges with rounded steel edging tool. 3. Apply curing compound to exposed surfaces upon completion of finishing. 4. Protect sidewalk from damage and allow to cure for at least 7 days. 3.4 SLAB CONSTRUCTION ON GRADE A. Thickness: Four inches or as shown. B. Contraction Joints: 1. As shown on Drawings. 2. Dimensions: 3/16-inch by 1-inch weakened plane joints. 3. Construct straight and at right angles to surface of slab. C. Finish: 1. Broom surface with fine-hair broom and tool of edges, joints, and markings. 2. Apply curing compound to exposed surfaces upon completion of finishing. 3. Protect sidewalk from damage and allow to cure for at least 7 days. END OF SECTION Project No. 18088080 1 Section 32 11 00 Lake Lewisville WTP Dewatering Improvements Base Course SECTION 32 11 00 - BASE COURSE PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work and materials required to install base course. B. Related sections: 1. Section 31 22 13 – Subgrade Preparation. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American Association of State Highway and Transportation Officials (AASHTO): a. T 89, Standard Method for Determining the Liquid Limit of Soils. b. T 90, Determining the Plastic Limit and Plasticity Index of Soils. c. T 96/ASTM C131, Standard Method for Resistance to Degradation of Small Size Course Aggregate by Abrasion and Impact in the Los Angeles Machine. d. T 99, Standard Methods of Test for the Moisture-Density Relations of Soils Using a 5.5 pound (2.5 kg) Rammer and a 12-inch (305 mm) Drop. e. T 180, Standard Methods of Test for the Moisture-Density Relations of Soils Using a 10 pound (4.54 kg) Rammer and an 18-inch (457 mm) Drop. f. T 191, Standard Method of Test for Density of Soil In-Place by the Sand-Cone Method. g. T 238, Standard Method of Test for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth). 1.3 DEFINITIONS A. Completed Course: Compacted, unyielding, free from irregularities, with smooth, tight, even surface, true to grade, line, and cross-section. B. Completed Lift: Compacted with uniform surface reasonably true to cross- section. C. Standard Specifications: The latest edition, including supplements, of the Texas Department of Transportation Standard Specifications for Construction and Maintenance of Highways, Streets, and Bridges. 1.4 SUBMITTALS A. Quality Control Submittals: 1. Certified Test Results on Source Materials: Submit copies from commercial testing laboratory 20 days prior to delivery of materials to project. 2. Certified Results of In-Place Density Tests from independent testing agency. PART 2 - PRODUCTS 2.1 BASE COURSE ROCK A. As specified for Type A, Grade 2 of Item 247 of the Standard Specifications. Project No. 18088080 2 Section 32 11 00 Lake Lewisville WTP Dewatering Improvements Base Course 2.2 SOURCE QUALITY CONTROL A. Contractor: tests necessary to locate acceptable source of materials meeting specified requirements. B. Final approval of aggregate material will be based on materials' test results on installed materials. C. Should separation of course from fine materials occur during processing or stockpiling, immediately change methods of handling materials to correct uniformity in grading. PART 3 - EXECUTION 3.1 PREPARATION A. As specified in Section 31 22 13, SUBGRADE PREPARATION. B. Obtain Engineer’s acceptance of subgrade before placement of base course rock. C. Do not place base materials in snow or on soft, muddy, or frozen subgrade. 3.2 EQUIPMENT A. In accordance with Section 3 of Item 247 of the Standard Specifications. B. Compaction Equipment: Adequate in design and number to provide compaction and obtain the specified density for each layer. 3.3 HAULING AND SPREADING A. Hauling Materials: 1. Do not haul over surfacing in process of construction. 2. Loads: Of uniform capacity. 3. Measure capacity of truck to determine vehicle load and quantity. 4. Maintain consistent gradation of material delivered; loads of widely varying gradations will be cause for rejection. B. Spreading Materials: 1. Distribute material to provide required density, depth, grade and dimensions with allowance for subsequent lifts. 2. Produce even distribution of material upon roadway without segregation. 3. Should segregation of coarse from fine materials occur during placing, immediately change methods of handling materials to correct uniformity in grading. 3.4 CONSTRUCTION OF COURSES A. General: Complete each lift in advance of laying succeeding lift to provide required results and adequate inspection. B. Base Course: 1. Maximum Completed Lift Thickness: 6 inches. 2. Completed Course Total Thickness: As shown. 3. Spread lift on preceding course to required cross-section. 4. Lightly blade and roll surface until thoroughly compacted. 5. Add keystone to achieve compaction and as required when aggregate does not compact readily due to lack of fines or natural cementing properties, as follows: Project No. 18088080 3 Section 32 11 00 Lake Lewisville WTP Dewatering Improvements Base Course a. Use base 1/4-minus crushed aggregate material as keystone. b. Spread evenly on top of crushed base course, using spreader boxes or chip spreaders. c. Roll surface until keystone is worked into interstices of crushed base course without excessive displacement. , d. Continue operation until course has become thoroughly keyed, compacted, and will not creep or move under roller. 6. Blade or broom surface to maintain true line, grade, and cross-section. 3.5 ROLLING AND COMPACTION A. Blade or otherwise work existing surface as necessary to achieve a smooth and thoroughly compacted surface. B. Commence compaction of each layer of base after spreading operations and continue until density of 100 percent of maximum density has been achieved as determined by AASHTO T 99. C. Commence rolling at outer edges of surfacing and continue toward center; do not roll center of road first. D. Apply water as needed to obtain densities. E. Place and compact each lift to required density before succeeding lift is placed. F. Bind up preceding course before placing leveling course. Remove floating or loose stone from surface. G. Blade or otherwise work surfacing as necessary to maintain grade and cross- section at all times, and to keep surface smooth and thoroughly compacted. H. Surface Defects: Remedy surface defects by loosening and rerolling entire area, including surrounding surface, until thoroughly compacted. 1. Finished Surface: True to grade and crown before proceeding with surfacing. 3.6 SURFACE TOLERANCES A. Finished Surface of Base Course: Within plus or minus 0.04-foot of grade shown at any individual point. B. Overall Average: Within plus or minus 0.01-foot from crown and grade specified. 3.7 FIELD QUALITY CONTROL A. In-Place Density Tests: 1. Construct base course so areas shall be ready for testing. 2. Allow reasonable length of time for testing laboratory to perform tests and obtain results during normal working hours. 3. Show proof that areas meet specified requirements before identifying density test locations. 4. Perform a minimum of 2 tests on completed course per 200 cubic yards of material placed in accordance with T 191, or T 238 at locations acceptable to Engineer. B. Cleaning 1. Remove excess material; clean stockpile areas of aggregate. END OF SECTION Project No. 18088080 1 Section 32 13 13 Lake Lewisville WTP Dewatering Improvements Portland Cement Concrete Paving SECTION 32 13 13 - PORTLAND CEMENT CONCRETE PAVING PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Concrete sidewalks, curbs and gutters and aprons. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 03 30 00 – Cast-in-Place Concrete. 3. Section 07 92 00 – Joint Sealants. 4. Section 32 11 00 – Base Course. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American Concrete Institute (ACI): a. ACI 211.1 – Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete b. ACI 301 – Specifications for Structural Concrete for Buildings c. ACI 304R – Guide for Measuring, Mixing, Transporting, and Placing Concrete; American Concrete Institute International; 2000. d. ACI 305R – Hot Weather Concreting e. ACI 306R – Cold Weather Concreting 2. American Society for Testing and Materials (ASTM): a. ASTM A185 – Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete b. ASTM A615 – Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement c. ASTM C33 – Standard Specification for Concrete Aggregates d. ASTM C39 – Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens e. ASTM C94 – Standard Specification for Ready Mixed Concrete f. ASTM C150 – Standard Specification for Portland Cement g. ASTM C260 – Standard Specification for Air-Entraining Admixtures for Concrete h. ASTM C309 – Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete i. ASTM C494 – Standard Specification for Chemical Admixtures for Concrete j. ASTM C685 – Standard Specification for Concrete Made by Volumetric Batching and Continuous Mixing k. ASTM D1751 – Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types) l. ASTM D1752 – Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction 1.3 SUBMITTALS A. See Section 01 33 00, SUBMITTAL PROCEDURES for submittal procedures. B. Product Data: Provide data on joint filler, admixtures, and curing compound. Project No. 18088080 2 Section 32 13 13 Lake Lewisville WTP Dewatering Improvements Portland Cement Concrete Paving C. Design Data: Indicate pavement thickness, designed concrete strength, reinforcement, and typical details. 1.4 QUALITY ASSURANCE A. Perform work in accordance with ACI 301. B. Obtain cementitious materials from same source throughout. C. Follow recommendations of ACI 305R when concreting during hot weather. D. Follow recommendations of ACI 306R when concreting during cold weather. 1.5 ENVIRONMENTAL REQUIRMENTS A. Do not place concrete when base surface temperature is less than 40 degrees F, or surface is wet or frozen. PART 2 - PRODUCTS 2.1 FORM MATERIALS A. Form Materials: conform to ACI 301. B. Joint Filler: Preformed; non-extruding bituminous type (ASTM D1751) or sponge rubber or cork (ASTM D1752). 1. Thickness: 1/2 inch. 2.2 REINFORCEMENT A. Reinforcing Steel: ASTM A615 / A615M Grade 60 (420); deformed billet steel bars; unfinished finish. B. Steel Welded Wire Reinforcement: Plain type, ASTM A185; in flat sheets; unfinished. C. Dowels: ASTM A615 Grade 60 (420); deformed carbon steel bars; unfinished finish. 2.3 CONCRETE MATERIALS A. Concrete Materials: As specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. 2.4 ACCESSORIES A. Curing Compound: ASTM C309, Type 1, Class A. 2.5 CONCRETE MIX DESIGN A. Proportioning Normal Weight Concrete: Comply with ACI 211.1 recommendations. Refer to Civil Plans and Specifications for site concrete design. B. Concrete Strength: Establish required average strength for each type of concrete on the basis of field experience or trial mixtures, as specified in ACI 301. 1. For trial mixtures method, employ independent testing agency acceptable to Owners Representative for preparing and reporting proposed mix designs. Project No. 18088080 3 Section 32 13 13 Lake Lewisville WTP Dewatering Improvements Portland Cement Concrete Paving C. Admixtures: Add acceptable admixtures as recommended in ACI 211.1 and at rates recommended by manufacturer. D. Concrete Properties: 1. Refer to Construction Documents. 2.6 MIXING A. On Project Site: Mix in drum type batch mixer, complying with ASTM C685. Mix each batch not less than 1-1/2 minutes and not more than 5 minutes. B. Transit Mixers: Comply with ASTM C94 / C94M. PART 3 - EXECUTION 3.1 EXAMINATION A. Verify compacted subgrade is acceptable and ready to support paving and imposed loads. B. Verify gradients and elevations of base are correct. 3.2 SUBBASE A. Prepare subbase in accordance with the Texas Department of Transportation Standards. 3.3 PREPARATION A. Moisten base to minimize absorption of water from fresh concrete. 3.4 FORMING A. Place and secure forms to correct location, dimension, profile, and gradient. B. Assemble formwork to permit easy stripping and dismantling without damaging concrete. C. Place joint filler vertical in position, in straight lines. Secure to formwork during concrete placement. 3.5 REINFORCEMENT A. Place reinforcement as indicated. B. Place dowels to achieve pavement and curb alignment as detailed. 3.6 PLACING CONCRETE A. Place concrete in accordance with ACI 304R. B. Ensure reinforcement, inserts, embedded parts and formed joints are not disturbed during concrete placement. C. Place concrete continuously over the full width of the panel and between predetermined construction joints. Do not break or interrupt successive pours such that cold joints occur. D. Apply surface retarder to all exposed surfaces in accordance with manufacturer’s instructions. Project No. 18088080 4 Section 32 13 13 Lake Lewisville WTP Dewatering Improvements Portland Cement Concrete Paving 3.7 JOINTS A. Place contraction joints at even intervals not to exceed 15 feet spacing and isolations joints at the end of each placements, but not to exceed 150 feet. B. Place contraction and isolation joints and edge of new concrete to align with existing joints beyond. C. Evenly space joint patterns not dimensioned on plans. Align joints with corners of masonry where shown on plans. D. Place joint filler between new sidewalks and building or adjacent saw cut paving. 3.8 FINISHING A. Sidewalk and Ramp Paving: Light broom, texture perpendicular to pavement direction. B. Place during compound on exposed concrete surfaces immediately after finishing. Apply in accordance with manufacturer’s instructions. 3.9 JOINT SEALING A. See Section 07 92 00, JOINT SEALANTS for joint sealant requirements. 3.10 TOLERANCES A. Maximum Variation of Surface Flatness: 1/4 inch in 10 feet. B. Maximum Variation From True Position: 1/4 inch. 3.11 FIELD QUALITY CONTROL A. An independent testing agency will perform field quality control tests. 1. Provide free access to concrete operations at project site and cooperate with appointed firm. 2. Submit proposed mix design of each class of concrete to inspection and testing firm for review prior to commencement of concrete operations. 3. Tests of concrete and concrete materials may be performed at any time to ensure conformance with specified requirements. B. Compressive Strength Tests: ASTM C39 / C39M. For each test, mold and cure three concrete test cylinders. Obtain test samples for every 100 cu yd or less of each class of concrete placed. 1. Take one additional test cylinder during cold weather concreting, cured on job site under same conditions as concrete it represents. 2. Perform one slump test for each set of test cylinders taken. C. Maintain records of placed concrete items. Record date, location of pour, quantity, air temperature, and test samples taken. 3.12 PROTECTION A. Immediately after placement, protect pavement from premature drying, excessive hot or cold temperatures and mechanical injury. Project No. 18088080 5 Section 32 13 13 Lake Lewisville WTP Dewatering Improvements Portland Cement Concrete Paving B. Do not permit pedestrian traffic over pavement until 75 percent design strength of concrete has been achieved. END OF SECTION Project No. 18088080 1 Section 32 31 13 Lake Lewisville WTP Dewatering Improvements Chain Link Fence and Gates SECTION 32 31 13 - CHAIN LINK FENCES AND GATES PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work and materials required to install chain link fence and gates. B. Related sections: 1. Section 02 41 00 – Demolition. 2. Section 03 30 00 – Cast-In-Place Concrete. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American Society for Testing and Materials (ASTM): a. ASTM A121, Standard Specification for Metallic-Coated Carbon Steel Barbed Wire. b. ASTM A392, Standard Specification for Zinc-Coated Steel Chain-Link Fence Fabric. c. ASTM A491, Standard Specification for Aluminum-Coated Steel Chain-Link Fence Fabric. d. ASTM A1018, Standard Specification for Steel, Sheet and Strip, Heavy-Thickness Coils, Hot-Rolled, Carbon, Commercial, Drawing, Structural, High-Strength Low- Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength. e. ASTM A824, Standard Specification for Metallic-Coated Steel Marcelled Tension Wire for Use with Chain Link Fence. f. ASTM B6, Standard Specification for Zinc. g. ASTM C94, Standard Specification for Ready-Mixed Concrete. h. ASTM C143, Standard Test Method for Slump of Hydraulic-Cement Concrete. i. ASTM C387, Standard Specifications for Packaged, Dry, Combined Materials for Concrete and High Strength Mortar. j. ASTM F552, Standard Terminology Relating to Chain Link Fencing. k. ASTM F567, Standard Practice for Installation of Chain-Link Fence. l. ASTM F626, Standard Specification for Fence Fittings. m. ASTM F668, Standard Specification for Polyvinyl Chloride (PVC) and Other Organic Polymer-Coated Steel Chain-Link Fence Fabric. n. ASTM F900, Standard Specification for Industrial and Commercial Swing Gates. o. ASTM F1043, Standard Specification for Strength and Protective Coatings on Steel Industrial Chain Link Fence Framework. p. ASTM F1083, Standard Specification for Pipe, Steel, Hot-Dipped Zinc-Coated (Galvanized) Welded, for Fence Structures. q. ASTM F1183, Standard Specifications for Aluminum Alloy Chain Link Fence Fabric. r. ASTM F1184, Standard Specifications for Industrial and Commercial Horizontal Slide Gates. 2. Institute of Electrical and Electronic Engineers (IEEE), Inc.: National Electrical Safety Code. 3. National Electrical Manufacturers Association (NEMA): 250, Enclosures for Electrical Equipment (1,000 volts max.). 1.3 DEFINITIONS A. Terms as defined in ASTM. Project No. 18088080 2 Section 32 31 13 Lake Lewisville WTP Dewatering Improvements Chain Link Fence and Gates 1.4 SUBMITTALS A. Shop Drawings: 1. Detailed information and specifications for materials, finishes, and dimensions. 2. Card access system serial communication interface card code message format. B. Samples: Approximately 6 inches square, or 6 inches long of posts, rails, braces, fabric, wire, ties, and fittings. C. Quality Control Submittals: 1. Manufacturers recommended installation instructions. 2. Evidence of Supplier and installer qualifications. 1.5 SCHEDULING AND SEQUENCING A. Complete necessary site preparation and grading before installing chain link fence and gates. PART 2 - PRODUCTS 2.1 GENERAL A. Match style, finish, and color of each fence component with that of other fence components. 2.2 CHAIN LINK FENCE FABRIC A. Galvanized fabric conforming to ASTM, Class 1; galvanized after weaving. B. Height: 72 inches, unless otherwise shown. C. Wire Gauge: No. 9, barewire. D. Pattern: 2-inch diamond-mesh. E. Diamond Count: Manufacturer's standard and consistent for fabric furnished of same height. F. Loops of Knuckled Selvages: Closed or nearly closed with space not exceeding diameter of wire. G. Wires of Twisted Selvages: 1. Twisted in a closed helix three full turns. 2. Cut at an angle to provide sharp barbs that extend minimum 1/4-inch beyond twist. 2.3 POSTS A. General: 1. Strength and Stiffness Requirements: ASTM F1043, Light Industrial Fence, except as modified in this section. 2. Steel Pipe: ASTM F1083. 3. Roll-Formed Steel Shapes: from ASTM A1018, Grade 45, Steel. 4. Lengths: Manufacturer's standard with allowance for minimum embedment below finished grade of 22 inches plus 3 inches for each 1 foot of fence height greater than 4 feet. 5. Protective Coatings: a. Zinc Coating: ASTM F1043, Type A external and internal coating. B. Line Posts: Project No. 18088080 3 Section 32 31 13 Lake Lewisville WTP Dewatering Improvements Chain Link Fence and Gates 1. Steel Pipe: a. Outside Diameter: 2.375-inch. b. Weight: 3.65 pounds per foot. C. End, Corner, Angle, and Pull Posts: 1. Steel Pipe: a. Outside Diameter: 2.875-inch. b. Weight: 5.79 pounds per foot. D. Posts for Swing Gates: 1. ASTM F900. a. Outside Dimensions: 4-inch diameter. b. Weight: 6.56 pounds per foot. 2.4 TOP RAILS AND BRACE RAILS 1. Galvanized steel pipe. 2. Protective Coatings: As specified for posts. 3. Strength and Stiffness Requirements: ASTM F1043, Top Rail, Heavy or Light Industrial Fence. 4. Steel Pipe: a. ASTM F1083. b. Outside Diameter: 1.66-inch. c. Weight: 2.27 pounds per foot. 2.5 FENCE FITTINGS A. General: In conformance with ASTM F626, except as modified by this article. B. Post and Line Caps: Designed to accommodate passage of top rail through cap, where top rail required. C. Tension and Brace Bands: No exceptions to ASTM. D. Tension Bars: 1. One-piece, no exceptions to ASTM F626. 2. Equal in length to full height of fabric. E. Truss Rod Assembly: 3/8-inch diameter. F. Barb Arms: 45-degree arms for supporting three strands of barbed wire. 2.6 TENSION WIRE A. Zinc-coated steel marcelled tension wire conforming to ASTM A824, Type II, Class 2. 2.7 BARBED WIRE A. Zinc-Coated Barbed Wire: ASTM A121, Chain Link Fence Grade: 1. Line Wire: Two strands of No. 12-112 gauge. 2. Barbs: a. Number of Points: Four. b. Length: 318-inch minimum. c. Shape: Round. d. Diameter: No. 14-gauge. e. Spacing: 5 inches. Project No. 18088080 4 Section 32 31 13 Lake Lewisville WTP Dewatering Improvements Chain Link Fence and Gates 2.8 GATES A. General: 1. Gate Operation: Opened and closed easily by one person. 2. Welded Steel Joints: Paint with zinc-based paint. 3. Chain Link Fabric: Attached securely to gate frame at intervals not exceeding 15 inches. B. Swing Gates: ASTM F900. 1. Hinges: a. Furnished with large bearing surfaces for clamping in position. b. Designed to swing either 180 degrees outward, 180 degrees inward, or 90 degrees in or out, as shown, and not twist or turn under action of gate. 2. Latches: Plunger bar arranged to engage stop, except single gates of openings less than 10 feet wide may each have forked latch. 3. Gate Stops: Mushroom type or flush plate with anchors, suitable for setting in concrete. 4. Locking Device and Padlock Eyes: Integral part of latch, requiring one padlock for locking both gate leaves of double gates. 5. Hold-Open Keepers: Designed to automatically engage gate leaf and hold it in open position until manually released. 2.9 CONCRETE A. Provide as specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. 2.10 REPAIR AND SALVAGE OF EXISTING FENCE A. Non-Salvageable or Non-Reusable Parts: 1. Fence posts. 2. Gate posts. 3. End, corner angle, and pull posts. 4. Tension and brace bands. 5. Tension wire. B. Salvageable or Reusable Items: 1. Fence fabric. 2. Post caps. 3. Top rails and brace rails. 4. Truss rod assemblies. 5. Barb arms. 6. Barbwire. C. All items noted as salvageable shall not be bent, twisted, dented, or damaged in any way. Any such items will not be considered for reuse. D. All items not considered for salvage or reuse shall be disposed of offsite at the Contractor's expense. See Section 02 41 00, DEMOLITION. PART 3 - EXECUTION 3.1 GENERAL A. Install chain link fences and gates in accordance with ASTM F567, except as modified in this section, and in accordance with fence manufacturer's recommendations, as approved by Engineer. Erect fencing in straight lines between angle points. Project No. 18088080 5 Section 32 31 13 Lake Lewisville WTP Dewatering Improvements Chain Link Fence and Gates B. Provide all necessary hardware for a complete fence and gate installation. 3.2 PREPARATION A. Establish locations of fence lines, gates, and terminal posts. 3.3 POST SETTING A. Driven posts are not acceptable. B. Post Hole Depth: 1. Minimum 3 feet below finished grade. 2. 2 inches deeper than post embedment depth below finish grade. C. Backfill post holes with concrete to 2 inches above finished grade. D. Before concrete sets, crown and finish top of concrete to readily shed water. 3.4 BRACING A. Brace gate and corner posts diagonally to adjacent line posts to ensure stability. 3.5 TOP RAILS A. Install top rail sleeves with springs at 105 feet maximum spacing to permit expansion in rail. 3.6 CHAIN LINK FABRIC A. Do not install fabric until concrete has cured minimum 7 days. B. Install fabric with twisted and barbed selvage at top. 3.7 BARBED WIRE A. Install three strands of barbed wire on brackets, tighten, and secure at each bracket. 3.8 GATES A. Hang gates and adjust hardware so gates operate satisfactorily from open or closed position. B. Set gate stops in concrete to engage center drop rod or plunger bar. 3.9 FIELD QUALITY CONTROL A. Gate Tests: Prior to acceptance of installed gates and gate operator systems, demonstrate proper operation of gates under each possible open and close condition specified. 3.10 REUSE OF EXISTING FENCE MATERIAL A. Existing fence material shall be installed on new posts using new tension bars, brace bands, and tension wire. B. Existing fence fabric shall not be spliced to new fence fabric at mid-length between posts where the existing fence fabric ends. A pull post shall be installed with new brace bands, tension Project No. 18088080 6 Section 32 31 13 Lake Lewisville WTP Dewatering Improvements Chain Link Fence and Gates bands, and tension wire. Provide a knuckled selvage at the cut portion of the fence as shown on the Drawings. END OF SECTION Project No. 18088080 1 Section 32 92 19 Lake Lewisville WTP Dewatering Improvements Seeding, Fertilizing and Mulching SECTION 32 92 19 - SEEDING, FERTILIZING, AND MULCHING PART 1 - GENERAL 1.1 SUMMARY A. Section includes: 1. Fertilizer. 2. Mulch. 3. Seed. 4. Preparation. 5. Maintenance. B. Related sections: 1. Section 31 22 19 – Grading. 2. Section 31 23 16 – Excavation. 3. Section 31 11 00 – Site Preparation. 1.2 ALTERNATE METHODS AND PRODUCTS A. Alternate methods from those specified will be considered for use, provided that in the Engineer's opinion the end product will be equal to or exceed that which would result from the specified methods and products. 1.3 DEFINITIONS A. Weeds: Includes Dandelion, Jimsonweed, Quackgrass, Horsetail, Morning Glory, Rush Grass, Mustard, Lambsquarter, Chickweed, Cress, Crabgrass, Canadian Thistle, Nutgrass, Poison Oak, Blackberry, Tansy Ragwort, Bermuda Grass, Johnson Grass, Poison Ivy, Nut Sedge, Nimble Will, Bindweed, Bent Grass, Wold Garlic, Perennial Sorrel, and Brome Grass. 1.4 REGULATORY REQUIREMENTS A. Comply with regulatory agencies for fertilizer and herbicide composition. 1.5 QUALITY ASSURANCE A. Provide seed mixture in containers showing percentage of seed mix, year of production, net weight, date of packaging, and location of packaging. 1.6 MAINTENANCE DATA A. Submit maintenance data for continuing Owner maintenance. B. Include maintenance instruction, cutting method, maximum grass height, types, application frequency, and recommended coverage of fertilizer. 1.7 DELIVERY, STORAGE, AND HANDLING A. Deliver grass seed mixture in sealed containers. Seed in damaged packaging is not acceptable. B. Deliver fertilizer in water proof bags showing weight, chemical analysis, and name of manufacturer. Project No. 18088080 2 Section 32 92 19 Lake Lewisville WTP Dewatering Improvements Seeding, Fertilizing and Mulching PART 2 - PRODUCTS 2.1 AGRICULTURAL LIMESTONE A. Shall be agricultural limestone with not less than 90 percent passing the No. 4 sieve and containing not less than 40 percent calcium carbonate equivalent. Lime shall be applied at the rate recommended by soil test. 2.2 FERTILIZER A. Shall be a standard commercial product which when applied at the proper rate will supply the equivalent quantity of total nitrogen, available phosphoric acid and soluble potash specified. Fertilizer shall be delivered to the site in bags or other suitable containers, each fully labeled, conforming to applicable state fertilizer laws, and bearing the name, trade name or trademark, and warranty of the producer. B. Requirements per acre: 1. Six hundred pounds of 17-17-17 grade fertilizer or equivalent. 2.3 MULCH A. Shall be vegetative mulch consisting of cereal straw from stalks of oats, rye, wheat or barley. Straw shall be free of prohibited weed seeds as stated in State Seed Law and shall be relatively free of all other noxious and undesirable seeds. Straw shall be clean and bright, relatively free of foreign material and be dry enough to be spread properly. 2.4 SEED A. Seed shall be a mixture with the specified minimum purity and germination requirements, as follows: % Mix Seed Type (By Wt.) Purity % Germination % Kentucky K-31 Fescue 52 97 85 Creeping Red Fescue 18 85 80 Rye Grass 8 98 85 Rye Grain 22 - - Variation in the above mix to suit local conditions or time of year may be required. B. Seed shall be labeled in accordance with USDA regulations. Care shall be taken during transportation to avoid segregation of seed mixtures. C. Seed shall be sown at a rate of 217 pounds of seed mix per acre for drill seeding. Seed mixture shall be thoroughly mixed prior to application. 2.5 SOD A. Sod may be required on slopes equal to or greater than 3:1 as directed by the engineer or as stated on the plans. B. Sod shall be fresh, locally grown Bermuda. Project No. 18088080 3 Section 32 92 19 Lake Lewisville WTP Dewatering Improvements Seeding, Fertilizing and Mulching PART 3 - EXECUTION 3.1 GENERAL A. The application of fertilizer, seed, and mulch shall follow each other in successive sequence as closely as possible. Seeding shall be accomplished in the first of the following two periods after completion of earthwork. February 15 to May 1st September 1st to October 1st B. Seeding outside the specified seeding periods may be permitted at the Engineer's option, provided the Contractor is willing to make appropriate modifications to his seeding operations, and will guarantee the crop. 3.2 INSPECTION A. Contractor must request that Engineer inspect site grading, clean-up and surface preparation to determine if site is ready for the seeding, fertilizing and mulching operations. B. Upon Engineer’s approval operations may begin. 3.3 SURFACE PREPARATION A. Immediately in advance of fertilizing, the surface to be seeded shall be repaired, if necessary, to eliminate all damage from erosion or construction operations. The surface shall then be loosened and thoroughly pulverized by discing, harrowing and raking or other approved methods, to such an extent that it is free from sod, stones, clods, or roots. All growth of vegetation that will seriously interfere with planting operations shall be removed and disposed of as directed. The final surface shall be smooth and uniform, and left in such a condition as to prevent formation of low places and pockets. 3.4 FERTILIZING A. Fertilizer and lime shall be dressed evenly over the areas to be seeded using approved mechanical type spreading equipment. B. Fertilizer and lime after spreading shall be immediately incorporated into the soil to a depth of approximately 2 inches, by chisel, spike tooth harrow, or other approved methods. 3.5 SEEDING METHODS A. General methods: The Contractor shall employ a satisfactory method of sowing by use of either approved mechanical hand seeders or mechanical power-driven drills. When delays in operation carry the work beyond the specified planting seasons, or when conditions are such that by reason of drought, high winds, excessive moisture, or other factors, satisfactory results are not likely to be obtained, seeding shall stop. It will be resumed only where the desired results are probable or when approved alternate procedures have been adopted. B. Broadcast seeding: When broadcast seeding is utilized, the seed shall be uniformly broadcast by mechanical hand seeder, in two directions at right-angles to each other and at 1/2 of the specified rate per acre in each direction. After the seed is broadcast it shall be covered by an approved method to a depth of 1/3 inch to 3/4 inch. Broadcast seeding shall not be done in windy weather. Project No. 18088080 4 Section 32 92 19 Lake Lewisville WTP Dewatering Improvements Seeding, Fertilizing and Mulching C. Drill seeding: When drilling is utilized, it shall be done with approved equipment best suited to perform the work under prevailing conditions. The seed shall be uniformly drilled to a depth of one-third (1/3) inch to three-fourths (3/4) inch at the rate per acre specified. Drill seeding may be required in windy weather. D. Prior to start of seeding, the Contractor shall demonstrate that the application of seed is being made at the specified rate. A final check of the total quantity of seed used shall be made against the area seeded. If the check shows that the Contractor has not applied seed at the specified rate, he shall uniformly distribute seed at a rate calculated to meet the shortage. E. The Contractor shall maintain the seeded areas until all fertilizing, seeding and mulching is complete and the work accepted by the Engineer. Areas damaged from the Contractor's own operations shall be repaired at his expense. After acceptance of the work the Contractor will not be held responsible for erosion due to weather, or conditions not due to the Contractor's own operations or negligence. The Contractor is not required to guarantee a crop, if seeding is done during the specified seeding periods. 3.6 MULCHING A. Immediately after seeding, the Contractor shall apply vegetative mulch at a rate between 1-1/2 and 2-1/2 tons per acre to all seeded areas. Quantity of mulch shall be adjusted within the above limits, as directed by the Engineer, to the particular area or slope being mulched. Total application of mulch for the project shall average approximately 2 tons per acre. Mulch shall be applied by mechanical mulch spreaders equipped to eject by means of a constant air stream controlled quantities of the vegetative mulch. B. Mulch shall be embedded by a disc type roller having flat serrated discs spaced not more than 10 inches apart, with cleaning scrapers for each disc. C. Where indicated, or in areas of the project where soil conditions are not suitable for satisfactory crimping, asphalt emulsion shall be applied with the mulching operation. The normal rate of application shall be 100 gallons per ton of straw; however, this rate may be varied as directed by the Engineer to suit the particular area or slope conditions. D. All mulch shall be distributed evenly over the areas to be mulched within 24 hours after the seeding operation. Following the mulching operation, suitable precautions shall be taken to prohibit traffic over mulched areas. Displaced mulch shall be replaced immediately, including repair of the underlying seed bed, if damaged as well. 3.7 MAINTENANCE A. The Contractor shall maintain all seeded areas until the grass is properly established (not less than 90 days) until satisfactory development. Maintenance shall be continued until final acceptance of the work. B. Maintenance of seeded areas shall include protecting, watering, mowing, fertilizing, and such other work as may be necessary to establish a permanent lawn. The Contractor shall reseed those seeded areas in which a satisfactory growth is not obtained, and shall refill any areas which become eroded prior to final acceptance of the work. C. Paved areas shall be kept clean while maintenance operations are in progress. Project No. 18088080 5 Section 32 92 19 Lake Lewisville WTP Dewatering Improvements Seeding, Fertilizing and Mulching 3.8 REPLACEMENT A. The Contractor shall replace all trees, shrubs, and flowers damaged by construction activities in the areas designated on the construction plans. The replacement trees and shrubs shall be equal in size to the damaged or removed specimen. END OF SECTION DIVISION 33 UTILITIES Project No. 18088080 1 Section 33 01 20 Lake Lewisville WTP Dewatering Improvements Wastewater Liquid and Solids Removal and Disposal SECTION 33 01 20 – WASTEWATER LIQUID AND SOLIDS REMOVAL AND DISPOSAL PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Removal and disposal of wastewater liquids and solids from the facility’s wastewater treatment facilities. B. Related sections: 1. Section 01 14 00 – Work Restrictions. 2. Section 01 33 00 – Submittal Procedures 1.2 DEFINITIONS A. Sludge: This material includes an undetermined volume and mixture of mixed liquor, settled solids and sludge that will be removed by the Contractor to promote the execution of required construction activities. B. Sludge Removal: Construction activities to remove mixed liquor, settled solids, and sludge from any wastewater treatment facility in an effort to gain access for subsequent construction activities and/or cleaning of a facility to facilitate inspection, repair, and/or other construction activities as required by the Contract Documents. C. Treatment Basin: Structures, both existing and new, whose primary function is to hold, treat and/or process wastewater, wastewater solids, and sludge. For this project, the facilities listed in paragraph 3.2.A are the primary treatment basins associated with this project; however any basin, wetwell, vault and chamber within the confines of the wastewater treatment plant are included. D. Project Locations: Facilities from which raw or partially treated wastewater or sludge is to be removed. 1.3 SUBMITTALS A. See Section 01 33 00, SUBMITTAL PROCEDURES. 1.4 QUALITY ASSURANCE A. Obtain Engineer’s approval before proceeding with wastewater, mixed liquor, settled solids, and/or sludge removal. 1.5 SCHEDULING AND SEQUENCING A. Conduct wastewater or sludge removal only after schedule has been approved by the Engineer. Removal schedule and sequencing must allow for continued operation of the facilities. B. Schedule shall achieve the requirements of Section 01 14 00 – Work Restrictions. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 GENERAL A. Contractor shall be responsible for removing all facilities’ liquid and solids. Project No. 18088080 2 Section 33 01 20 Lake Lewisville WTP Dewatering Improvements Wastewater Liquid and Solids Removal and Disposal B. Contractor is responsible for removal and handling of all other material, including the material resulting from the tanks’ cleaning. C. Remove wastewater or sludge from the existing basins within the limits shown or specified, and send all removed sludge to the influent pump station or an upstream manhole (as designated by the Owner during construction). D. Do not damage the existing basins and equipment or remove material that is not designated for removal. E. Contractor is responsible for all expenses related to sludge removal and disposal, which shall be covered under the BASE BID for other associated pay items, such as but not limited to the facility demolition, replacement, and rehabilitation. These expenses include, but are not limited to, the following: equipment, labor, gas/fuel, and spill clean up. F. Contractor is responsible for maintaining and protecting all roads, drives, equipment, structures, etc. during sludge and wastewater removal and shall repair any damaged as a result of their work. 3.2 PROJECT LOCATION A. As follows, but not to extend beyond Project limits. 1. Grit Chambers 2. Primary Clarifier No. 1 3. Control Manhole No. 1 4. All piping that requires wastewater and sludge removal 5. All other treatment plant facilities that require dewatering and cleaning to perform the work. 3.3 TREATMENT BASIN CLEANING A. Remove sludge from the Treatment Basins within limits or as specified. B. As part of the treatment basin cleaning, equipment and associated equipment that are designated for removal and demolition may be removed with written approval by the Owner. 3.4 EQUIPMENT A. Provide necessary equipment for sludge removal and transport to the existing sludge holding tank. 3.5 RECORD KEEPING A. Maintain records of sludge transfer and submit records to Engineer and Owner, as required by this specification. END OF SECTION Project No. 18088080 1 Section 33 11 16.13 Lake Lewisville WTP Dewatering Improvements Domestic Water Piping Specialties SECTION 33 11 16.13 - DOMESTIC WATER PIPING SPECIALTIES PART 1 - GENERAL 1.1 SUMMARY A. This Section includes the following domestic water piping specialties: 1. Vacuum breakers. 2. Backflow preventers. 3. Water pressure-reducing valves. 4. Strainers. 5. Freeze-proof hose bibbs. 6. Water hammer arresters. 1.2 PERFORMANCE REQUIREMENTS A. Minimum Working Pressure for Domestic Water Piping Specialties: 125 psig, unless otherwise indicated. 1.3 SUBMITTALS A. Product Data: For each type of product indicated. B. Field quality-control test reports. 1.4 QUALITY ASSURANCE A. NSF Compliance: 1. Comply with NSF 14, "Plastics Piping Components and Related Materials," for plastic domestic water piping components. 2. Comply with NSF 61, "Drinking Water System Components - Health Effects; Sections 1 through 9." PART 2 - PRODUCTS 2.1 VACUUM BREAKERS A. Hose-Connection Vacuum Breakers: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. Arrowhead Brass Products, Inc. b. Cash Acme. c. Conbraco Industries, Inc. d. Legend Valve. e. MIFAB, Inc. f. Prier Products, Inc. g. Watts Industries, Inc.; Water Products Div. h. Woodford Manufacturing Company. i. Zurn Plumbing Products Group; Light Commercial Operation. j. Zurn Plumbing Products Group; Wilkins Div. 2. Standard: ASSE 1011. 3. Body: Bronze, nonremovable, with manual drain. 4. Outlet Connection: Garden-hose threaded complying with ASME B1.20.7. 5. Finish: Chrome or nickel plated. Project No. 18088080 2 Section 33 11 16.13 Lake Lewisville WTP Dewatering Improvements Domestic Water Piping Specialties 2.2 BACKFLOW PREVENTERS A. Reduced-Pressure-Principle Backflow Preventers (RPZ): 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. Ames Co. b. Conbraco Industries, Inc. c. FEBCO; SPX Valves & Controls. d. Flomatic Corporation. e. Watts Industries, Inc.; Water Products Div. f. Zurn Plumbing Products Group; Wilkins Div. 2. Standard: ASSE 1013. 3. Operation: Continuous-pressure applications. 4. Pressure Loss: 12 psig maximum, through middle 1/3 of flow range. 5. Body: Bronze for NPS 2 and smaller; cast iron with interior lining complying with AWWA C550 or that is FDA approved or steel with interior lining complying with AWWA C550 or that is FDA approved or stainless steel for NPS 2-1/2 and larger. 6. End Connections: Threaded for NPS 2 and smaller; flanged for NPS 2-1/2 and larger. 7. Configuration: Designed for horizontal, straight through or vertical flow as indicated on Drawings. 8. Accessories: a. Valves: Ball type with threaded ends on inlet and outlet of NPS 2 and smaller; outside screw and yoke gate-type with flanged ends on inlet and outlet of NPS 2-1/2 and larger. b. Air-Gap Fitting: ASME A112.1.2, matching backflow-preventer connection. 2.3 WATER PRESSURE-REDUCING VALVES A. Water Regulators: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. Cash Acme. b. Conbraco Industries, Inc. c. Honeywell Water Controls. d. Watts Industries, Inc.; Water Products Div. e. Zurn Plumbing Products Group; Wilkins Div. 2. Standard: ASSE 1003. 3. Pressure Rating: Initial working pressure of 150 psig. 4. Size: Same as upstream pipe 5. Design Inlet Pressure: 175 psig 6. Design Outlet Pressure Setting: 65 psig 7. Body: Bronze for NPS 2 and smaller; cast iron with interior lining complying with AWWA C550 or that is FDA approved for NPS 2-1/2 and NPS 3. 8. Valves for Booster Heater Water Supply: Include integral bypass. 9. End Connections: Threaded for NPS 2 and smaller; flanged for NPS 2-1/2 and NPS 3. 2.4 STRAINERS FOR DOMESTIC WATER PIPING A. Y-Pattern Strainers: 1. Pressure Rating: 125 psig minimum, unless otherwise indicated. 2. Body: Bronze for NPS 2 and smaller; cast iron with interior lining complying with AWWA C550 or FDA-approved, epoxy coating and for NPS 2-1/2 and larger. 3. End Connections: Threaded for NPS 2 and smaller; flanged for NPS 2-1/2 and larger. 4. Screen: Stainless steel with round perforations, unless otherwise indicated. 5. Perforation Size: a. Strainers NPS 2 and Smaller: 0.020 inch. Project No. 18088080 3 Section 33 11 16.13 Lake Lewisville WTP Dewatering Improvements Domestic Water Piping Specialties b. Strainers NPS 2-1/2 to NPS 4: 0.045 inch. 6. Drain: Factory-installed, hose-end drain valve. 2.5 FREEZE-PROOF HOSE BIBBS A. Freeze-Proof Hose Bibbs: 1. Standard: ASME A112.18.1 for sediment faucets. 2. Body Material: Bronze. 3. Seat: Bronze, replaceable. 4. Supply Connections: NPS 1/2 or NPS 3/4 threaded or solder-joint inlet. 5. Outlet Connection: Garden-hose thread complying with ASME B1.20.7. 6. Pressure Rating: 125 psig. 7. Vacuum Breaker: Integral nonremovable, drainable, hose-connection vacuum breaker complying with ASSE 1011. 2.6 WATER HAMMER ARRESTERS A. Water Hammer Arresters: 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. AMTROL, Inc. b. Josam Company. c. MIFAB, Inc. d. PPP Inc. e. Sioux Chief Manufacturing Company, Inc. f. Smith, Jay R. Mfg. Co.; Division of Smith Industries, Inc. g. Tyler Pipe; Wade Div. h. Watts Drainage Products Inc. i. Zurn Plumbing Products Group; Specification Drainage Operation. 2. Standard: ASSE 1010 or PDI-WH 201. 3. Type: Metal bellows. 4. Size: ASSE 1010, Sizes AA and A through F or PDI-WH 201, Sizes A through F. PART 3 - EXECUTION 3.1 INSTALLATION A. Refer to Section 23 05 17 for piping joining materials, joint construction, and basic installation requirements. B. As indicated on Drawings, install backflow preventers in each water supply to mechanical equipment and systems and to other equipment and water systems that may be sources of contamination. Comply with authorities having jurisdiction. 1. Install drain for backflow preventers with atmospheric-vent drain connection with air-gap fitting, fixed air-gap fitting, or equivalent positive pipe separation of at least two pipe diameters in drain piping and pipe to floor drain. Locate air-gap device attached to or under backflow preventer. Simple air breaks are not acceptable for this application. 2. Do not install bypass piping around backflow preventers. C. Where water pressure exceeds 70 PSIG, install water regulators with inlet and outlet shutoff valves. Install pressure gages on inlet and outlet. D. Install water control valves with inlet and outlet shutoff valves. Install pressure gages on inlet and outlet. Project No. 18088080 4 Section 33 11 16.13 Lake Lewisville WTP Dewatering Improvements Domestic Water Piping Specialties E. Install Y-pattern strainers for water on supply side of each control valve, water pressure-reducing valve, and solenoid valve. F. Install water hammer arresters in water piping according to PDI-WH 201. 3.2 CONNECTIONS A. Piping installation requirements are specified in other Division 33 Sections. Drawings indicate general arrangement of piping and specialties. 3.3 FIELD QUALITY CONTROL A. Perform the following tests and prepare test reports: 1. Test each reduced-pressure-principle backflow preventer according to authorities having jurisdiction and the device's reference standard. B. Remove and replace malfunctioning domestic water piping specialties and retest as specified above. 3.4 ADJUSTING A. Set field-adjustable pressure set points of water pressure-reducing valves. END OF SECTION Project No. 18088080 1 Section 33 13 00 Lake Lewisville WTP Dewatering Improvements Disinfection of Water Systems SECTION 33 13 00 - DISINFECTION OF WATER SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work, material, and procedures for disinfection of installed potable water lines. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American Water Works Association (AWWA): a. AWWA B300, Hypochlorites. b. AWWA B301, Liquid Chlorine. c. AWWA B303, Sodium Chlorite. d. AWWA C651, Disinfecting Water Mains. e. AWWA C652, Disinfection of Water-Storage Facilities. f. AWWA C653, Disinfection of Water Treatment Plants. g. AWWA C654, Disinfection of Wells. 1.3 QUALITY CONTROL SUBMITTALS A. Submittals shall be made as required in Section 01 33 00, SUBMITTAL PROCEDURES. The following specific information shall be provided: 1. Procedures and plans for disinfection and testing. 2. Type of disinfecting solution and method of preparation. 1.4 SEQUENCING AND SCHEDULING A. Commence disinfection after completion of following: 1. Completion and acceptance of internal painting of system(s). 2. Hydrostatic and pneumatic testing, pressure testing, functional and performance testing and acceptance of pipelines, pumping systems, structures, and equipment. PART 2 - PRODUCTS 2.1 WATER FOR DISINFECTION AND TESTING A. Clean, uncontaminated, and potable. B. Owner will supply potable quality water, Contractor shall convey in disinfected pipelines or containers. 2.2 CONTRACTOR'S EQUIPMENT A. Furnish chemicals and equipment, such as pumps and hoses, to accomplish disinfection. 2.3 MIXING DISINFECTANT A. Prepare solution by mixing any of following as described below. The purpose of the stock solution is to facilitate mixing and dilution to ensure a uniform disinfecting solution. The Project No. 18088080 2 Section 33 13 00 Lake Lewisville WTP Dewatering Improvements Disinfection of Water Systems Contractor will not be required to mix a stock solution if a liquid chlorine gas feed system that can accurately feed a desired amount of chlorine to mix a final (dilute) disinfecting solution is used. 1. Liquid chlorine gas conforming to AWWA B301 and water mixture. 2. Dry chlorine gas conforming to AWWA B301. 3. Calcium hypochlorite conforming to AWWA B300 or sodium hypochlorite conforming to AWWA B303 powder or liquid and water mixture. B. Feed dry chlorine gas through devices to regulate the rate of flow and ensure uniform diffusion of gas into water within the pipe or vessel being treated. Chlorinating devices for feeding chlorine gas solution or the gas itself shall prevent of water into chlorine cylinder. C. Use following proportions of hypochlorite or chlorine to water: 1. Chlorine Gas or Liquid (100 Percent Cl):1 pound per 1 1.75 gallons water. a. Apply liquid chlorine gas-water solution by means of a solution feed chlorinating device. 2. Calcium Hypochlorite (65 to 70 Percent Cl): 1 pound per 7.5 gallons water. a. If calcium hypochlorite is used, first mix dry powder with water to make a thick paste, then thin to a 1 percent solution (10,000 ppm chlorine). 3. Sodium Hypochlorite (5.25 Percent Cl): 1 gallon per 4.25 gallons water. a. If sodium hypochlorite procedure is used, dilute the liquid with water to obtain a 1 percent solution. PART 3 - EXECUTION 3.1 GENERAL A. Disinfect pumps and pipelines, installed or modified under this Project, intended to hold, transport, or otherwise contact potable water: 1. Disinfect new pipelines that connect to existing pipelines up to the point of connection. 2. Disinfect surfaces of materials that will contact finished water, both during and following construction using spray method described below. 3. Disinfect prior to contact with finished water. Take care to avoid recontamination following disinfection. B. Prior to application of disinfectants, clean equipment and pipelines of loose and suspended material. Flush pipelines until clear of suspended solids and color. Use water suitable for flushing and disinfecting. C. Conform to AWWA C651 for pipes and pipelines, C652 for tanks and reservoirs, and AWWA C654 for wells, except as modified in these Specifications. D. Allow freshwater and stock disinfectant solution to flow into the pipe or vessel at a measured rate so that the chlorine-water solution is at the specified strength. Do not place concentrated commercial disinfectant in the pipeline or vessel before it is filled with water. 3.2 PIPING AND PIPELINES A. Flushing: 1. Before disinfecting, flush all foreign matter from pipeline. Provide hoses, temporary pipes, ditches, and other conduits as needed to dispose of flushing water without damage to adjacent properties. Flushing velocities shall be at least 2.5 fps. For large diameter pipe, where it is impractical or impossible to flush the pipe at specified velocity, clean the pipeline in-place from the inside by brushing and sweeping, then flush the line. Project No. 18088080 3 Section 33 13 00 Lake Lewisville WTP Dewatering Improvements Disinfection of Water Systems 2. Flush pipelines through flushing branches and remove branches after flushing is completed. Operate valves during flushing process at least twice during each flush. 3. Flush service connections and hydrants. Flush distribution lines prior to flushing hydrants and service connections. B. Disinfecting Solution: Chlorine-water solution having a free chlorine concentration of not less than 50 ppm. C. Disinfecting Procedure: In accordance with AWWA C651, unless herein modified. D. Point of Application: 1. Inject chlorine mixture into pipeline to be treated at beginning of line through corporation stop or suitable tap in top of pipeline. 2. Control water from existing system to flow slowly into pipeline during application of chlorine. 3. Control rate of chlorine solution flow in proportion to rate of water entering pipe so that combined mixture shall contain not less than 50 ppm of free available chlorine. 4. Prevent of chlorine solution into line supplying water. E. Retention Period: 1. Retain treated water in pipeline for at least 24 hours to destroy all nonspore-forming bacteria. At end of 24 hour period, disinfecting solution shall contain at least 10 ppm of free chlorine or the pipeline shall be recleaned, disinfecting solution shall be reapplied, and specified procedure repeated. 2. Operate valves, hydrants, and appurtenances during disinfection to ensure that disinfecting solution is dispersed into all parts of pipeline, including dead-ends and areas that otherwise may not be treated. 3. After disinfection, flush water from the permanent source until water through the pipeline is equal chemically and bacteriologically to permanent source of supply. 3.3 PUMPS A. Disinfecting Solutions: Minimum free chlorine concentration of 200 ppm. B. Disinfecting Procedure: In accordance with AWWA unless herein modified. C. Application: 1. Inject the disinfecting solution into the pump and associated piping and circulate for a minimum 2 hour period of time. At the end of the 2 hour period, the solution shall have a strength of at least 100 ppm free chlorine. 2. Operate valves and/or pump appurtenances during disinfection to ensure that the disinfecting solution is dispersed into all parts of the pumps and lines. 3. If the disinfecting solution contained in the pumps has a residual free chlorine concentration less than 100 ppm after the 2 hour retention period, reclean the pump, reapply disinfecting solution, and retest until a satisfactory test result is obtained. 4. After chlorination, flush the water from the pumps until the water through the units is chemically and bacteriologically equal to the permanent source of supply. 3.4 DISPOSAL OF DISINFECTING WASTEWATER A. Do not allow flow into a waterway without neutralizing disinfectant residual. 1. See AWWA C652 for acceptable neutralization methods. Project No. 18088080 4 Section 33 13 00 Lake Lewisville WTP Dewatering Improvements Disinfection of Water Systems 3.5 TESTING A. Test Equipment: 1. Clean containers and equipment used in sampling and assure they are free of contamination. 2. Obtain sampling bottles with instructions for handling from laboratory. B. Chlorine Concentration Sampling and Analysis: 1. Sampling Frequency for Disinfecting Solution: Two samples per disinfecting procedure. 2. Residual Free Chlorine Samples: Two samples per disinfecting procedure. 3. Dechlorinated Disinfecting Wastewater Residual Samples: Two samples per disinfecting procedure. 4. Sampling Locations: Each 1,000 feet of pipeline or each building. 5. Analysis to be performed by the Owner’s laboratory. C. After pipelines have been cleaned, disinfected, and refilled with potable water, Owner will take water Samples and have them analyzed for conformance to bacterial limitations for public drinking water supplies. Samples shall be analyzed for coliform concentrations in accordance with the latest edition of Standard Methods for the Examination of Water and Wastewater. 1. A minimum of two Samples on each of 2 consecutive days from each separable structure every 1,000 feet of pipeline will be obtained and analyzed by standard procedures outlined by state and local regulatory agencies. D. If the minimum Samples required above are not bacterially negative, the disinfecting procedures and bacteriological testing shall be repeated on the respective facilities until bacterial limits are met. END OF SECTION Project No. 18088080 1 Section 33 31 23 Lakes Lewisville WTP Dewatering Improvements Testing Sanitary Sewer Systems SECTION 33 31 23 – TESTING SANITARY SEWER SYSTEMS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: the Work necessary to test gravity sewer pipe, force main pipe, manholes and appurtenances. B. Related sections: 1. The Contract Documents are complementary; what is called for by one is as binding as if called for by all. 2. It is the CONTRACTOR’s responsibility for scheduling and coordinating the Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work. 3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the CONTRACTOR to see that the completed Work complies accurately with the Contract Documents. a. Section 33 39 13 – Concrete Manholes. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 GENERAL A. The contractor is responsible for supplying all equipment required to conduct testing and all testing shall be conducted by the Contractor. B. All testing shall be conducted in the presence of the Engineer. 3.2 GRAVITY SEWER TESTING A. The Contractor shall have the option of verifying water tightness by either air testing or water testing. The Engineer shall have the option to require testing by both methods to verify marginal results. B. Gravity Sewers – Air Testing: 1. After gravity sanitary sewer and service pipe have been laid, all newly laid sewer main pipe shall be subject to an air pressure test to determine watertightness from air loss. 2. Test Equipment: a. All necessary equipment to perform the air test in accordance with this specification shall be provided by the Contractor. The test gauge shall have incremental divisions of 0.10 psi and have an accuracy of at least plus or minus 0.04 psi. In no case shall a test gauge be used which has incremental divisions of greater than 0.25 psi. The gauge shall be of sufficient size to determine accuracy. 3. Procedure: a. As each section of sewer is completed between manholes, each section shall be air tested. When practical, house connections in each section shall be completed. Air test shall be low-pressure air test based on the principal of air-pressure loss per time period. Contractor shall prepare a log of testing and submit this to the Engineer as each section is completed and tested. All tests shall be accomplished in the presence of the Engineer. Project No. 18088080 2 Section 33 31 23 Lakes Lewisville WTP Dewatering Improvements Testing Sanitary Sewer Systems b. The test section of the sewer line is plugged at each end. One of the plugs used at the manhole must be tapped and equipped for air inlet connection for filling the line from the air compressor. c. All service laterals, stubs and fittings into the sewer test section shall be properly capped or plugged, and carefully braced against the internal pressure to prevent air leakage by slippage and blowouts. d. Connect air hose to tapped plug selected for the air inlet. Then connect the other end of the air hose to the portable air control equipment which consists of valves and pressure gauge used. 1) To control air entry rate to the sewer test section, and 2) To monitor the air pressure in the pipe line. More specifically, the air control equipment includes a shutoff valve, pressure regulating valve, pressure reduction valve and a monitoring pressure gauge having a pressure range from 0-5 psi. The gauge shall have minimum divisions of 0.10 psi and an accuracy of 0.04 psi. e. Connect another air hose between the air compressor (or other source of compressed air) and the air control equipment. This completes the test equipment set-up. Test operations may commence. f. Supply air to the test section slowly, filling the pipe line until a constant pressure of 4.0 psig is maintained. The air pressure must be regulated to prevent the pressure inside the pipe from exceeding 5.0 psig. g. When constant pressure of 4.0 psig is reached, throttle the air supply to maintain the internal pressure between 3.5 to 4.0 psig for at least 5 minutes. This time permits the temperature of the entering air to equalize with the temperature of the pipe wall. If leakage is detected at any cap or plug, release the pressure in the line and tighten all leaky caps and plugs. Then start the test operation again by supplying air. When it is necessary to bleed off the air to tighten or repair a faulty plug, a new five-minute interval must be allowed after the pipeline has been refilled. h. After the stabilization period, adjust the air pressure to 3.5 psig and shutoff or disconnect the air supply. Observe the gauge until the air pressure reaches 3.5 psig. At 3.5 psig commence timing with a stop watch which is allowed to run until the line pressure drops to 2.5 psig at which time the stop watch is stopped. The time required, as shown on the stop watch for a pressure loss of 1.0 psig, is used to compute the air loss. i. If the time in minutes and seconds for the air pressure to drop from 3.5 to 2.5 psig is greater than that shown in the table for the designated pipe size, the section undergoing test shall have passed and shall be presumed to be free of defects. The test may be discontinued at that time. j. If the time in minutes and seconds for the 1.0 psig drop is less than that shown on the table for the designated pipe size, the section of pipe shall not have passed the test; therefore, adequate repairs must be made and the line retested. k. Pipe sizes with their respective recommended minimum times, in minutes and seconds, for acceptance by the air test method are as shown below. Project No. 18088080 3 Section 33 31 23 Lakes Lewisville WTP Dewatering Improvements Testing Sanitary Sewer Systems Minimum Time For A 1.0 psig Pressure Drop (Min:Secs) Distance Between Manholes Nominal Diameter (inches) 8 10 12 15 18 21 24 30 36 42 100' 7:33 9:26 11:20 14:10 17:00 19:50 22:47 35:37 51:17 69:48 150' 7:33 9:26 11:20 14:10 17:00 26:11 34:11 53:25 76:55 104:42 200' 7:33 9:26 11:23 17:48 25:38 34:54 45:34 71:13 102:34 139:37 250' 7:33 9:53 14:14 22:15 32:03 43:38 56:58 89:02 128:12 174:30 300' 7:35 11:52 17:05 26:42 38:27 52:21 68:22 106:50 153:50 209:24 350' 8:51 13:51 19:56 31:09 44:52 61:08 79:46 124:38 179:29 244:19 400' 10:07 15:49 22:47 35:36 51:17 69:48 91:10 142:26 205:07 279:13 450’ 11:23 17:48 25:38 40:04 57:41 78:32 102:33 160:15 230:46 314:07 500’ 12:39 19:47 28:29 44:31 64:06 87:15 113:57 178:03 256:24 349:01 Times for distances not listed in the table can be obtained by calculating the straight-line ratio between distances given. l. For testing of long sections or sections of larger diameter pipes, or both, a timed- pressure drop of 0.5 psig may be used in lieu of a 1.0 psig timed-pressure drop as approved by the Owner or Engineer. If a 0.5 psig pressure drop is used, the appropriate required test time shall be exactly one-half the values shown in the table above. m. An air pressure correction is required when the prevailing ground water is above the sewer line being tested. Under this condition, the air test pressure must be increased 0.433 psi for each foot the ground water level is above the invert of the pipe. n. Height of ground water above sewer pipe shall be determined by a method approved by the Engineer. o. Any leaks in the system shall be repaired immediately upon discovery. Costs for repairing faulty work, including excavating and re-backfilling and for making tests, shall be paid for by the Contractor. 4. Safety Precautions: a. The low pressure air test may be dangerous to personnel if, through lack of understanding or carelessness, a line is over pressurized or plugs are installed improperly. It is extremely important that the various plugs be installed to prevent the sudden expulsion of a poorly inflated plug. As an example of the hazard, a force of 250 pounds is exerted on an 8 inch plug by an internal pressure of 5 psi. Observe the following safety precautions. 1) No one shall be allowed in the manholes during the test or when a plugged pipe is under pressure. 2) Gauges, air piping manifolds, and valves shall be located at the top of the ground. 3) Install and brace all plugs securely. 4) Do not over pressurize the lines. C. Gravity Sewers – Water Testing: 1. Water testing will be by either the infiltration method or by the exfiltration method if approved by the Engineer. Testing for water-tightness shall be made by the Contractor in the presence of the Engineer. The Contractor shall provide all equipment, plugs, bulkheads, fittings, water, etc. needed for the testing. The water used for testing shall be paid for by the Contractor. Project No. 18088080 4 Section 33 31 23 Lakes Lewisville WTP Dewatering Improvements Testing Sanitary Sewer Systems 2. The Engineer shall have the right to direct that either the infiltration or the exfiltration water testing be performed based on groundwater conditions at the time. 3. The tests and measurements of the infiltration method shall be as approved by the Engineer. In all cases, the pipeline shall not leak under exterior ground water pressure in excess of 100 gallons per inch of nominal pipe diameter per mile of pipe per 24 hours. Leaks causing any sewer to fail such test shall be repaired until infiltration meets the allowable limit. 4. If, in the opinion of the Engineer, the ground water table at the time of testing is too low to produce dependable infiltration measurement results, the Contractor shall perform the exfiltration method test. The allowable limit shall be as given above including any manholes in the section(s) being tested. Water required for exfiltration test shall be obtained at the Contractor’s expense. 5. Where the exfiltration test method is used, the following shall apply: a. The downstream end of the pipe section being tested shall be plugged and the plug shall be braced and blocked securely. No one shall be allowed to enter a manhole where a plugged pipe is under pressure. Any other pipe entrances to the upstream manhole shall likewise be securely plugged. b. Only water from a source approved by the Engineer shall be used to perform the test. Waste water shall not be used to perform exfiltration testing. c. Water shall be added through the upstream manhole of the line section being tested to a depth of 2.0 feet above the inside top of the outgoing pipe (or 2.0' above the ground water level - see d. below). The water shall be maintained at this level for 24 hours prior to beginning the exfiltration test measurement. d. There shall be a minimum of 2.0' positive head above the inside top of the pipe at the high end of the section being tested. This means, if the ground water in the trench is at (or above) the top of the pipe, then the manhole shall be filled to a point at least 2.0' above the ground water level. e. The test shall be conducted for two hours. The leakage shall be determined by the calculated change in total volume of water used in the test. 3.3 PIPE DEFLECTION TESTING A. General 1. All PVC, FRP, and Ductile Iron gravity sewer lines shall be mandrel tested in accordance with these specifications prior to acceptance. B. Allowable Deflection: 1. The maximum allowable pipe deflection shall not exceed 5 percent of the inside diameter. C. Mandrel: 1. The mandrel shall be hand-pulled by the Contractor through all PVC, FRP, and Ductile Iron gravity sewer lines no earlier than 30 days after the trench has been completely backfilled. Any sections of the sewer not passing the mandrel shall be uncovered and the Contractor shall rebed, reround, or replace the sewer to the satisfaction of the Engineer. Any repaired section shall be retested after a sufficient time has elapsed to ensure that trench settlement has stopped. This retest time shall be totally dependent upon method of repair. If the trench has been opened, the retest shall have the same requirements as the original installation. If the pipe has been rerounded, retest shall not occur sooner than seven days after rerounding. 2. The mandrel (go/no-go) device shall be cylindrical in shape and constructed with either 9 or 16 evenly spaced arms or prongs. Mandrels with fewer arms will be rejected as not sufficiently accurate. The contact length of the mandrel's arms shall equal or exceed the nominal diameter of the sewer to be inspected. Critical mandrel dimensions shall carry a tolerance of plus or minus 0.01 inch. The mandrel and all necessary equipment for the mandrel test shall be provided by the Contractor. Project No. 18088080 5 Section 33 31 23 Lakes Lewisville WTP Dewatering Improvements Testing Sanitary Sewer Systems 3. The Owner reserves the right to mandrel test any PVC, FRP, or Ductile Iron sewer pipe before acceptance, and also prior to expiration of the first year of operation. If a previously accepted line fails a mandrel test performed during the first year of operation, the defects must be corrected at the Contractor's expense. 3.4 TELEVISION INSPECTION A. The Contractor shall televise all newly installed sewer mains as follows: B. The Contractor shall clean all lines thoroughly prior to the start of televising. C. The Contractor shall televise each segment of pipe. D. The camera shall be moved through the line in either direction at a uniform slow rate not to exceed 60 feet per minute, by means of cable winches, or similar mechanisms. Under no circumstances shall the camera be tethered to a hydraulically propelled or high-velocity jet cleaning device while the cleaning device is on. E. The Contractor shall review the video for possible defects in material or workmanship. F. The Contractor shall correct any defects discovered during the television inspection at the Contractor’s expense. G. The Contractor shall deliver to the Engineer final video in DVD format and logs after all defects have been repaired. 3.5 INSPECTION OF SERVICE LINES A. All building sewer lines shall be installed and tested in accordance with all state, regional, and local plumbing codes. B. All building sewer installations shall be inspected and approved by an authorized local governing agency inspector. C. Backfill may only be placed on the completed portions of a building sewer following inspection. No approval certificate shall be issued until all portions of a building sewer from the main connection to the building foundation have been inspected and approved by an authorized inspector. At the time of inspection, the pipe should be in place in the trench and "safed-up", but the top half of the pipe barrel exposed. No approval will be given for building sewers all or a portion of which are covered at the time of inspection. D. All building sewers are subject to testing to insure water tightness. All tests must be performed in the presence of the Engineer. Tests may be either by: 1. Water Loss Test Procedure; or, 2. Low Pressure Air Loss Procedure. E. If, in the opinion of the Engineer, the line in question is properly installed and free from open joints and breaks, building sewers constructed entirely of cast iron soil pipe may be connected to the sewer without testing. F. Water Loss Test Procedure 1. Plug the section of line to be tested at the lower end and fill section with water so that at least four (4) feet of head is obtained. Project No. 18088080 6 Section 33 31 23 Lakes Lewisville WTP Dewatering Improvements Testing Sanitary Sewer Systems 2. The maximum acceptable water loss while so filled is not more than 100 gallons per twenty-four hours per inch of pipe diameter per mile of pipe. This is approximately 3/16 gallon for a one hundred (100) foot long section of four (4) inch pipe tested thirty minutes. G. Low Pressure Air Loss Procedure 1. Plug securely both ends of the line to be tested. 2. Charge the line with air to a pressure of 4.5 psig. 3. Allow at least five minutes for the temperature in the pipe to stabilize. 4. Measure the time required for a one (1.0) psi drop in pressure. 5. The minimum time for a one psi loss is 28.5 x d seconds where d = the nominal diameter in inches of the pipe being tested. 3.6 MANHOLE TESTING A. Testing, Observations and Guarantee Period: 1. The testing required shall be performed by the Contractor at all manholes and documented to the satisfaction of the Engineer. 2. Testing shall not be performed on a specific manhole until all work has been completed for that specific manhole. 3. Any manholes that are observed to be leaking by the Engineer shall be subject to additional repairs and retested by the Contractor at no additional cost to the Owner. B. Inflow Testing: 1. All rehabilitated manholes and new manholes shall be dye tested. Manholes shall be dye water tested in the presence of the Engineer. The dye test shall consist of applying a concentrated dye solution around the manhole frame. Dyed water shall be applied for at least ten (10) minutes. 2. Manholes observed to be actively leaking will have failed the test and will not be acceptable. Manholes failing the test will require additional rehabilitation by the Contractor at no additional compensation. The manhole shall then be retested as described above until a successful test is made. C. Vacuum Testing: 1. All new and rehabilitated manholes shall be vacuum tested by the Contractor in the presence of the Engineer for sources of infiltration. Testing will be made during high groundwater conditions, wherever possible. 2. 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. The lines entering the manhole shall be temporarily plugged with the plugs braced to prevent them from being drawn into the manhole. The plugs shall be installed in the lines beyond drop-connections, gas sealing connections, etc. The test head shall be placed inside the frame at the top of the manhole and inflated in accordance with the manufacturer’s recommendations. Plate type test heads that rest on top of the frame are also acceptable. A vacuum of 10 inches of mercury shall be drawn, and the vacuum pump will be turned off. With the valve closed, the level of vacuum shall be read after the required test time. If the drop in the level is less than 1-inch of mercury (final vacuum greater than 9 inches of mercury), the manhole will have passed the vacuum test. After a successful test, the temporary plugs will be removed. The required test time is determined from the table below. Project No. 18088080 7 Section 33 31 23 Lakes Lewisville WTP Dewatering Improvements Testing Sanitary Sewer Systems Minimum Time Required for a Vacuum Drop of 1” Hg (10”Hg - 9”Hg ) (min:sec) Depth of Manhole (ft.) Manhole Inside Diameter (inches) 48” 60” 72” 96” 8’ :20 :26 :32 :45 10’ :25 :33 :40 1:00 12’ :30 :39 :48 1:07 14’ :35 :46 :57 1:18 16’ :40 :52 1:05 1:29 18’ :45 :59 1:13 1:40 20’ :50 1:05 1:21 1:52 22’ :55 1:12 1:29 2:03 24’ :60 1:19 1:37 2:14 26’ 1:05 1:25 1:45 2:25 28’ 1:10 1:32 1:53 2:36 30’ 1:15 1:38 1:01 2:47 Add for each Additional 2’ :05 :07 :08 :11 3. Manhole vacuum levels observed to drop greater than 1-inch of mercury (Final vacuum less than 9 inches of mercury) will have failed the test and will require additional rehabilitation. The Contractor shall make the necessary repairs at no additional compensation for only those work items completed by the Contractor. The manhole shall then be retested as described above until a successful test is made. 3.1 HYDROSTATIC TEST FOR FORCE MAINS A. Test piping as indicated in pipe schedule. B. Fluid: Clean water of such quality to prevent corrosion of materials in piping system. C. Test pressure shall be the lesser of 150 psi or the maximum pressure of all components in the system. D. All piping shall be tested in accordance with AWWA C600, latest revision. E. All tests shall be performed by the contractor in the presence of a City Inspector and the Engineer of Record. F. Contractor shall provide all equipment required to perform tests. Including but not limited to, gauges, meters, and pumps. The contractor shall also make all taps and connections required to perform testing. G. Exposed Piping: 1. Perform testing on installed piping prior to application of insulation. 2. Maximum Filling Velocity: 0.25 feet per second, applied over full area of pipe. 3. Vent piping during filling: Open vents at high points of piping system or loosen flanges, using at least four bolts, or use equipment vents to purge air pockets. 4. Maintain hydrostatic test pressure continuously for 60 minutes, minimum, and for such additional time as necessary to conduct examinations for leakage. 5. Examine joints and connections for leakage. 6. Correct visible leakage and retest as specified. 7. Empty pipe of water prior to final cleaning. Project No. 18088080 8 Section 33 31 23 Lakes Lewisville WTP Dewatering Improvements Testing Sanitary Sewer Systems H. Buried Piping: 1. Test after backfilling has been completed. 2. Flush piping and expel air from piping system during filling. 3. Apply and maintain specified test pressure with hydraulic force pump. Valve off piping system when test pressure is reached. 4. Maintain hydrostatic test pressure continuously for 2 hours minimum, if the test pressure falls more than 5 psi within the 2 hour period the test will be terminated and considered a failure due to assumed leaks. 5. Determine actual leakage at the end of the 2 hour test period by restoring the pressure to the initial test pressure and measuring the quantity of water necessary to restore pressure to the initial test presure. 6. Maximum Allowable Leakage: L = S D √ P 148,000 Where: L = Allowable leakage, in gallons per hour. S = Length of pipe tested, in feet. D = Nominal diameter of pipe, in inches. P = Test pressure during leakage test, in pounds per square inch. 7. Correct leakage greater than allowable, and retest as specified. 3.2 SYSTEM COORDINATION A. Maintain existing sewer flow through new connecting manholes until new sewer is approved by Engineer. B. Reshape manhole bottom to divert sewer flow into new sewer after new sewer is approved by Engineer. C. Locate sewer services before completing the first manhole downstream from the sewer service. END OF SECTION Project No. 18088080 1 Section 33 39 13 Lake Lewisville WTP Dewatering Improvements Concrete Manholes SECTION 33 39 13 – CONCRETE MANHOLES PART 1 - GENERAL 1.1 SUMMARY A. Section includes: the Work necessary to completely furnish and install cast-in-place manholes and pre-cast manholes and related items. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 60 00 – Product Requirements. 3. Section 03 11 00 – Concrete Formwork. 4. Section 03 20 00 – Concrete Reinforcement. 5. Section 03 30 00 – Cast-In-Place Concrete. 6. Section 03 41 00 – Pre-Cast Concrete. 7. Section 03 62 00 – Non-Shrink Grout. 8. Section 33 31 23 – Testing Sanitary Sewer Systems. 1.2 GENERAL A. Manholes shall be of diameter and constructed to elevations as shown on plans. B. Pre-Cast or Cast-In-Place manholes are acceptable, however all manholes for this project shall be of like kind, unless otherwise stated in the Plans or as directed by the Engineer. C. Manhole steps are not required and will not be accepted. D. All materials shall equal or exceed the standards specified herein. E. During the process of unloading, all manhole materials shall be inspected by the Contractor and any damaged material set aside. F. All manholes where the top elevation is greater than two (2) feet above adjacent ground shall use hinged frames and cover as specified herein. G. After manholes and connecting pipelines are installed, the Contractor shall test for defects and leakage as specified in Section 33 31 23, TESTING SANITARY SEWER SYSTEMS of these specifications. H. Inspection of materials at the manufacturer's plant, at the point of delivery, on the job site, or in place shall not relieve the Contractor of his responsibility and the material may be subject to rejection until final acceptance of the completed project. 1.3 SUBMITTALS A. General: Administrative, shop drawings, samples, quality control, and contract closeout submittals shall conform to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES. B. In addition to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES, submit the following additional specific information: 1. Quality Control Submittals: a. Shop drawings for pre-cast manholes. b. Diameter, dimensions, and thickness. c. Reinforcement. Project No. 18088080 2 Section 33 39 13 Lake Lewisville WTP Dewatering Improvements Concrete Manholes d. Manhole frame and cover make and model. e. Concrete mix designs. f. Other materials used in construction of manholes. g. Special shipping, storage and protection, and handling instructions. h. Test procedures. i. Test results, reports, and certifications. PART 2 - PRODUCTS 2.1 CAST-IN-PLACE MANHOLES A. Concrete 1. Concrete shall be as specified in 03 30 00, CAST-IN-PLACE CONCRETE. B. Inverts 1. Inverts shall be formed as shown on the detail drawings to the grades specified. Manholes with inverts not conforming to these grades may be subject to removal and replacement at the Contractor’s expense. 2. Concrete for inverts shall be as specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. C. Pipe Connections 1. Waterstop gaskets shall be required at ALL cast-in-place manhole connections. Manhole seals shall be concrete manhole adapter by Fernco, A-Lok, or equal. 2.2 PRE-CAST MANHOLES A. Pre-cast concrete shall conform to Section 03 41 00, PRE-CAST CONCRETE B. Pre-cast manholes shall conform to ASTM C478 – Standard Specifications for Pre-Cast Reinforced Concrete Manhole Sections. C. The top section shall be a concentric cone section conforming to ASTM C478. D. Integral pre-cast floors shall be allowed, subject to the approval of Engineer. Cast-in-place floors shall be allowed. E. Inverts may be pre-cast or field formed into the base section of the manhole, but in either case, shall meet the proper sewer line gradient and alignment shown in the Plans. F. Precast concrete manhole sections shall not be delivered to the site until the sections are at least ten (10) days old. Two lift holes shall be cast into each cone or riser section for the purpose of handling and placing. The Contractor shall provide and install water plugs into lift holes after laying the sections. G. Cutouts in the bottom sections shall be appropriate for the pipe being laid. 1. Bottom sections shall have clear identifying markings to assure their being used in the right locations. 2. Suitable openings for the inlet and outlet pipe shall be cored into the base section (and into the riser sections for drop or "pass-through" manholes). 3. These openings shall be true size, circular and located as needed to maintain the proper sewer gradient for each manhole. 4. Doghouse style bases shall only be used for manholes to be placed over existing sewer lines. Project No. 18088080 3 Section 33 39 13 Lake Lewisville WTP Dewatering Improvements Concrete Manholes H. Each manhole shall be made up with as few risers as possible. The joints between risers shall be leak proofed with a mechanical water stop seal as approved by the Engineer and meeting the requirements of ASTM C443 and C361. There shall be a suitable spigot cast into the tongue of each component to contain the seal. The seal shall consist of a supporting compression section and a thin sliding flap which has been pre-lubricated. When the sections are fitted together, the edge of the bell shall encounter the flap which then slides towards the compression section. I. No more than 8 inches of concentric rings shall be allowed to bring the manhole to finished grade. J. Manhole Section Joints 1. Flexible rubber sealant for joints in pre-cast manhole sections shall provide permanently flexible watertight joints, shall remain workable over a wide temperature range and shall not shrink, harden or oxidize upon aging. Material shall be equal to RFS Prelubricated Gaskets by Press-Seal Gasket Corporation and shall meet ASTM C443 and ASTM C1619 (Classes C and E) requirements. 2. All manhole joints shall be sealed with an external joint wrap material, six (6) inch minimum width, material shall be Bidco Butyl Wrap as manufactured by NPC or approved equal. K. Pipe Connections 1. Manufactured pipe-to-manhole connectors shall be installed at each opening to assure a flexible watertight seal of the pipe to the manhole. 2. The connector shall be capable of a 7-degree pipe deflection after installation without loss of sealing. 3. The connector shall be manufactured expressly for embedment in the wall of concrete manholes and shall be specifically designed for the pipe material and size being utilized on the project. 4. No adhesives or lubricants shall be employed in the installation of the connector into the manhole. 5. All stainless steel parts of the connector shall be totally non-magnetic Series 304 Stainless except the worm screw for tightening the steel band which shall be Series 305 Stainless. The worm screw shall be torqued by a break-away type torque wrench set for 60 – 70 in/lbs. 6. The connector shall be installed in the manhole so that it shall have a minimum cover of 3-inches of concrete at all points and in strict accordance with the manufacturer's recommendations. 7. Cutouts should be equipped with rubber boots to ensure a watertight connection. Material shall be A-Lok compression connector or A-Lok G3 Boot System, as manufactured by A-Lok Products, Inc or equal. L. Rejecting Pre-cast Manhole Sections 1. Precast reinforced concrete manholes, risers and tops shall be subject to rejection for failure to conform to any of the following specification requirements: a. Fractures or cracks passing through the shell, except for a single end crack that does not exceed the depth of the joint; b. Defects that indicate imperfect proportioning, mixing and molding; c. Surface defects indicating honeycombed or open texture; d. Damaged ends, where such damage would prevent making a satisfactory joint; e. Infiltration into manhole exceeding allowed limits; f. The internal diameter of the manhole section shall not vary more than one (1) percent from the nominal diameter; g. Not clearly marked date of manufacturer, trade name, size designation part number, and ASTM number; Project No. 18088080 4 Section 33 39 13 Lake Lewisville WTP Dewatering Improvements Concrete Manholes h. Having a deviation more than 1/4" from the straight edge at any point across the top of manhole cone section or riser ring; and/or i. Having any visible steel bars along inside or outside surface of the manhole except for reinforcement stirrups or spacers used to position the cage during manufacture. 2.3 MANHOLE FRAMES AND COVERS A. Standard Frames and Covers 1. Frames: a. Frame material shall be cast iron or ductile iron conforming to ASTM A48, Class 35 or better. The frame shall exhibit a tensile strength of not less than 35,000 psi. b. Frames for standard manholes shall be Deeter 1266 for non-traffic areas and Deeter 1235-A for traffic areas, or approved equal(s), and shall have 4 - ¾-inch diameter holes drilled in the bottom flange. The holes shall be centered in the flange and shall be equally spaced 90-degrees apart. c. Bearing surfaces between the ring and cover shall be machine finished or ground to assure non-rocking fit in any position, and interchangeability. 2. Covers: a. The cover shall form a water resistant seal between the frame and manhole cover surface. The cover shall have concealed pick holes and a machined bearing surface on the bottom of the casting. The cover shall conform to ASTM A48, Class 35 or better, for Gray Iron. The cover shall have a tensile strength of 35,000 psi. b. A typical standard manhole cover design shall be Deeter 1266 for non-traffic areas and Deeter 1235-A for traffic areas or approved equal(s). c. Covers shall set flush with the rim of the frame and shall have no larger than a 1/8- inch gap between the frame and cover. d. Bearing surfaces shall be machine finished. e. Manhole lids shall have "SANITARY SEWER" cast on the lids. B. Hinged Manhole Frames and Covers 1. Covers and frames shall conform to ASTM A48, Class 35 or better, for Gray Iron or equivalent ISO standard. Contractor shall provide verification of equivalency. 2. Covers shall be hinged and incorporate a 90 degree blocking system to prevent accidental closure. 3. Covers shall be one man operable using standard tools. 4. Frames shall be circular with a 22-inch clear opening. 5. The frame depth shall not exceed 4 inches, and the flange shall incorporate bedding slots, bolt holes and lifting eyes. 6. Lids shall be lockable and lock/unlock hardware and tools shall be provided with each lid. 7. Lids shall have "SANITARY SEWER" cast on the surface. C. Manhole Frame Seals 1. The material for the seals between the frames and concrete shall be a bitumastic gasket material, meeting or exceeding ASTM C990. Bitumastic gasket material shall be Ram- Nek, EZ-STIK, or approved equal. 2.4 COATINGS A. Interior Coatings 1. Manholes located on 15-inch and larger sewer lines shall be epoxy coated on the interior. 2. Manhole located within 100 feet of a 15-inch and larger sewer line shall be epoxy coated on the interior. 3. Transition manholes in which, a force main discharges into a gravity sewer line shall be epoxy coated on the interior. Project No. 18088080 5 Section 33 39 13 Lake Lewisville WTP Dewatering Improvements Concrete Manholes 4. The products shall only be applied by personnel thoroughly familiar with handling of the coating material, and in accordance with the manufacturer's specifications, recommendations and requirements. a. Raven Ultra High-Build Epoxy Coating, designated as Raven 405, with an average thickness of 100 mils and a minimum thickness of 80 mils. b. Warren Environmental Systems, designated as S-301, with an average thickness of 100 mils and a minimum thickness of 80 mils. c. All epoxies shall meet the following minimum requirements: 1) Flexural Strength ASTM D790 6,000 psi 2) Compressive Strength ASTM D695 8,000 psi 3) Tensile Strength ASTM D638 4,000 psi 4) Tensile Elongation ASTM D638 4% 5) Adhesion ASTM D4541 Concrete Substrate Failure 5. Any damage to an epoxy system on existing manholes shall be repaired by the Contractor at the expense of the Contractor. B. Exterior Coatings 1. All precast manhole sections shall have the exterior coated with two mop coats of coal tar epoxy, Kop Coat “Bitumastic Black Solution,” Tnemec, “46-450 Heavy Tnemecol,” Carboline “Bitumastic 300M,” or equal. Dry film thickness shall be a minimum of 14.0 mils per coat. Recoating shall be done in accordance with manufacturer’s recommendations. PART 3 - EXECUTION 3.1 GENERAL A. Perform excavation and prepare base area in accordance with Section 31 23 16, EXCAVATION. B. Never install base in a water filled excavation. C. Place base in accordance with the Plans and Section 03 30 00, CAST-IN-PLACE CONCRETE. Extend base a minimum of six inches beyond finished sides of manhole. D. Manhole base shall be placed on 8” of compacted Class 7 aggregate base. E. Extend all pipes entirely through the manhole wall so that a joint occurs no closer than 24 inches outside the manhole wall. F. Pipe installed for future extensions shall have one full joint of pipe installed. G. After manhole is constructed, wait no less than 48 hours, then backfill per Section 31 23 23.13, FILL AND BACKFILL. 3.2 CAST-IN-PLACE MANHOLES A. Dimension and layout shall be in accordance with the Plans. The top section or cone must be concentric with the barrel unless otherwise noted. B. The frame shall be set in accordance with the Plans. C. Install rubber waterstop gaskets in the walls around all pipes. D. Interior finish shall be smooth, free of fins or sharp edges. Project No. 18088080 6 Section 33 39 13 Lake Lewisville WTP Dewatering Improvements Concrete Manholes E. Invert to be constructed in accordance with Plans. The bench wall shall be formed to the spring line of the inlet and outlet pipes to form a "U" as shown in the Plans. F. Care should be taken to prevent the end of the pipe from deflecting, due to loads imposed by the weight of the concrete. G. Construction joints on manholes of excessive depth shall be connected with reinforcement approved by the Engineer. 3.3 PRE-CAST MANHOLES A. Dimension and layout shall be in accordance with the plans. The top section or cone must be concentric with the barrel unless otherwise noted. B. The bottom section for pre-cast manholes shall be manufactured as an integral part of the manhole base slab. C. Install remaining sections in a truly vertical plane. D. Fill space between pipe and periphery of cutout on the interior of the manhole with non-shrink grout from the bottom of the invert to the spring line of the sewer pipe (1/2 pipe depth). E. Grout joints between sections, interior only. F. Interior finish: smooth, free of fins or sharp edges. G. Invert to be constructed in accordance with the Plans. The bench wall shall be formed to the spring line of the inlet and outlet pipes to form a "U" as shown in the Plans. H. Grout and/or plug lifting holes for manholes. I. All manhole joints shall be sealed with an external joint wrap material. 3.4 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Comply with Section 01 60 00, PRODUCT REQUIREMENTS. B. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. C. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. 3.5 FIELD QUALITY CONTROL A. Contractor shall visually inspect all materials upon delivery and set aside and damaged or flawed materials and shall not install any damaged or flawed material. B. Contractor shall test for defects and leakage as specified in Section 33 31 23, TESTING SANITARY SEWER SYSTEMS. END OF SECTION Project No. 18088080 1 Section 33 40 00 Lake Lewisville WTP Dewatering Improvements Storm Drainage Piping SECTION 33 40 00 - STORM DRAINAGE PIPING PART 1 - GENERAL 1.1 SUMMARY A. Section includes: 1. Storm drainage piping, fittings, and accessories. 2. Connection of drainage system to municipal sewers. 3. Catch basins, Paved area drainage, and site surface drainage. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 31 23 16 – Excavation. 3. Section 31 23 23.13 – Fill and Backfill. 4. Section 31 23 16.13 – Trenching for Site Utilities. 5. Section 03 30 00 – Cast-In-Place Concrete. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American Society for Testing and Materials (ASTM): a. ASTM C14 – Standard Specification for Nonreinforced Concrete Sewer, Storm Drain, and Culvert Pipe b. ASTM C76 – Standard Specification for Reinforced Concrete Culvert, Storm Drain and Sewer Pipe c. ASTM C443 – Standard Specification for Joints for Concrete Pipe and Manholes, Using Rubber Gaskets. 1.3 DEFINITIONS A. Bedding: Fill placed under, beside and directly over pipe, prior to subsequent backfill operations. 1.4 SUBMITTALS A. See Section 01 33 00, SUBMITTAL PROCEDURES for submittal procedures. B. Product Data: Provide data indicating pipe, pipe accessories. C. Manufacturer’s Installation Instructions: Indicate special procedures required to install Products specified. D. Manufacturer’s Certificate: Certify that products meet or exceed specified requirements. E. Project Record Documents: 1. Record location of pipe runs, connections, catch basins, cleanouts, and invert elevations. 2. Identify and describe unexpected variations to subsoil conditions or discovery of uncharted utilities. 1.5 REGULATORY REQUIREMENTS A. Conform to applicable code for materials and installation of the Work of this section. Project No. 18088080 2 Section 33 40 00 Lake Lewisville WTP Dewatering Improvements Storm Drainage Piping PART 2 - PRODUCTS 2.1 STORM SEWER PIPE MATERIALS A. Reinforced Concrete Pipe: Shall meet ASTM C76, Class III, inside nominal diameter as indicated on drawings. B. Reinforced Concrete Pipe Joint Device: ASTM C443 rubber compression gasket joint. 2.2 PIPE ACCESSORIES A. Pipe Joints: Mechanical clamp ring type, stainless steel expanding and contracting sleeve, neoprene ribbed gasket for positive seal. B. Fittings: Same material as pipe molded or formed to suit pipe size and end design, in required tee, bends, elbows, cleanouts, reducers, traps and other configurations required. C. Trace Wire: Magnetic detectable conductor, clear plastic covering, imprinted with “Storm Sewer Service” in large letters. 2.3 CATCH BASIN, CLEANOUT, AND AREA DRAIN COMPONENTS A. Lids and Drain Covers: Cast iron, hinged to cast iron frame. 1. Catch Basin: a. Lid Design: Linear grill 2. Cleanout: a. Lid Design: Linear grill. B. Shaft Construction and Concentric cone Top Section: Reinforced precast concrete pipe sections, lipped male/female dry joints, nominal shaft diameter as indicated on drawings. C. Base Pad: Cast-in-Place concrete of type specified in Section 03 30 00, leveled top surface to receive concrete shaft sections, sleeved to receive sanitary sewer pipe sections. 2.4 BEDDING AND BACKFILL MATERIALS A. As specified in Section 31 23 23.16, TRENCH BACKFILL. PART 3 - EXECUTIONS 3.1 TRENCHING A. See Section 31 23 23.16, TRENCH BACKFILL, and Section 31 23 16.13, TRENCHING FOR SITE UTILITIES for additional requirements. B. Backfill around sides and to top of pipe with cover fill, tamp in place and compact, then complete backfilling. 3.2 INSTALLATION – PIPE A. Install pipe, fittings and accessories in accordance with manufacturer’s instructions. Seal watertight. B. Lay pipe to slope gradients noted on layout drawings; with maximum variation from true slope of 1/8 inch in 10 feet. Project No. 18088080 3 Section 33 40 00 Lake Lewisville WTP Dewatering Improvements Storm Drainage Piping C. Install continuous trace wire 6 inches above top of pipe; coordinate with Section 31 23 16.13. 3.3 INSTALLATION – CATCH BASINS AND CLEANOUTS A. Form bottom of excavation clean and smooth to correct elevation. B. Form and place cast-in-place concrete base pad, with provision for sanitary sewer pipe end sections. C. Establish elevations and pipe inverts for inlets and outlets as indicated. D. Mount lid and frame level in grout, secured to top cone section to elevation indicated. 3.4 FIELD QUALITY CONTROL A. If tests indicate work does not meet specified requirements, remove Work, replace and retest at no cost to Owner. 3.5 PROTECTION A. Protect pipe and bedding cover from damage or displacement until backfilling operation is in progress. END OF SECTION Project No. 18088080 1 Section 33 41 19 Lake Lewisville WTP Dewatering Improvements Pipe Laying SECTION 33 41 19 – PIPE LAYING PART 1 - GENERAL 1.1 SUMMARY A. Section includes: the Work necessary to install gravity sewer, force main pipe, water pipe and appurtenances. B. Related sections: 1. Section 01 60 00 – Product Requirements 2. Section 31 23 16.13 – Trenching for Site Utilities 3. Section 33 31 23 – Testing Sanitary Sewer Systems 4. Section 33 31 26 – Testing Water Distribution Systems 5. Section 33 39 13 – Concrete Manholes 1.2 GENERAL A. General Requirements: See Division 01, GENERAL REQUIREMENTS, which contains information and requirements that apply to the work specified herein and are mandatory for this project. PART 2 - PRODUCTS 2.1 GENERAL A. All pipe materials shall be as specified on the Plans and conforming to these specifications. 2.2 WARNING TAPE A. Non-metallic sanitary sewer marking tape shall be warning tape as manufactured by Rhino Marking and Protection Systems, Harris Industries, Inc., or approved equal. B. Tape shall have a minimum thickness of 4 mils and manufactured with heavy metal-free polyethylene tape that is impervious to all known alkalis, acids, chemical reagents, and solvents found in soil. The minimum overall width of the tape shall not be less than 3-inches. Standard rolls shall be 1000’ length. C. The tape for sewer lines shall be color coded Green and imprinted with the following message: Caution Buried Sewer Line Below. D. The tape for water lines shall be color coded Blue and imprinted with the following message: Caution Buried Water Line Below. 2.3 TRACER WIRE A. Tracer wire shall be 12-gauge, stranded coated copper for underground burial. B. Jacket color shall be GREEN, and made of High Density Polyethylene (HDPE) or High Molecular Weight Polyethylene (HMWPE) designed for direct burial. C. Connectors shall be used for all splices or repairs. Connectors shall be moisture displacement style as manufactured by 3M DBR, or equal. D. A locate or conductivity test shall be performed prior to signing off on the project. Project No. 18088080 2 Section 33 41 19 Lake Lewisville WTP Dewatering Improvements Pipe Laying 2.4 PIPE BEDDING AND BACKFILL A. Shall be in accordance with 31 23 23.13, TRENCH BEDDING AND BACKFILL FOR WATER AND SEWER LINES. PART 3 - EXECUTION 3.1 GENERAL A. All pipe, fittings, bedding, backfill, and all other appurtenances shall be installed in accordance with these specifications and the Plans. 3.2 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Comply with Section 01 60 00, PRODUCT REQUIREMENTS. B. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. C. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. D. Pipe and accessories shall be handled in such a manner that will ensure their condition after installation to be sound and undamaged. Equipment, tools and methods used in unloading, reloading, hauling and laying pipe and fittings shall be such that they are not damaged. Under no circumstances shall loading forks, or other equipment, be inserted into the barrel of the pipe or fitting. E. Pipe having pre-molded joint rings shall be handled in such a manner that no weight, including the weight of the pipe itself, will bear on or be supported by the spigot rings at any time. Care shall be taken to avoid dragging the spigot ring on the ground or allowing it to come in contact with gravel, crushed stone, rocks, or other hard objects. Joint rings which have been damaged in any way will not be accepted and shall not be incorporated in the work. 3.3 FIELD QUALITY CONTROL A. Provide skilled workmen to insure embedment of pipe. B. Contractor shall test for defects and leakage as specified in Section 33 31 23, Testing Sanitary Sewer Systems, and Section 33 31 26, Testing Water Distribution Systems. 3.4 TRACER WIRE A. Regardless of pipe material, a trace wire or coated metal strip shall be placed immediately above the initial backfill material and directly over the pipe. At valves, the trace wire shall be brought up into the valve box as indicated in the plans. A tracing test of trace wire will be required prior to final acceptance. 3.5 PIPE DETECTION TAPE A. Pipe detection tape shall be provided in all trenches for force main and water line construction. Installation shall be per manufacturer's recommendations and shall be as close as practical to finished grade while maintaining a required minimum of 18 inches between the detection tape and the top of any pipe. Project No. 18088080 3 Section 33 41 19 Lake Lewisville WTP Dewatering Improvements Pipe Laying 3.6 LAYING PIPE A. Proper means and equipment shall be used for lowering pipe into the trenches. B. The Contractor shall have full responsibility for any diversion of drainage and for dewatering trenches. C. Recesses for the pipe bells are mandatory and shall be hand excavated so that the entire pipe barrel is uniformly supported by the bedding material. D. Pipe shall be protected from lateral displacement by means of pipe embedment material installed as provided in this specification. Under no circumstances shall pipe be laid in water and no pipe shall be laid under unsuitable weather or trench conditions. E. When jointed in the trench, the pipe shall form a true and smooth line. Pipe shall not be trimmed except for closures, and pipe not making a good fit shall be removed. F. Unless otherwise approved by the Engineer, the laying of pipe shall begin at the lowest point, and the pipe shall be installed so that the spigot ends point in the direction of flow. G. Pipe which is a part of a gravity sewer line shall be aligned and constructed to grades as shown on the plans. Lines not conforming to theses grades shall be subject to removal and replacement at the Contractor’s expense. Force main pipe shall match the horizontal alignment and shall closely match the grades shown on the plans. H. Pipe lines or runs intended to be straight shall be laid straight. I. During installation, each pipe and fitting shall be inspected for defects. All defective, damaged, or unsound pipe and fittings shall be rejected and removed from the site of the work. J. Dependent on type of application, gravity or pressure, place thrust blocking at all pipe fittings, including bends and reducers, as shown on the Plans. K. Prior to joining the pipe, the plain ends of the pipe and the bells of the pipe shall be thoroughly cleaned using a soapy water and cloth, removing all foreign materials from the bells, especially the gasket seats. Any burrs or imperfections in that part of the plain end or bell which will be in contact with the gasket shall be removed. L. The clean gasket shall be inserted in the bell and a thin film of lubricant shall be applied to the inside surface of the gasket. M. The cleaned plain end shall initially be entered in the bell straight. The plain end shall be forced inside the gasket and bell until the limit mark is just visible. The pipe may then be deflected as allowed by the manufacturer. N. Lubricants shall be supplied by the pipe manufacturer in sufficient quantities. No substitutes shall be made. O. The Contractor shall furnish such jacks, or other devices as are necessary for forcing the pipe into the bell and gasket. Care shall be exercised to avoid damage to the pipe where the pushing device or machine part contacts the pipe. A wood block or suitable pad shall be placed between the pipe and that part of the pushing device which contacts the pipe. P. All plain ends that enter a push on bell shall be beveled at 30° for at least one eighth (1/8) inch. All cut pieces or ends of pipe of other classifications shall be so beveled. Project No. 18088080 4 Section 33 41 19 Lake Lewisville WTP Dewatering Improvements Pipe Laying 3.7 PIPE BEDDING NON-FERROUS PIPE A. Non-ferrous pipe includes PVC, Polyethylene and FRP. B. Bedding material shall be as specified in Section 31 23 23.19, TRENCH BEDDING AND BACKFILL FOR WATER AND SEWER LINES. C. Place 6-inches, minimum, of bedding between excavated trench bottom or stabilized trench bottom and bottom of pipe or fitting. Provide depression in bedding for joints so that barrel of pipe or fitting rests on bedding. Place bedding in 6-inch maximum layers, compacted to 95% standard maximum density, to 6-inches over the top of pipe and fittings. D. Bedding is considered to be an integral part of the pipe installation. Therefore particular care shall be given to insure that bedding is in intimate contact with the pipe in all directions and that no portion of the bedding shall be compacted to less than the specified density, particularly the area below the springline of the pipe. E. Place bedding a minimum of 6-inches over the top of pipe and fittings. Bedding shall be compacted to 95% maximum density. F. For areas undercut, whether by Contractor’s negligence or by direction of Engineer, provide and place crushed aggregate, compacted to 95% standard maximum density, to bottom elevation of pipe bedding. G. When used, the bottom of trench boxes will be above the level of pipe bedding before bedding is compacted. In no case will pipe bedding be compacted against the trench box or before the trench box is raised to allow compaction of bedding. 3.8 PIPE BEDDING DUCTILE IRON PIPE A. Bedding material shall be as specified in Section 31 23 23.19, TRENCH BEDDING AND BACKFILL FOR WATER AND SEWER LINES. B. Place 6-inches, minimum, of bedding between excavated trench bottom or stabilized trench bottom and bottom of pipe or fitting. Provide depression in bedding for joints so that barrel of pipe or fitting rests on bedding. Place bedding in 6-inch maximum layers, compacted to 95% standard maximum density, to a minimum total depth of 3/4 (75%) of the outside diameter of the pipe as indicated on the drawings. C. Bedding is considered to be an integral part of the pipe installation. Therefore particular care shall be given to insure that bedding is in intimate contact with the pipe in all directions and that no portion of the bedding shall be compacted to less than the specified density, particularly the area below the springline of the pipe. D. For areas undercut, whether by Contractor’s negligence or by direction of Engineer, provide and place crushed aggregate, compacted to 95% standard maximum density, to bottom elevation of pipe bedding. E. When used, the bottom of trench boxes will be above the level of pipe bedding before bedding is compacted. In no case will pipe bedding be compacted against the trench box or before the trench box is raised to allow compaction of bedding. Project No. 18088080 5 Section 33 41 19 Lake Lewisville WTP Dewatering Improvements Pipe Laying 3.9 TRENCH BACKFILL A. Shall be as specified in Section 31 23 23.19, TRENCH BEDDING AND BACKFILL FOR WATER AND SEWER LINES. 3.10 ALIGNMENT AND GRADE A. All pipe shall be laid straight between changes in alignment, except as shown on the Plans, and at a uniform grade between changes in grade. All lines shall be laid so that each section between manholes will lamp. 3.11 JOINTING A. Boltless gasketed joints: All instructions and recommendations of the pipe manufacturer, relative to gasket installation and other jointing operations, shall be observed and followed by the Contractor. All joint surfaces shall be lubricated as recommended by the manufacturer immediately before the joint is completed. B. Mechanical joints: Mechanical joints shall be carefully assembled in accordance with the manufacturer's recommendations. If effective sealing is not obtained, the joint shall be disassembled, thoroughly cleaned and reassembled. Overtightening bolts to compensate for poor installation practice will not be permitted. 3.12 CUTTING PIPE A. Cutting of pipe shall be done in a neat manner, without damage to the pipe or to the lining therein. Pipe cuts shall be smooth, straight and at right angles to the pipe axis. All cutting of pipe shall be done with mechanical pipe cutters of an approved type except that in locations where the use of mechanical cutters would be difficult or impracticable, existing pipe may be cut with diamond point chisels, saws, or other tools which will cut the pipe without damaging impact or shock. 3.13 CLEANING A. The interior of all pipe shall be cleaned of all foreign matter before being installed and shall be kept clean until the work has been accepted. All lumps, blisters and excess coating shall be removed from exterior spigot and interior bell surfaces. Such surfaces shall be wire brushed and wiped clean, dry, and free from oil and grease before placing the spigot in the bell. All joint contact surfaces shall be kept clean until the jointing is completed. B. Every precaution shall be taken to prevent foreign material from entering the pipe while it is being installed. No debris, tools, clothing, or other materials shall be placed in the pipe. C. Whenever pipe laying is stopped, the open end of the line shall be sealed with a watertight plug. 3.14 WATER AND SEWER LINE CROSSINGS A. Water and sewer lines crossing one another shall have a minimum 18-inch vertical separation. B. In general water lines shall be above sewer lines. However if water line cannot meet the 18- inch clearance above sewer line because of cover limitations or other obstructions, the water line may be above or below the sewer line but either the water or sewer line shall be encased 10 feet either side of the crossing line in steel encasement as specified in Section 33 31 13, STEEL ENCASEMENT PIPE. Project No. 18088080 6 Section 33 41 19 Lake Lewisville WTP Dewatering Improvements Pipe Laying C. Water lines shall not pass through manholes. 3.15 PARALLEL WATER AND SEWER LINES A. Water and sewer line shall have a minimum 10 feet horizontal separation. B. Water lines shall have a minimum 10 foot horizontal separation from sewer manholes. C. Water and sewer lines shall not be installed within the same trench. 3.16 TESTING A. Acceptance testing for gravity lines and force mains shall conform to Section 33 31 23, TESTING SANITARY SEWER SYSTEMS. B. Acceptance testing for water mains shall conform to the relevant portions of Section 33 31 26, TESTING WATER DISTIBUTION SYSTEMS. 3.17 CONNECTION OF NEW SEWER PIPELINES TO EXISTING SANITARY SEWERS A. Construct, clean, test, and obtain Engineer's approval for pipelines and manholes before connecting new pipeline to the existing sewer. B. If, in the opinion of the Engineer, conditions exist which require connection prior to final line acceptance, plug all lines entering the manhole connecting to the existing system until the new system is accepted. In addition, plug the line leaving the first manhole upstream. Never allow water being used to flush the new lines to enter the existing system. C. All new pipelines must connect to the existing system at a new or existing manhole. If a new manhole is built over an existing sewer line, do not break out the top of the existing pipe until the new line is accepted. Flexible pipe couplings, as manufactured by Fernco or equal, may be used to connect existing gravity sewer line to new gravity sewer lines as approved by the Engineer. D. If a new pipeline is to discharge into an existing manhole, divert the sewage flow around the existing manhole while the tie-in is under construction. Intercept the sewage flow at the existing manhole first upstream from the tie-in construction. Provide suitable pumping equipment and re- routing conduit to pump the sewage around the tie-in construction. Discharge into an appropriate manhole downstream from the construction. E. Connection to an existing manhole shall be made by core drilling. A concrete manhole adapter, A-LOK G3 boot system or equal, shall be installed on the sewer pipe, and the annular space grouted. F. Connect new pipelines to existing manholes in a neat, workmanlike manner, to ensure a watertight connection. 3.18 TRENCHING A. Pipe trenching shall be as specified in Section 31 23 16.16, TRENCHING FOR WATER AND SEWER LINES. Project No. 18088080 7 Section 33 41 19 Lake Lewisville WTP Dewatering Improvements Pipe Laying 3.19 CONNECTIONS TO MANHOLES A. Pipe connections to concrete manholes and other concrete structures shall be as specified in Section 33 39 13, CONCRETE MANHOLES. 3.20 STEEL ENCASEMENT A. Pipe installed within steel encasement shall conform to Section 33 31 13, STEEL ENCASEMENT PIPE. END OF SECTION DIVISION 40 PROCESS INTEGRATION Project No. 18088080 1 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing SECTION 40 05 00 – PIPING SYSTEMS TESTING PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Test requirements for piping systems. B. Related Sections: 1. Section 01 41 00 – Regulatory Requirements. 2. Section 01 50 00 – Temporary Facilities and Controls. 3. Section 40 23 39 – Process Piping - General. 1.2 REFERENCES A. National Fuel Gas Code (NFGC): 1. ANSI Z 223.1 or NFPA 54. B. American Society of Mechanical Engineers (ASME): 1. B31.8 – Gas Transmission and Distribution Piping Systems. 2. B31.1 – Power Piping. 3. B31.3 – Process Piping. C. American Water Works Association (AWWA): 1. C600-17 Installation of Ductile Iron Mains and Their Appurtenances 1.3 TESTING REQUIREMENTS A. General Requirements: 1. Testing requirements are stipulated in Laws and Regulations; are included in the Piping Schedule in Section 40 23 39; are specified in the specifications covering the various types of piping; and are specified herein. 2. Requirements in Laws and Regulations supersede other requirements of Contract Documents, except where requirements of Contract Documents are more stringent, including higher test pressures, longer test times, and lower leakage allowances. 3. Test plumbing piping in accordance with Laws and Regulations, the plumbing code, as specified in Section 01 41 00, and UL requirements. 4. Test Natural Gas or Digester Gas Piping: a. For less than 125 pounds per square inch gauge working pressure, test in accordance with mechanical code, as specified in Section 01 41 00, or the National Fuel Gas Code, whichever is more stringent. b. For 125 pounds per square inch gauge or greater working pressure, test per ASME B31.3 or ASME B31.8, whichever is more stringent. 5. When testing with water, the specified test pressure is considered to be the pressure at the highest point of the piping section under test. Lower test pressure as necessary to prevent testing the lowest point above a safe test pressure. B. Furnish necessary personnel, materials, and equipment, including bulkheads, restraints, anchors, temporary connections, pumps, water, pressure gauges, and other means and facilities required to perform tests. C. Water for Testing, Cleaning, and Disinfecting: 1. Water for testing, cleaning, and disinfecting will be provided as specified in Section 01 50 00. Project No. 18088080 2 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing D. Pipes to be tested: Test only those portions of pipes that have been installed as part of this Contract. Test new pipe sections prior to making final connections to existing piping. Furnish and install test plugs, bulkheads, and restraints required to isolate new pipe sections. Do not use existing valves as test plug or bulkhead. E. Unsuccessful Tests: 1. Where tests are not successful, correct defects or remove defective piping and appurtenances and install piping and appurtenances that comply with the specified requirements. 2. Repeat testing until all tests are successful. F. Test Completion: Drain and leave piping clean after successful testing. G. Test Water Disposal: CONTRACTOR is responsible for coordinating the disposal of testing water. Facility must be in accordance with requirements of federal, state, county, and city regulations governing disposal of wastes in the location of the Project and disposal site. 1.4 SUBMITTALS A. Submit in accordance with Section 01 33 00, SUBMITTAL PROCEDURES. The following specific information shall be provided: 1. Quality Control Submittals: a. Testing Plan: Submit at least 30 days prior to testing and include at least the information that follows. 1). Testing Dates 2). Piping systems and section(s) to be tested 3). Test type 4). Method of isolation 5). Calculation of maximum allowable leakage for piping section(s) to be tested b. Certifications of Calibration: Testing equipment c. Certified Test Report B. Schedule and Notification of Tests: 1. Notification of Readiness to Test: Immediately before testing, notify Engineer in writing of readiness, not just intention, to test piping. Have personnel, materials, and equipment specified in place before submitting notification of readiness. 1.5 PREPARATION A. Notify ENGINEER in writing 5 days in advance of testing. Perform testing in presence of ENGINEER. B. Clean piping before pressure or leak tests. C. Test section may be filled with water and allowed to stand under low pressure prior to testing. D. Pressure Piping: 1. Install temporary thrust blocking or other restraint as necessary to protect adjacent piping or equipment and make taps in piping prior to testing. 2. Wait 5 days minimum after concrete thrust blocking is installed to perform pressure tests. If high-early strength cement is used for thrust blocking, wait may be reduced to 2 days. 3. Prior to test, remove or suitably isolate appurtenant instruments or devices that could be damaged by pressure testing. 4. New Piping connected to Existing Piping: Project No. 18088080 3 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing a. Isolate new piping with grooved-end pipe caps, spectacle blinds, blind flanges, or as acceptable to Engineer. b. Test joint between new piping and existing piping by methods that do not place entire existing system under test load, as approved by Engineer. 5. Items that do not require testing include: Equipment seal drains, tank overflows to atmospheric vented drains, and tank atmospheric vents. 6. Test Pressure: As indicated on the Piping Schedule. E. Gravity Piping: 1. Perform test as specified hereinafter 2. Perform testing after service connections, manholes, and backfilling have been completed between stations to be tested. 3. Determine groundwater level at time of testing by exploratory holes or other method acceptable to Engineer. F. Underground Piping 1. Test underground gravity piping, including sanitary sewers, for visible leaks before backfilling and compacting. 2. Underground pressure piping may be tested before or after backfilling when not indicated or specified otherwise. 3. Backfill and compact trench or provide blocking that prevents pipe movement before testing underground piping with a maximum leakage allowance. 4. Test underground piping before encasing piping in concrete or covering piping with slab, structure, or permanent improvement. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION 3.1 HYDROSTATIC PRESSURE PIPING TESTING METHOD A. Test Hydrostatic Pressure Piping indicated with “H” in the Piping Schedule for the specified test pressure. B. Fluid: Clean water of such quality to prevent corrosion of materials in piping system. C. Exposed Piping: 1. Perform testing on installed piping prior to application of insulation. 2. Maximum Filling Velocity: 0.25 feet per second, applied over full area of pipe. 3. Vent piping during filling: Open vents at high points of piping system or loosen flanges, using at least four bolts, or use equipment vents to purge air pockets. 4. Maintain hydrostatic test pressure continuously for 60 minutes, minimum, and for such additional time as necessary to conduct examinations for leakage. 5. Examine joints and connections for leakage. 6. Correct visible leakage and retest as specified. 7. Empty pipe of water prior to final cleaning. D. Buried Piping: 1. Test after backfilling has been completed. 2. Expel air from piping system during filling. 3. Apply and maintain specified test pressure with hydraulic force pump. Valve off piping system when test pressure is reached. 4. Maintain hydrostatic test pressure continuously for 2 hours minimum, reopening isolation valve only as necessary to restore test pressure. Project No. 18088080 4 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing 5. Determine actual leakage by measuring quantity of water necessary to maintain specified test pressure for duration of test. 6. When leakage is allowed, calculate the maximum allowable leakage by the following AWWA C600-17 formula: ܮൌ ܵܦξܲ ͳͶͺǡͲͲͲ Where: L = Testing allowance (makeup water) (gph) S = Length of the test section (ft) D = Nominal diameter of the piping (in). P = Average observed test pressure (psi [gauge]) at the lowest point of the test section, corrected for elevation of the pressure gauge. 7. Correct leakage greater than allowable, and retest as specified. E. Gravity Piping 18-inch through 30-inch 1. Testing equipment accuracy: Plus or minus ½-gallon of water leakage under specified conditions. 2. Maximum allowable leakage: 0.16 gallons per hour per inch diameter per 100 feet. Include service connection footage in test section, subjected to minimum had specified. 3. Exfiltration Test: a. Length of pipe tested: limit length such that pressure on invert of lower and end of section does not exceed 30 feet of water column. b. The downstream end of the pipe section being tested shall be plugged and the plug shall be braced and blocked securely. No one shall be allowed to enter a manhole where a plugged pipe is under pressure. Any other pipe entrances to the upstream manhole shall likewise be securely plugged. c. Only water from a source approved by the ENGINEER shall be used to perform the test. Wastewater shall not be used to perform exfiltration testing. d. Water shall be added upstream of the section being tested to a depth at least 2.0 feet above the inside top of the outgoing pipe (or 2.0 feet above the groundwater level). e. There shall be a minimum of 2.0 feet positive head above the inside top of the pipe at the high end of the section being tested. f. The test shall be conducted for two hours. The leakage shall be determined by the calculated change in total volume of water used in the test. 4. Infiltration Test: a. Groundwater level: at least 6 feet above inside top of highest section of pipe in test section, including service connections. 5. Piping with groundwater infiltration rate greater than allowable leakage rate for exfiltration will be considered defective, even if pipe preciously passed a leakage test. a. Defective piping sections: replace or test and seal individual joints, and retest as specified. 3.2 HIGH-HEAD PRESSURE PIPING TESTING METHOD A. Test piping for which the specified test pressure in the Piping Schedule is 20 pounds per square inch gauge or greater, by the high head pressure test method, indicated “HH” in the Piping Schedule. Project No. 18088080 5 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing B. General: 1. Test connections, hydrants, valves, blowoffs, and closure pieces with the piping. 2. Do not use installed valves for shutoff when the specified test pressure exceeds the valve’s maximum allowable seat differential pressure. Provide blinds or other means to isolate test sections. 3. Do not include valves, equipment or piping specialties in test sections if test pressure exceeds the valve, equipment or piping specialty safe test pressure allowed by the item’s manufacturer. 4. During the performance of the tests, test pressure shall not vary more than plus or minus 5 pounds per square inch gauge with respect to the specified test pressure. 5. Select the limits of testing to sections of piping. Select sections that have the same piping material and test pressure. 6. When test results indicate failure of selected sections, limit tests to piping: a. Between valves. b. Between a valve and the end of the piping. c. Less than 500 feet long. 7. Test piping for minimum 2 hours for visible leaks test and minimum 2 hours for the pressure test with maximum leakage allowance. C. Visible Leaks Test: 1. Fill piping section under test slowly with water while venting air. Use potable water for all potable waterlines and where noted on the Piping Schedule. 2. Before pressurizing for the test, retain water in piping under slight pressure for a water absorption period of minimum 24 hours. 3. Raise pressure to the specified test pressure and inspect piping visually for leaks. Consider visible leakage testing complete when no visible leaks are observed. D. Pressure Test with Maximum Leakage Allowance: 1. Leakage allowance is zero for piping systems using flanged, National Pipe Thread threaded and welded joints. 2. Pressure test piping after completion of visible leaks test. 3. For piping systems using joint designs other than flanged threaded or welded joints, accurately measure the makeup water necessary to maintain the pressure in the piping section under test during the minimum pressure test period of 2 hours. a. Successful completion of the pressure test with maximum leakage allowance shall have been achieved when the observed leakage during the test period is equal or less than the allowable leakage and no damage to piping and appurtenances has occurred. 3.3 LOW-HEAD PRESSURE PIPING TESTING METHOND A. Test piping for which the specified test pressure is less than 20 pounds per square inch gauge, by the low head pressure test method, indicated "LH" in the Piping Schedule. B. General: 1. Test pressures shall be as scheduled in Section 40 23 39. 2. During the performance of the tests, test pressure shall not vary more than plus or minus 2 pounds per square inch gauge with respect to the specified test pressure. 3. Test connections, blowoffs, vents, closure pieces, and joints into structures, including existing bell rings and other appurtenances, with the piping. 4. Test piping for minimum 2 hours for visible leaks test and minimum 2 hours for the pressure test with maximum leakage allowance. C. Visible Leaks Test: 1. Subject piping under test to the specified pressure measured at the lowest end. Project No. 18088080 6 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing 2. Fill piping section under test slowly with water while venting air. Use potable water for all potable waterlines and where noted on the Piping Schedule. 3. Before pressurizing for the tests, retain water in piping under slight pressure for the water absorption period of minimum 24 hours. 4. Raise pressure to the specified test pressure and inspect piping visually for leaks. Consider testing complete when no visible leaks are observed. D. Pressure Test with Maximum Leakage Allowance: 1. Pressure test piping after completion of visible leaks test. 2. Accurately measure the makeup water necessary to maintain the pressure in the piping section under test during the pressure test period. a. Consider the pressure test to be complete when makeup water added is less than the allowable leakage of 80 gallons per inch of nominal diameter, per mile of piping section under test after 24 hours and no damage to piping and appurtenances has occurred. b. Successful completion of the leakage test shall have been achieved when the observed leakage is equal or less than the allowable leakage and no damage to piping and appurtenances has occurred. E. Optional Joint Test: 1. Joint testing will be allowed only for low head pressure piping. 2. Joint testing may be performed with water or air. 3. Joint test piping after completion of backfill and compaction to the top of the trench. 4. When Joint Testing Is Allowed by Note in the Piping Schedule, the Procedure Shall Be as follows: a. Joint Testing with Water: 1). Measure test pressure at the invert of the pipe. Apply pressure of 4 feet plus the inside diameter of the pipe in water column within 0.20 feet in water column. 2). Maintain test pressure for one minute. 3). Base the allowable leakage per joint on 80 gallons per inch nominal diameter, per mile of piping, per 24 hours equally distributed to the actual number of joints per mile for the type of piping. 4). Consider the pressure test to be complete when makeup water added is less than the allowable leakage. 5). Successful completion of the joint test with water shall have been achieved when the observed leakage is equal or less than the allowable leakage. b. Joint Testing with Air: 1). Apply test pressure of 3 pounds per square inch gauge with a maximum variation of plus 0.20 and minus 0.00 pounds per square inch. 2). Maintain test pressure for 2 minutes. 3). Consider the pressure test to be complete when the test pressure does not drop below 2.7 pounds per square inch for the duration of the test. 3.4 PNEUMATIC PRESSURE PIPING TESTING METHOD A. Pneumatic test piping, indicated with “P” in the Piping Schedule, with air or another nonflammable or inert gas. 1. DO NOT perform on: a. PVC or CPVC pipe b. Piping larger than 18 inches c. Buried or other non-exposed piping B. Test gas, air, liquefied petroleum gas, liquid chlorine, and chlorine gas piping by the air test method: Project No. 18088080 7 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing 1. Test chlorine piping with oil-free dry air or nitrogen having a dew point of minus 40 degrees Fahrenheit or less. Supply temporary air dryers as necessary. C. Test at pressure as specified in Piping Schedule in Section 40 23 39: 1. Provide temporary pressure relief valve for piping under test. Set at the lesser of 110 percent of the test pressure or 50 pounds per square inch gauge over the test pressure. 2. Air method test pressures shall not exceed 110 percent of the piping maximum allowable working pressure calculated in accordance with the most stringent of ASME B31.1. AS<E B31.3, ASE B31.8, or the pipe manufacturer’s stated maximum working pressure. 3. Gradually increase test pressure to an initial test pressure equal to the lesser of one-half the test pressure or 25 pounds per square inch gauge. 4. Apply soap bubble moisture to joins and connections. Perform initial check for leakage. 5. Gradually increase test pressure to half of specified test pressure. Thereafter increase pressure in steps of approximately one-tenth of specified test pressure until required rest pressure is reached. Check for leakage at each step increase until test pressure reached. 6. At each step in the pressure, examine and test piping being air tested for leaks with soap solution. 7. Consider examination complete when piping section under test holds the test pressure for 10 minutes, minimum, without losses, and for such additional time as necessary to conduct soap bubble examinations. 8. Correct visible leakage and retest as specified. D. Allowable Leakage: Piping system, exclusive of possible localized instances at pump or valve packing, shall show no visual evidence of leakage. E. After testing and final cleaning, purge with nitrogen those lines that will carry flammable gases to assure no explosive mixtures will be present in the system during filling process 3.5 GRAVITY FLOW PIPING TESTING METHOD A. Test Gravity Flow Piping indicated with “G” in the Piping Schedule B. General 1. Unless specified otherwise, subject gravity flow piping to the following tests: a. Alignment and grade. b. Deflection test – for plastic piping. c. Visible leaks and pressure with maximum leakage allowance tests, except for storm drains and culverts. C. Alignment and Grade: 1. Visually inspect the interior of gravity piping with artificial light, reflected light, or laser beam. 2. Consider inspection complete when no broken or collapsed piping, no open or poorly made joints, no grade changes that affect the piping capacity, or no other defects are observed. D. Deflection Test: 1. Maximum allowable pipe deflection shall not exceed 5 percent of the inside diameter. 2. Pull a mandrel through the clean piping section under test. 3. Perform the test not sooner than 30 days after installation and not later than 60 days after installation. 4. Use a 9-rod mandrel with a contact length of not less than the nominal diameter of the pipe within one percent plus or minus. 5. Consider test complete when the mandrel can be pulled through the piping with reasonable effort by 1 person, without the aid of mechanical equipment. E. Procedure Project No. 18088080 8 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing 1. Inspect piping for visible leaks before backfilling. Provide temporary restraints when needed to prevent movement of piping. Pressure test piping with maximum leakage allowance after backfilling. 2. With the lower end plugged, fill piping slowly with water while allowing air to escape from high points. Keep piping full under a slight head of water at least 24 hours. a. Examine piping for visible leaks. Consider examination complete when no visible leaks are observed. b. Maintain piping with water or allow a new water absorption period of 24 hours for the performance of the pressure test with maximum leakage allowance. c. After successful completion of the test for visible leaks and after the piping has been restrained and backfilled, subject piping to the test pressure for minimum of 4 hours while accurately measuring the volume of water added to maintain the test pressure. 1). Consider the test complete when leakage is equal to or less than the following maximum leakage allowances: a). For Concrete Piping with Rubber Gasket Joints: 80 gallons per day per inch of diameter per mile of piping under test. (1) Advise manufacturer of concrete piping with rubber gasket joints of more stringent than normal maximum leakage allowance. b). For Vitrified Clay and Other Piping: 500 gallons per day per inch of diameter per mile of piping under test. F. Joint testing for 36-inch and larger gravity piping 1. The CONTRACTOR shall develop a numbering system for the pipeline joints so that the test logs can be tied to the tested joint. 2. The CONTRACTOR shall develop a test system that allows the ENGINEER reasonable access for witnessing the joint testing. The CONTRACTOR shall submit their proposed testing plan to the ENGINEER for approval prior to the start of testing. 3. Pressurize the void at the joint with air to 3.5 psi greater than the pressure exerted by groundwater above the pipe. Allow the air pressure and temperature to stabilize before shutting off the air supply, and start of test timing. If pressure holds, or drops less than 1 psi in 5 seconds, the joint is acceptable. 4. If there is any visible leakage within the pipeline after the joint testing, repairs will be required before the pipeline is accepted. 3.6 LOW PRESSURE TESTING METHOD A. Test Low Pressure Piping indicated with “LP” in the Piping Schedule for the specified test pressure. B. General 1. The CONTRACTOR shall have the option of verifying water tightness by either air testing or water testing. The ENGINEER shall have the option to require testing by both methods to verify marginal results. 2. Test Equipment: All necessary equipment to perform the air test in accordance with this specification shall be provided by the CONTRACTOR. The test gauge shall have incremental divisions of 0.10 psi and have an accuracy of at least plus or minus 0.04 psi. In no case shall a test gauge be used which has incremental divisions of greater than 0.25 psi. The gauge shall be of sufficient size to determine accuracy. 3. Safety Precautions: It is extremely important that the various plugs be install to prevent the sudden expulsion of a poorly inflated plug. Observe the following safety precautions a. No one shall be allowed in the manholes during the test or when a plugged pipe is under pressure b. Gauges, air piping manifolds, and valves shall be located at the top of the ground c. Install and brace all plugs securely d. Do not over pressurize the lines. Project No. 18088080 9 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing C. Air Testing - Procedure 1. All service laterals, stubs and fittings into the test section shall be properly capped or plugged, and carefully braced against the internal pressure to prevent air leakage by slippage and blowouts. 2. Connect air hose to tapped plug selected for the air inlet. Then connect the other end of the air hose to the portable air control equipment which consists of valves and pressure gauge used: a. To control air entry rate to the test section, and b. To monitor the air pressure in the pipeline. More specifically, the air control equipment includes a shutoff valve, pressure regulating valve, pressure reduction valve and a monitoring pressure gauge having a pressure range from 0-5 psi and an accuracy of 0.04 psi. 3. Connect another air hose between the air compressor (or other source of compressed air) and the air control equipment. This completes the test equipment set-up. Test operations may commence. 4. Supply air to the test section slowly, filling the pipe line until a constant pressure of 4.0 psig is maintained. The air pressure must be regulated to prevent the pressure inside the pipe from exceeding 5.0 psig. 5. When constant pressure of 4.0 psig is reached, throttle the air supply to maintain the internal pressure between 3.5 to 4.0 psig for at least 5 minutes. This time permits the temperature of the entering air to equalize with the temperature of the pipe wall. If leakage is detected at any cap or plug, release the pressure in the line and tighten all leaky caps and plugs. 6. Then start the test operation again by supplying air. When it is necessary to bleed off the air to tighten or repair a faulty plug, a new five-minute interval must be allowed after the pipeline has been refilled. 7. After the stabilization period, adjust the air pressure to 3.5 psig and shutoff or disconnect the air supply. Observe the gauge until the air pressure reaches 3.5 psig. At 3.5 psig commence timing with a stop watch which is allowed to run until the line pressure drops to 2.5 psig at which time the stop watch is stopped. The time required, as shown on the stop watch for a pressure loss of 1.0 psig, is used to compute the air loss. 8. If the time in minutes and seconds for the air pressure to drop from 3.5 to 2.5 psig is greater than that shown in the table for the designated pipe size, the section undergoing test shall have passed and shall be presumed to be free of defects. The test may be discontinued at that time. 9. If the time in minutes and seconds for the 1.0 psig drop is less than that shown on the table for the designated pipe size, the section of pipe shall not have passed the test; therefore, adequate repairs must be made and the line retested. 10. Pipe sizes with their respective recommended minimum times, in minutes and seconds, for acceptance by the air test method are as shown below. Minimum Time For A 1.0 psig Pressure Drop (Min:Secs) Distance Between Manholes Nominal Diameter (inches) 8 10 12 15 18 21 24 30 36 42 100' 7:33 9:26 11:20 14:10 17:00 19:50 22:47 35:37 51:17 69:48 150' 7:33 9:26 11:20 14:10 17:00 26:11 34:11 53:25 76:55 104:42 200' 7:33 9:26 11:23 17:48 25:38 34:54 45:34 71:13 102:34 139:37 250' 7:33 9:53 14:14 22:15 32:03 43:38 56:58 89:02 128:12 174:30 300' 7:35 11:52 17:05 26:42 38:27 52:21 68:22 106:50 153:50 209:24 350' 8:51 13:51 19:56 31:09 44:52 61:08 79:46 124:38 179:29 244:19 400' 10:07 15:49 22:47 35:36 51:17 69:48 91:10 142:26 205:07 279:13 450’ 11:23 17:48 25:38 40:04 57:41 78:32 102:33 160:15 230:46 314:07 Project No. 18088080 10 Section 40 05 00 Lake Lewisville WTP Dewatering Improvements Piping Systems Testing 500’ 12:39 19:47 28:29 44:31 64:06 87:15 113:57 178:03 256:24 349:01 D. Water Testing - Procedure 1. Water testing will be by either the infiltration method or by the exfiltration method if approved by the ENGINEER. Testing for water-tightness shall be made by the CONTRACTOR in the presence of the ENGINEER. The CONTRACTOR shall provide all equipment, plugs, bulkheads, fittings, water, etc. needed for the testing. The water used for testing shall be paid for by the CONTRACTOR. 2. The ENGINEER shall have the right to direct that either the infiltration or the exfiltration water testing be performed based on groundwater conditions at the time. 3. The tests and measurements of the infiltration method shall be as approved by the ENGINEER. In all cases, the pipeline shall not leak under exterior ground water pressure in excess of 100 gallons per inch of nominal pipe diameter per mile of pipe per 24 hours. Leaks causing any pipe to fail such test shall be repaired until infiltration meets the allowable limit. 4. If, in the opinion of the ENGINEER, the groundwater table at the time of testing is too low to produce dependable infiltration measurement results, the CONTRACTOR shall perform the exfiltration method test. The allowable limit shall be as given above including any manholes in the section(s) being tested. Water required for exfiltration test shall be obtained at the CONTRACTOR’s expense. 3.7 FIELD QUALITY CONTROL A. Test Report Documentation: 1. Date test performed 2. Description and identification of piping tested 3. Test fluid 4. Test pressure 5. Remarks, including: a. Leaks (define type and location) b. Repair/replacement performed to remedy excessive leakage 6. Signed by CONTRACTOR and ENGINEER to represent that test has been satisfactorily completed END OF SECTION Project No. 18088080 1 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General SECTION 40 23 39 - PROCESS PIPING - GENERAL PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Basic Process Piping Materials, Methods, and Appurtenances. B. Related sections: 1. Section 01 60 00 – Product Requirements. 2. Section 03 30 00 – Cast-In-Place Concrete. 3. Section 09 90 00 – Painting and Protective Coatings. 4. Section 22 05 29 – Process Supports and Anchors. 5. Section 22 05 53 – Mechanical Identification. 6. Section 31 23 23.16 – Trench Backfill. 7. Section 33 11 11 – Piping Leakage Testing. 8. Section 33 13 00 – Disinfection of Water Systems. 9. Section 40 41 13 – Heat Tracing. 10. Section 40 24 00 – Process Piping Specialties. 11. Section 40 42 00 – Process Mechanical Insulation. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this Section and any supplemental Data Sheets: 1. American Association of State Highway and Transportation Officials (AASHTO): Standard Specifications for Highway Bridges. 2. American National Standards Institute (ANSI): a. A21.52, Ductile Iron Pipe, Centrifugally Cast, for Gas. b. B1.20.1, Pipe Threads, General Purpose (Inch). c. B16.1, Cast Iron Pipe Flanges and Flanged Fittings. d. B16.3, Malleable Iron Threaded Fittings. e. B16.5, Pipe Flanges and Flanged Fittings. f. B16.9, Factory-Made Wrought Steel Butt welding Fittings. g. B16.11, Forged Fittings, Socket-Welding and Threaded. h. B16.15, Cast Bronze Threaded Fittings, Classes 125 and 250. i. B16.21, Nonmetallic Flat Gaskets for Pipe Flanges. j. B16.22, Wrought Copper and Copper Alloy Solder Joint Pressure Fittings. k. B16.24, Cast Copper Alloy Pipe Flanges and Flanged Fittings Class 150,300,400,600,900, 1500 and 2500. l. B16.25, Butt Welding Ends. m. B16.42, Ductile Iron Pipe Flanges and Flanged Fittings, Classes 150 and 300. 3. American Petroleum Institute (API): 5L, Specification for Line Pipe. 4. American Society of Mechanical Engineers (ASME): a. Boiler and Pressure Vessel Code, Section VITI, Division 1, Pressure Vessels. b. Boiler and Pressure Vessel Code, Section IX, Welding and Brazing Qualifications. c. B31.1, Power Piping. d. B31.3, Chemical Plant and Petroleum Refinery Piping. e. B31.9, Building Services Piping. f. B36.10M, Welded and Seamless Wrought Steel Pipe. 5. American Society for Nondestructive Testing (ASNT): SNT-TC-1A, Recommended Practice for Nondestructive Testing Personnel Qualifications. 6. American Society for Testing and Materials (ASTM): a. A47, Standard Specification for Ferritic Malleable Iron Castings. b. A53 Rev A, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated, Welded and Seamless. Project No. 18088080 2 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General c. A105/ A105M, Standard Specification for Forgings, Carbon Steel, for Piping Components. d. A106, Standard Specification for Seamless Carbon Steel Pipe for High Temperature Service. e. A126, Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings. f. A135, Standard Specification for Electric-Resistance-Welded Steel Pipe. g. A139 Rev A, Standard Specification for Electric-Fusion (Arc) -Welded Steel Pipe (NPS 4 and Over). h. A153, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. i. A181/A181M Rev A, Standard Specification for Forgings, Carbon Steel, for General-Purpose Piping. j. A182/A182M Rev C, Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service. k. A183, Standard Specification for Carbon Steel Track Bolts and Nuts. l. A193/A193M Rev A, Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service. m. A194/A194M, Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service. n. A197, Standard Specification for Cupola Malleable Iron. o. A216/A216M, Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High Temperature Service. p. A234/A234M, Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures. q. A240, Standard Specification for Heat-Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessels. r. A276, Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes. s. A283/A283M Rev A, Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates. t. A285/ A285M, Standard Specification for Pressure Vessel Plates, Carbon Steel, Low and Intermediate Tensile Strength. u. A307, Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength. v. A312/A312M, Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipes. w. A320/A320M, Standard Specification for Alloy Steel Bolting Materials for Low- Temperature Service. x. A395, Standard Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures. y. A403/ A403M Rev A, Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings. z. A409/ A409M, Standard Specification for Welded Large Diameter Austenitic Steel Pipe for Corrosive or High-Temperature Service. aa. A536, Standard Specification for Ductile Iron Castings. bb. A563, Standard Specification for Carbon and Alloy Steel Nuts. cc. 587, Standard Specification for Electric-Resistance-Welded Low-Carbon Steel Pipe for the Chemical Industry. dd. A774/A774M, Standard Specification for As-Welded Wrought Austenitic Stainless Steel Fittings for General Corrosive Service at Low and Moderate Temperatures. ee. A778 Rev A, Standard Specification for Welded, Un-annealed Austenitic Stainless Steel Tubular Products. ff. B32, Standard Specification for Solder Metal. gg. B43, Standard Specification for Seamless Red Brass Pipe, Standard Sizes. hh. B61, Standard Specification for Steam or Valve Bronzed Casting. Project No. 18088080 3 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General ii. B62, Standard Specification for Composition Bronzed or Ounce Metal Castings. jj. B75, Standard Specification for Seamless Copper Tube. kk. B88 Rev A, Standard Specification for Seamless Copper Water Tube. ll. B98, Standard Specification for Copper-Silicone Alloy Rod, Bar, and Shapes. mm. 582, Standard Specification for Contact-Molded Reinforced Thermosetting Plastic (RTP) Laminates for Corrosion Resistant Equipment. nn. D412, Standard Testing Method for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers-Tension. oo. D413, Standard Testing Methods for Rubber Property-Adhesion to Flexible Substrate. pp. D1248, Standard Specification for Polyethylene Plastics Molding and Extrusion Materials. qq. D1784, Standard Specifications for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds. rr. D1785, Standard Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120. ss. D2000, Standard Classification System for Rubber Products in Automotive Applications. tt. D2310, Standard Classification for Machine-Made “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe. uu. D2464, Standard Specification for Threaded Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. vv. 2466, Standard Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 40. ww. D2467, Standard Specification for Socket-Type Poly (Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. xx. D2564, Standard Specification for Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Piping Systems. yy. D2665, Standard Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe for Drain, Waste, and Vent Pipe and Fittings, Schedule 40. zz. D2996, Standard Specification for Filament-Wound “Fiberglass” (Glass-Fiber-Reinforced Thermosetting Resin) Pipe. aaa. D3222 Rev A, Standard Specification for Unmodified Poly (Vinylidene Fluoride) (PVDF) Molding Extrusion and Coating Materials. bbb. D3350, Standard Specification for Polyethylene Plastics Pipe and Fittings Materials. ccc. D4101 Rev B, Standard Specification for Propylene Plastic Injection and Extrusion Materials. ddd. F437, Standard Specification for Threaded Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80. eee. F439 Rev A, Standard Specification for Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80. fff. F441, Standard Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80. ggg. F491 Rev A, Standard Specification for Poly (Vinylidene Fluoride) (PVDF) Plastic-Lined, Ferrous Metal Pipes, and Fittings. hhh. F493 Rev A, Standard Specification for Solvent Cements for Chlorinated Poly Vinyl Chloride) (CPVC) Plastic Pipe and Fittings. iii. F714, Standard Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) based on outside diameter. 7. American Welding Society (AWS): a. A5.8, Specification for Filler Metals for Brazing and Braze Welding. b. QC 1, Standard for AWS Certification of Welding Inspectors. 8. American Water Works Association (AWWA): a. C104/A21.4, Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water. Project No. 18088080 4 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General b. C110/A21.10, Ductile-Iron and Gray-Iron Fittings, 3” through 48”for Water and Other Liquids. c. C111/A21.11, Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings. d. C115/A21.15, Flanged Ductile-Iron Pipe with Threaded Flanges. e. C151/A21.51, Ductile-Iron Pipe, Centrifugally Cast, for Water or Other Liquids. f. C153/A21.53, Ductile-Iron Compact Fittings 3” through 16”, for Water and Other Liquids. g. C200, Steel Water Pipe – 6” and Larger. h. C205, Cement-Mortar Protective Lining and Coating for Steel Water Pipe-4” and Larger-Shop Applied. i. C207, Steel Pipe Flanges for Water Works Service, Sizes 4” through 144”. j. C208, Dimensions for Fabricated Steel Water Pipe Fittings. k. C214, Fusion Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines. l. C606, Grooved and Shouldered Type Joints. m. M11, Steel Pipe - A Guide for Design and Installation. 9. Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (MSS): SP 43, Wrought Stainless Steel Butt-Welding Fittings Including Reference to Other Corrosion Resistant Materials. 10. National Fire Protection Association (NFPA): 24, Standard for the Installation of Private Fire Service Mains and Their Appurtenances. 1.3 DEFINITIONS A. Submerged or Wetted: 1. Zone below elevation of: a. Top face of channel walls and cover slabs. b. Top face of basin walkways. c. Top face of clarifier walkways. d. Top face of digester walls, including structure piping penetrations. e. Liquid surface or within 2 feet above top of liquid surface. f. Top of tank wall or under tank cover. 1.4 SUBMITTALS A. Shop Drawings: 1. Shop Fabricated Piping: a. Detailed pipe fabrication or spool drawings showing special fittings and bends, dimensions, coatings, and other pertinent information. b. Layout drawing showing location of each pipe section and each special length; number or otherwise designate laying sequence on each piece. 2. Pipe Wall Thickness: Identify wall thickness and rational method or standard applied to determine wall thickness for each size of each different service including exposed, submerged, buried, and concrete-encased installations for Contractor-designed piping. 3. Hydraulic Thrust Restraint for Restrained Joints: Details including materials, sizes, assembly ratings, and pipe attachment methods. 4. Thrust Blocks: Concrete quantity, bearing area on pipe, and fitting joint locations. 5. Dissimilar Buried Pipe Joints: Joint types and assembly drawings. 6. Gasket material, temperature rating, and pressure rating for each type of pipe and each type of service. B. Quality Control Submittals: 1. Manufacturer’s Certification of Compliance. 2. Qualifications: a. Weld Inspection and Testing Agency: Certification and qualifications. b. Welding Inspector: Certification and qualifications. Project No. 18088080 5 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General c. Welders: 1) List of qualified welders and welding operators. 2) Current test records for qualified welder(s) and weld type(s) for factory and field welding. 3. Weld Procedures: Records in accordance with ASME Boiler and Pressure Vessel Code, Section IX for weld type(s) and base metal(s). 4. Nondestructive inspection and testing procedures. 5. Manufacturer’s Certification of Compliance: a. Pipe and fittings. b. Factory applied resins and coatings. 6. Certified weld inspection and test reports. 7. Test logs. 1.5 QUALITY ASSURANCE A. Weld Inspection and Testing Laboratory Qualifications: 1. Retain approved independent testing laboratory that will provide the services of an AWS certified welding inspector qualified in accordance with AWS QC1 with prior inspection experience of welds specified herein. 2. Perform weld examinations with qualified testing personnel who will carry out radiography, ultrasonic, magnetic particle, and other nondestructive testing methods as specified herein. 3. Welding Inspector: a. Be present when shop or field welding is performed to certify that welding is in accordance with specified standards and requirements. b. Duties include, but are not limited to, the following: 1) Job material verification and storage. 2) Qualification of welders. 3) Certify conformance with approved welding procedure specifications. 4) Maintain records and prepare reports in a timely manner. 5) Notify Engineer within 1 hour of discovery of unsatisfactory weld perfor- mance and within 24 hours of weld test failure. 6) Supervision of testing personnel. B. Welder and Welding Operator Performance: 1. Qualify welders and welding operators by approved testing laboratory before performing any welding under this section. 2. Perform welder qualification tests in accordance with Section IX, Article III of the ASME Boiler and Pressure Vessel Code. 3. Qualification tests may be waived if evidence of prior qualification is deemed suitable by the Engineer. 4. Qualify welders and operators in the performance of making groove welds in each different pipe material, including carbon steel pipe, in Positions 2G and 5G for each welding process to be used. 5. Qualify welders and welding operators for stainless steel as stated herein on the type of stainless steel being welded with the welding process used. C. Certifications: 1. Coal-Tar Epoxy Applicator: Certified by Piping Manufacturer to be qualified to apply coal- tar epoxy coating to submerged or embedded ductile iron or cast iron soil piping. 2. Weld Testing Agency: Certified in accordance with current American Society for Nondestructive Testing (4153 Arlingate Plaza, Columbus, OH 43228) recommended practice SNT-TC-1A, NDT Level II. D. Quality Control Submittals: 1. Manufacturer’s Certification of Compliance. Project No. 18088080 6 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General 2. Laboratory Testing Equipment: Certified calibrations, Manufacturer’s product data, and test procedures. 3. Certified welding inspection and test results. 4. Qualifications: a. Weld Inspection and Testing Agency: Certification and qualifications. b. Welding Inspector: Certification and qualifications. c. Welders: 1) List of qualified welders and welding operators. 2) Current test records for qualified welder(s) and weld type(s) for factory and field welding. 5. Weld Procedures: Records in accordance with ASME Boiler and Pressure Vessel Code, Section IX for weld type(s) and base metal(s). 6. Nondestructive inspection and testing procedures. 7. Manufacturer’s Certification of Compliance: a. Pipe and fittings. b. Welding electrodes and filler materials. c. Factory applied resins and coatings. 8. Certified weld inspection and test reports. 9. Pipe coating applicator certification. 1.6 DELIVERY, STORAGE, AND HANDLING A. In accordance with Section 01 60 00, PRODUCT REQUIREMENTS, and: 1. Flanges: Securely attach metal, hardboard, or wood protectors over entire gasket surface. 2. Threaded or Socket Welding Ends: Fit with metal, wood, or plastic plugs or caps. 3. Linings and Coatings: Prevent excessive drying. 4. Cold Weather Storage: Locate products to prevent coating from freezing to ground. 5. Handling: Use heavy canvas or nylon slings to lift pipe and fittings. PART 2 - PRODUCTS 2.1 PIPING A. As specified on Piping Data Sheet(s) and Piping Schedule located at the end of this section as Supplement. B. Diameters Shown: 1. Standardized Products: Nominal size. 2. Fabricated Steel Piping (Except Cement-Lined): Outside diameter, ASME 836.l0M. 3. Cement-Lined Steel Pipe: Lining inside diameter. 2.2 JOINTS A. Grooved End System: 1. Rigid, except where joints are used to correct misalignment, to provide flexibility, or where shown, furnish flexible type. 2. Flanges: When required, furnish with grooved type flange adapters of same manufacturer as grooved end couplings. B. Flanged Joints: 1. Flat-faced carbon steel or alloy flanges when mating with flat-faced cast or ductile iron flanges. 2. Higher pressure rated flanges as required, to mate with equipment when equipment flange is of higher pressure rating than required for piping. Project No. 18088080 7 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General C. Threaded Joints: NPT taper pipe threads in accordance with ANSI B 1.20. 1. D. Thrust Tie-Rod Assemblies: NFPA 24; tie-rod attachments relying on clamp friction with pipe barrel to restrain thrust are unacceptable. E. Mechanical Joint Anchor Gland Follower: 1. Ductile iron anchor type, wedge action, with break off tightening bolts. 2. Manufacturer and Product: EBAA Iron Inc.; Megalug. F. Flexible Mechanical Compression Joint Coupling: 1. Stainless steel, ASTM A276, Type 305 bands. 2. Manufacturers: a. Pipeline Products Corp. b. Ferno Joint Sealer Co. G. Mechanical connections of the high density polyethylene pipe to auxiliary equipment such as valves, pumps, tanks, and other piping systems shall be through flanged connections consisting of the following: 1. A polyethylene stub end thermally butt-fused to the end of the pipe. 2. ASTM A240, Type 304 stainless steel backing flange, 125-pound, ANSI B16.1 Standard. Insulating flanges shall be used where shown. 3. Bolts and nuts of sufficient length to show a minimum of three complete threads when the joint is made and tightened to the Manufacturer’s standard. Re-torque the nuts after 4 hours. 4. Gaskets as specified on Data Sheet. H. Press-Fit 1. Stainless Steel, Type 304L/316L, ASTM A312 2. Fitting material and type shall match connecting pipe material and type. 3. Manufacturers: a. Victaulic b. Anvil International c. Or equal 2.3 COUPLINGS A. Steel Middle Rings and Followers: 1. Fusion bonded, epoxy-lined, and coated in accordance with Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. B. Flexible Couplings: 1. Manufacturers and Products: a. Steel Pipe: 1) Dresser; Style 38. 2) Smith-Blair; Style 411. b. Ductile Iron Pipe: 1) Dresser; Style 153. 2) Smith-Blair; Style 411. C. Transition Couplings: 1. Manufacturers and Products: a. Dresser; Style 162. b. Smith-Blair; Style 413. D. Flanged Coupling Adapters: Project No. 18088080 8 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General 1. Manufacturers and Products: a. Steel Pipe: 1) Smith-Blair; Series 913. 2) Dresser Industries, Inc.; Style 128. b. Ductile Iron Pipe: 1) Smith-Blair; Series 912. 2) Dresser Industries, Inc.; Style 127. 2.4 GASKET LUBRICANT A. Lubricant shall be supplied by pipe Manufacturer and no substitute or “or-equal” will be allowed. 2.5 DOUBLE WALL CONTAINMENT PIPING SYSTEM A. All system components shall be pre-engineered, factory fabricated, tested, and assembled such that field assembly is minimized to primarily that of straight joints. 2.6 THRUST BLOCKS A. Concrete: As specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. 2.7 VENT AND DRAIN VALVES A. Pipeline 2-1/2” Diameter and Larger: Vent connections shall be 3/4-inch with V300 ball valve. Drain connection shall be 1-inch with V300 ball valve, unless shown otherwise. B. Pipeline 2” Diameter and Smaller: Vent connections shall be 1/2-inch with V300 ball valve. Drain connection shall be 1-inch with V300 ball valve, unless shown otherwise. C. Provide galvanized steel pipe plug in each ball valve. 2.8 FABRICATION A. Mark each pipe length on outside: 1. Size or diameter and class. 2. Manufacturer’s identification and pipe serial number. 3. Location number on laying drawing. 4. Date of manufacture. B. Code markings according to approved Shop Drawings. C. Flanged pipe shall be fabricated in the shop, not in the field, and delivered to the site with flanges in place and properly faced. Threaded flanges shall be individually fitted and machine tightened on matching threaded pipe by the Manufacturer. 2.9 FINISHES A. Factory prepare, prime, and finish coat in accordance with Pipe Data Sheet(s), Piping Schedule, and Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. B. Galvanizing: 1. Hot-dip applied, meeting requirements of ASTM A153. 2. Electroplated zinc or cadmium plating is unacceptable. 3. Stainless steel components may be substituted where galvanizing is specified. Project No. 18088080 9 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General PART 3 - EXECUTION 3.1 EXAMINATION A. Verify size, material, joint types, elevation, horizontal location, and pipe service of existing pipelines to be connected to new pipelines or new equipment. B. Inspect size and location of structure penetrations to verify adequacy of wall pipes, sleeves, and other openings. C. Welding Electrodes: Verify proper grade and type, free of moisture and dampness, and coating is undamaged. 3.2 PREPARATION A. Notify Engineer at least 2 weeks prior to field fabrication of pipe or fittings. B. Inspect pipe and fittings before installation, clean ends thoroughly, and remove foreign matter and dirt from inside. C. Damaged Coatings and Linings: Repair using original coating and lining materials in accordance with Manufacturer’s instructions, except for damaged glass-lined pipe or PVDF- lined pipe that is to be promptly removed from the site. 3.3 WELDING A. Perform in accordance with Section IX, ASME Boiler and Pressure Vessel Code and ASME B31.1 for Pressure Piping, as may be specified on Piping Data Sheets, and if recommended by piping or fitting Manufacturer. B. Weld Identification: Mark each weld with symbol identifying welder. C. Pipe End Preparation: 1. Machine Shaping: Preferred. 2. Oxygen or Arc Cutting: Smooth to touch, true, and slag removal by chipping or grinding. 3. Beveled Ends for Butt Welding: ANSI B16.25. D. Surfaces: 1. Clean and free of paint, oil, rust, scale, slag, or other material detrimental to welding. 2. Clean stainless-steel joints with stainless steel wire brushes or stainless steel wool prior to welding. 3. Thoroughly clean each layer of deposited weld metal, including final pass, prior to deposition of each additional layer of weld metal with a power-driven wire brush. E. Alignment and Spacing: 1. Align ends to be joined within existing commercial tolerances on diameters, wall thicknesses, and out-of-roundness. 2. Root Opening of Joint: As stated in qualified welding procedure. 3. Minimum Spacing of Circumferential Butt Welds: Minimum four times pipe wall thickness or 1”, whichever is greater. F. Climatic Conditions: 1. Do not perform welding if there is impingement of any rain, snow, sleet or high wind on the weld area, or if the ambient temperature is below 32 °F. Project No. 18088080 10 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General 2. Stainless Steel and Alloy Piping: f the ambient is less than 32 °F, local preheating to a temperature warm to the hand is required. G. Tack Welds: Performed by qualified welder using same procedure as for completed weld, made with electrode similar or equivalent to electrode to be used for first weld pass, and not defective. Remove those not meeting requirements prior to commencing welding procedures. H. Surface Defects: Chip or grind out those affecting soundness of weld. I. Weld Passes: As required in welding procedure. J. Weld Quality: Free of cracks, incomplete penetration, weld undercutting, excessive weld reinforcement, porosity slag inclusions, and other defects in excess of limits shown in applicable piping code. 3.4 INSTALLATION - GENERAL A. Join pipe and fittings in accordance with Manufacturer’s instructions, unless otherwise shown or specified. B. Remove foreign objects prior to assembly and installation. C. Flanged Joints: 1. Install perpendicular to pipe centerline. 2. Bolt Holes: Straddle vertical centerlines, aligned with connecting equipment flanges or as shown. 3. Use torque-limiting wrenches to ensure uniform bearing and proper bolt tightness. 4. Plastic Flanges: Install annular ring filler gasket at joints of raised-face flange. 5. Raised-Face Flanges: Use flat-face flange when joining with flat-faced ductile or cast iron flange. D. Threaded and Coupled Joints: 1. Conform to ANSI B1.20.1. 2. Produce sufficient thread length to ensure full engagement when screwed home in fittings. 3. Countersink pipe ends, ream and clean chips and burrs after threading. 4. Make connections with not more than three threads exposed. 5. Lubricate male threads only with thread lubricant or tape as specified on Piping Data Sheets. E. Soldered Joints: 1. Use only solder specified for particular service. 2. Cut pipe ends square and remove fins and burrs. 3. After thoroughly cleaning pipe and fitting of oil and grease using solvent and emery cloth, apply non-corrosive flux to the male end only. 4. Wipe excess solder from exterior of joint before hardened. 5. Before soldering, remove stems and washers from solder joint valves. F. Press-Fit 1. Install in accordance with Manufacturer’s written instructions. 2. Press tool shall be approved by Manufacturer. G. Couplings: 1. General: a. Install in accordance with Manufacturer’s written instructions. Project No. 18088080 11 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General b. Before coupling, clean pipe holdback area of oil, scale, rust, and dirt. c. Remove pipe coating if necessary to present smooth surface. 2. Application: a. Metallic Piping Systems: Flexible couplings, transition couplings, and flanged coupling adapters. b. Nonmetallic Piping Systems: Teflon bellows connector. c. Concrete Encased Couplings: Sleeve type coupling. d. Corrosive Service Piping: Elastomer bellows connector. e. Grit Slurry Piping: Elastomer bellows connector. H. Service Saddle Applications: 1. Ferrous Metal Piping (except stainless steel): Double-strap iron. 2. Plastic Piping: Nylon-coated iron. 3. Buried Plastic Piping (Odor Control): PVC solvent weld saddle with retaining clamps. I. Pipe Connections at Concrete Structures: As specified in article PIPING FLEXIBILITY PROVISIONS in Section 40 24 00, PROCESS PIPING SPECIALTIES. J. Penetrations: 1. Watertight Penetrations: a. Provide wall pipes with thrust collars, as specified in Section 40 24 00, PROCESS PIPING SPECIALTIES. b. Provide taps for stud bolts in flanges to be set flush with wall face. 2. Non-watertight Penetrations: a. Pipe sleeves with seep ring as specified in Section 40 24 00, PROCESS PIPING SPECIALTIES. b. Pipe sleeves with modular mechanical seal may be provided where fabrication of seep ring on pipe sleeve is impractical. 3. Existing Walls: a. Pipe sleeve with modular mechanical seal as specified in Section 40 24 00, PROCESS PIPING SPECIALTIES. b. Rotary drilled holes may be provided in lieu of sleeves in concrete walls. 4. Fire-Rated or Smoke-Rated Walls, Floor, or Ceilings: Insulated and encased pipe sleeves as specified in Section 40 24 00, PROCESS PIPING SPECIALTIES. K. PVC and CPVC Piping: 1. Provide Schedule 80 threaded nipple where necessary to connect to threaded valve or fitting. 2. Use strap wrench for tightening threaded plastic joints. Do not over tighten fittings. 3. Do not thread Schedule 40 pipe. L. Ductile Iron, Cement-Lined Ductile Iron, and Glass-Lined Ductile Iron Piping: 1. Cutting Pipe: Cut pipe with milling type cutter, rolling pipe cutter, or abrasive saw cutter. Do not flame cut. 2. Dressing Cut Ends: a. General: As required for the type of joint to be made. b. Rubber Gasketed Joints: Remove sharp edges or projections. c. Push-On Joints: Bevel, as recommended by pipe Manufacturer. d. Flexible Couplings, Flanged Coupling Adapters, and Grooved End. e. Pipe Couplings: As recommended by the coupling or adapter Manufacturer. 3.5 INSTALLATION-EXPOSED PIPING A. Piping Runs: 1. Parallel to building or column lines and perpendicular to floor, unless shown otherwise. Project No. 18088080 12 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General 2. Piping upstream and downstream of flow measuring devices shall provide straight lengths as required for accurate flow measurement. B. Supports: As specified in Section 22 05 29, PROCESS SUPPORTS AND ANCHORS. C. Group piping wherever practical at common elevations; installing to conserve building space and not interfere with use of space and other work. D. Unions or Flanges: Provide at each piping connection to equipment or instrumentation on equipment side of each block valve to facilitate installation and removal. E. Install piping so that no load or movement in excess of that stipulated by equipment Manufacturer will be imposed upon equipment connection; install to allow for contraction and expansion without stressing pipe, joints, or connected equipment. F. Piping clearance, unless otherwise shown: 1. Over Walkway and Stairs: Minimum of 7’ 6”, measured from walking surface or stair tread to lowest extremity of piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems. 2. Between Equipment or Equipment Piping and Adjacent Piping: Minimum 3’ 0”, measured from equipment extremity and extremity of piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems. 3. From Adjacent Work: Minimum 1” from nearest extremity of completed piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems. 4. Do not route piping in front of or to interfere with access ways, ladders, stairs, platforms, walkways, openings, doors, or windows. 5. Head room in front of openings, doors, and windows shall not be less than the top of the opening. 6. Do not install piping containing liquids or liquid vapors in transformer vaults or electrical equipment rooms. 7. Do not route piping over, around, in front of, in back of, or below electrical equipment including controls, panels, switches, terminals, boxes, or other similar electrical work. 3.6 INSTALLATION-BURIED PIPE A. Joints: 1. Dissimilar Buried Pipes: a. Provide flexible mechanical compression joints for pressure pipe. b. Provide concrete closure collar for gravity and low pressure (maximum 10 psi) piping or as shown. 2. Concrete Encased or Embedded Pipe: Do not encase joints in concrete unless specifically shown. B. Placement: 1. Keep trench dry until pipe laying and joining are completed. 2. Pipe Base and Pipe Zone: As specified in Section 31 23 23.16, TRENCH BACKFILL. 3. Exercise care when lowering pipe into trench to prevent twisting or damage to pipe. 4. Measure for grade at pipe invert, not at top of pipe. 5. Excavate trench bottom and sides of ample dimensions to permit visual inspection and testing of entire flange, valve, or connection. 6. Prevent foreign material from entering pipe during placement. 7. Close and block open end of last pipe section laid when placement operations are not in progress and at close of day’s work. 8. Lay pipe upgrade with bell ends pointing in the direction the pipe is laying. 9. Install closure sections and adapters for gravity piping at locations where pipe laying changes direction. Project No. 18088080 13 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General 10. Deflect pipe at joints for pipelines laid on a curve using unsymmetrical closure of spigot into bell. If joint deflection of standard pipe lengths will not accommodate horizontal or vertical curves in alignment, provide: a. Shorter pipe lengths. b. Special mitered joints. c. Standard or special fabricated bends. 11. After joint has been made, check pipe alignment and grade. 12. Place sufficient pipe zone material to secure pipe from movement before next joint is installed. 13. Prevent uplift and floating of pipe prior to backfilling. C. PVC and CPVC Pipe Placement: 1. Lay pipe snaking from one side of trench to other. 2. Offset: As recommended by Manufacturer for maximum temperature variation between time of solvent welding and during operation. 3. Do not lay pipe when temperature is below 40 °F, or above 90 °F when exposed to direct sunlight. 4. Shield ends to be joined from direct sunlight prior to and during the laying operation. D. Tolerances: 1. Deflection from Horizontal Line, Except PVC, CPVC, or HDPE: Maximum 2”. 2. Deflection from Vertical Grade: Maximum 1/4”. 3. Joint Deflection: Maximum of 75% of Manufacturer’s recommendation. 4. Horizontal position of pipe centerline on alignment around curves maximum variation of 1.75’ from position shown. 5. Pipe Cover: Minimum 5’, unless otherwise shown. 3.7 THRUST RESTRAINT A. Location: 1. Buried Piping: At pipeline tees, plugs, caps, bends, and other locations where unbalanced forces exist. 2. Exposed Piping: At all joints in pressure piping. B. Thrust Ties: 1. Install as detailed. 2. Anchoring retainer glands or thrust ties with setscrews is unacceptable. C. Mechanical Joint Valve Restraint in Proprietary Restrained Joint Piping: Install pipe joint Manufacturer’s adapter gland follower and pipe end retainer, or thrust tie-rods and socket clamps. D. Thrust Blocking: 1. Place between undisturbed ground and fitting to be anchored. 2. Quantity of Concrete: Sufficient to cover bearing area on pipe and provide required soil bearing area as shown. 3. Place blocking so that pipe and fitting joints will be accessible for repairs. 4. Place concrete in accordance with Section 03 30 00, CAST-IN-PLACE CONCRETE. 3.8 WALL PIPES A. Applications: As specified in Section 40 24 00, PROCESS PIPING SPECIALTIES. B. Wall Pipe Installation: Project No. 18088080 14 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General 1. Isolate embedded metallic piping from concrete reinforcement using coated pipe penetrations as specified in Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. 2. Support wall pipes securely by formwork to prevent contact with reinforcing steel and tie wires. 3.9 BRANCH CONNECTIONS A. Do not install branch connections smaller than 1/2-inch nominal pipe size, including instrument connections, unless shown otherwise. B. When line of lower pressure connects to a line of higher pressure, requirements of Piping Data Sheet for higher pressure rating prevails up to and including the first block valve in the line carrying the lower pressure, unless otherwise shown. C. Threaded Pipe Tap Connections: 1. Ductile Iron Piping: Connect only with service saddle or at a tapping boss of a fitting, valve body, or equipment casting. 2. Welded Steel or Alloy Piping: Connect only with welded thread-o-let or half-coupling as specified on Piping Data Sheet. 3. Limitations: Threaded taps in pipe barrel are unacceptable. 3.10 VENTS AND DRAINS A. Vents and drains at high and low points in piping required for completed system may or may not be shown. Install the vents on high points, and drains on low points of pipelines, whether shown or not. 3.11 CLEANING A. Following assembly and testing, and prior to disinfection and final acceptance, flush pipelines (except as stated below) with water at 2.5 fps minimum flushing velocity until foreign matter is removed. B. Blow clean of loose debris plant process air, natural gas, and instrument air-lines with compressed air at 4,000 fpm; do not flush with water. C. If impractical to flush large diameter pipe at 2.5 fps or blow at 4,000 fpm velocity, clean in-place from inside by brushing and sweeping, then flush or blow line at lower velocity. D. Insert cone strainers in flushing connections to attached equipment and leave in-place until cleaning is complete. E. Remove accumulated debris through drains 2” and larger or by removing spools and valves from piping. 3.12 DISINFECTION A. Disinfect pipelines intended to carry potable water (W1). B. See Section 33 13 00, DISINFECTION OF WATER SYSTEMS Project No. 18088080 15 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General 3.13 FIELD FINISHING A. Notify Engineer at least 3 days prior to start of any surface preparation or coating application work. B. As specified in Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. 3.14 PIPE IDENTIFICATION A. See Section 22 05 53, MECHANICAL IDENTIFICATION and 09 90 00 PAINTING AND PROTECTIVE COATINGS. 3.15 INSULATION A. See Section 40 42 00, PROCESS MECHANICAL INSULATION. 3.16 HEAT TRACING A. See Section 40 41 13, HEAT TRACING. 3.17 FIELD QUALITY CONTROL A. Pressure Leakage Testing: As specified. See Section 33 11 11, PIPING LEAKAGE TESTING. B. Minimum Duties of Welding Inspector 1. Job material verification and storage 2. Qualifications of welders. 3. Certify conformance with approved welding procedures. 4. Maintenance of records and preparation of reports in a timely manner 5. Notification to Engineer of unsatisfactory weld performance within 24 hours of weld test failure. C. Required Weld Examinations: 1. Perform Examinations in accordance with Piping Code ASME B31.1. 2. Perform examinations for every pipe thickness and for each welding procedure, progressively, for all piping covered by this section. 3. Examine at least one of each type and position of weld made by each welder or welder operator. 4. For each weld found to be defective under the acceptable standards or limitations on imperfections contained in the applicable Piping Code, examine two additional welds made by the same welder that produced the defective weld. Such additional examinations are in addition to the minimum required above 3. Examine, progressively, two additional welds for each tracer examination found to be unsatisfactory. 3.18 SUPPLEMENTS A. The supplements listed below, following “END OF SECTION,” are a part of this Specification. 1. Piping Schedule. 2. Data Sheets. Number Title 40 23 39.13 Ductile Iron Pipe and Fittings 40 23 39.40 C900 & C905 PVC Pipe and Fittings 40 23 39.43 Polyvinyl Chloride (PVC) Pipe and Fittings 40 23 39.46 Chlorinated Polyvinyl Chloride (CPVC) Pipe and Fittings Project No. 18088080 16 Section 40 23 39 Lake Lewisville WTP Dewatering Improvements Process Piping - General 40 23 39.53 Copper and Copper Alloy Pipe, Tubing, and Fittings END OF SECTION Project No. 18088080 1 of 1 40 23 39 Supplement Lake Lewisville WTP Dewatering Improvements Process Piping Schedule Notes: 1 Encased – All buried piping under concrete slabs 4 H - Hydrostatic Test and/or structures shall be concrete encased per P - Pneumatic Test standard detail D40/2400-009 unless indicated G - Gravity Piping otherwise on the Drawings. See Section 33 11 11 for Piping Leakage Testing requirements, for systems specified in Division 33 Exposed – Inside/Outside AM – Air Method Submerged – Below Liquid Surface HH – High Head Buried – Directly into Soil LH – Low Head 2 > Greater Than LP – Low-Pressure Pneumatic Test < Less Than See Section 40 05 00 for Piping Leaking Testing requirements for systems specified in Division 40. <= Less Than or Equal To Pipe testing required as specified above. >= Greater Than or Equal To 5 See Section 09 90 00 for required painting. 3 BS – Black Steel For buried piping, no color shall be required; coordinate for proper coatings, as necessary. CLDI – Cement Lined Ductile Iron Where no color is indicated, color to be selected by Owner. CPVC - Chlorinated Polyvinyl Chloride For exposed piping not coated, provide colored banding and identification. CU – Copper 6 General - Deviations from this schedule are indicated directly by note on Drawings where DWV – Drain Waste Vent deviation is required. HDPE – High Density Polyethylene 7 General – The piping material shall conform to the requirements for the service listed being SST - Stainless Steel drained or vented. FL PVC – Flanged Polyvinyl Chloride Pipe 8 EPP – Epoxy and Polyurethane Coating System PO PVC – Push on Joint Polyvinyl Chloride Pipe HSE – High Solids Epoxy SW PVC – Solvent Weld Polyvinyl Chloride Pipe CTP – Coal Tar Pitch HT – High Temperature Remarks: 1 Where buried piping transitions to exposed PVC piping, the buried piping shall be extended at least six (6) inches above the finished floor before transitioning to exposed PVC piping. 2 Natural gas piping shall be tested in accordance with Section 406 of the International Fuel Gas Code. 3 SW PVC or FL PVC, FL PVC where shown 4 Heat trace and insulate all outside piping PROCESS PIPING SCHEDULE Service Flow Stream Identifier Installation (Note 1) Nominal Diameter (Note 2) Material (Note 3) Coating (Note 8) Spec / Data Sheet No. Max Operating Temp (°F) Max Operating Pressure (psig) Test Pressure (psig) & Method (Note 4) Pipe Color (Note 5) Remarks Backwash Waste/Settled Water Waste BWW/SWW Exposed – Outside Buried Buried All <16” ≥16” CLDI CLDI C900/905 PVC HSE - - 40 23 39.13 40 23 39.13 40 23 39.40 Ambient 25 50, H 4 Gravity Filtered Water GFW Buried All SDR 26 PVC - 40 23 39.43 Ambient Gravity Flow 4,G Cationic Polymer PO Exposed – Inside All CPVC - 40 23 39.46 Ambient 50 100, HH Liquid Polymer POL Exposed - Inside All CPVC - 40 23 39.46 Ambient 50 100, HH Plant/Process Drain PD Sump Pump Discharge All PVC - 40 23 39.43 Ambient Gravity Flow 4, G Plant/Process Drain PD Buried Encased Exposed - Outside All All All SDR 26 PVC DWV CLDI - - 40 23 39.43 40 23 39.42 40 23 39.13 Ambient Gravity Flow Gravity Flow 20 4, G 4, G 40, H Thickened Residuals TR Encased Exposed – Outside Exposed – Inside All CLDI CLDI CLDI - - - 40 23 39.13 40 23 39.13 40 23 39.13 Ambient 20 40, H 4 Water, Potable W, W1 Exposed – Inside Buried Buried All ≥4” <4” CU C900/905 PVC CU HT - - 40 23 39.53 40 23 39.40 40 23 39.53 150 Ambient Ambient 100 200, H Purple - - Water, Non-Potable NPW, W2 Buried Exposed – Inside All C900/905 PVC CLDI - - 40 23 39.40 40 23 39.13 Ambient 80 120 160. HH 240, HH Project No. 18088080 1 of 3 40 23 39.13 Data Sheet Lake Lewisville WTP Dewatering Improvements Ductile Iron Pipe and Fittings SECTION 40 23 39.13 DUCTILE IRON PIPE AND FITTINGS Item Description Pipe Buried Liquid Service: Push-On, Mechanical, or Proprietary Restrained Joints: AWWA C110/A21.10-93, AWWA C115/A21.15- 88, and AWWA C151/A21.51-91, pressure class conforming to Tables 51.1 and 51.3 for Type 4 trench, 250 psi minimum working pressure. Exposed Pipe: Grooved End or Flange Joints: AWWA C115/A21.15-88, and AWWA C151/A21.51-91, thickness Class 53 minimum conforming to Table 51.7, 250 psi minimum working pressure. Coating Buried Pipe: Exterior coating used under normal conditions shall be an asphaltic coating approximately 1 mil (25 μm) thick and per AWWA C151/A21.51-17. Exposed Pipe: Shall be as indicated in the schedule. Encasement Polyethylene encasement shall be used on all underground ductile iron pipe, fittings, valves, and appurtenances. See Specification Section 40 42 13.16 – POLYETHEYLENE ENCASEMENT FOR DUCTILE IRON AND CAST IRON PIPE. Lining Lining shall be Cement-Mortar AWWA C104/A21.4-90 unless noted otherwise. Ceramic Epoxy Protecto 401 or equal shall be used where indicated in the pipe schedule. Glass Lining: VITCO Corp. SG-14 or equal shall be used where indicated in the schedule. Linings for fittings shall be as indicated below. Joints Push-On: 250 psi minimum working pressure, AWWA C110/A21.10- 93 and C111/A21.11-90. American Cast Iron Pipe Co., Fastite Joints; U.S. Pipe and Foundry, Tyton Joint. Mechanical: 250 psi minimum working pressure, AWWA C111. American Cast Iron Pipe Co., Mechanical Joint; U.S. Pipe and Foundry, Mechanical Joint. Proprietary Restrained: 150 psi minimum working pressure. Clow Corp., Super-Lock; American Cast Iron Pipe Co., Flex-Ring or Lok- Ring; U.S. Pipe, TR Flex. Grooved End: Rigid type radius cut conforming to AWWA C606-87, 250 psi minimum working pressure. Victaulic; Gustin-Bacon. Flange: 125-pound flat face, 250-pound raised face, ductile iron, threaded conforming to AWWA C115/A21-15.88. Gray cast iron will not be allowed. Project No. 18088080 2 of 3 40 23 39.13 Data Sheet Lake Lewisville WTP Dewatering Improvements Ductile Iron Pipe and Fittings SECTION 40 23 39.13 DUCTILE IRON PIPE AND FITTINGS Item Description Fittings Push-On: AWWA C110/A21.10-93 and C111/A21.11-90, gray or ductile iron, 250 psi minimum working pressure. American Cast Iron Pipe Co., Fastite Joints; U.S. Pipe and Foundry, Tyton Joint. Mechanical Joint: For Buried Service. AWWA C110/A21.10-93, C111/A21.11-90, and C153/A21.53-88 gray or ductile iron, 250 psi minimum working pressure. Coating/lining shall be Fusion-Bonded Epoxy meeting AWWA C116. American Cast Iron Pipe Co., Mechanical Joint; U.S. Pipe and Foundry, Mechanical Joint. Proprietary Restrained Joint: AWWA C111/A21.11-90 and C153/A21.53-88, ductile iron, 250 psi minimum working pressure. Coating/lining shall be Fusion-Bonded Epoxy meeting AWWA C116. Clow Corp., Super-Lock Joint; American Cast Iron Pipe Co., Flex- Ring or Lok-Ring Joint; U.S. Pipe, TR Flex. Proprietary Restrained River Crossing: Clow Ball and Socket; U.S. Pipe Usiflex. Coating/lining shall be Fusion-Bonded Epoxy meeting AWWA C116. Grooved End: AWWA C606-87 and C110/A21.10-93, ductile iron, 250 psi minimum working pressure. Lining and coating shall match connecting pipe. Victaulic; Gustin-Bacon. Flange: AWWA C110/A21.10-93 and ANSI B16.1-89, ductile or gray cast iron, faced and drilled, 125-pound flat face or 250-pound raised face. Gray cast iron will not be allowed. Lining and coating shall match connecting pipe. Couplings Grooved End: 250 psi minimum working pressure, malleable iron per ASTM A47-90 or ductile iron per ASTM A536-84. Victaulic; Gustin-Bacon. Grooved End Adapter Flanges: 250-pound malleable iron per ASTM A47-90 or ductile iron per ASTM A536-84. Victaulic; Gustin-Bacon. Bolting Mechanical, Proprietary Restrained, and Grooved End Joints: 316 Stainless Steel Hardware. 125-pound Flat-Faced Flange: Exposed piping - ASTM A307-94, Grade A carbon steel hex head bolts and ASTM A563-93, Grade A steel hex head nuts. 250-pound Raised-Face Flange: Exposed piping - ASTM A307-94, Grade B carbon steel hex head bolts and ASTM A563-93, Grade A carbon steel heavy hex head nuts. All hardware on submerged piping or piping below the top elevation of tanks and directly exposed to water, wastewater and/or wastewater solids , including but not limited to bolts, nuts, washers, and threaded rod shall be stainless steel. Project No. 18088080 3 of 3 40 23 39.13 Data Sheet Lake Lewisville WTP Dewatering Improvements Ductile Iron Pipe and Fittings SECTION 40 23 39.13 DUCTILE IRON PIPE AND FITTINGS Item Description Gaskets Mechanical, and Proprietary Restrained Joints, Water and Sewage: Rubber conforming to ANSI/AWWA C111/A21.11-90 Locking gaskets produced in accordance with AWWA C111 are acceptable for use as a joint restraint mechanism for buried push- on type joints. Locking gaskets shall be rated for the same working pressure as the pipe. American Cast Iron Pipe Co., Fast-Grip Gasket; US Pipe, Field LOK Gaskets. Mechanical and Proprietary Restrained Joints, Air: Viton, Fluorel, or Manufacturer’s standard for high temperature air service, rated to 300 degrees F minimum, conforming to ANSI/AWWA C111/A21.11-90 Grooved End Joints: Halogenated butyl conforming to ASTM D2000-90 and AWWA C606-87. Gaskets for air service shall be pressure-responsive synthetic rubber, rated to 300 degrees F minimum, conforming to ASTM D2000. Flanged, Water and Sewage Services: 1/8-inch thick, unless otherwise specified, homogenous black rubber (EPDM), hardness 60 (Shore A), rated to 212 degrees F., conforming to ANSI B16.21 and ASTM D1330 Steam Grade. Flanged, Air Service: 1/8-inch thick, unless otherwise specified, Teflon, PTFE, or compressed inorganic fiber with nitrile binder, rated to 300 degrees F. minimum, conforming to ANSI B16.21 and ASTM D1330. Ring gaskets shall not be permitted. Blind flanges shall be gasketed covering the entire inside face with the gasket cemented to the blind flange. Gasket pressure rating equal to the pressure rating as the pipe or fitting. Joint Lubricant Manufacturer’s Standard. END OF SECTION Project No. 18088080 1 of 1 40 23 39.40 Data Sheet Lake Lewisville WTP Dewatering Improvements C900 & C905 PVC Pipe and Fittings SECTION 40 23 39.40 C900 & C905 PVC Pipe and Fittings Item Size/Installation Description Pipe 4 IN. – 12 IN. 14 IN – 48 IN. C900 DR 18: Conforming to ASTM D1784 with a cell classification of 12454. Conforming to AWWA C900 C905 DR 18: Conforming to AWWA C905 Fittings Buried Ductile Iron Mechanical Joint Fittings as specified in 40 23 39.13 CM LINED DUCTILE IRON PIPE AND FITTINGS with restraint gland Joints All Push-on: Meeting ASTM D3139 with gasket meeting ASTM F477 Restrained Joints: x C900: Proprietary Locking Gaskets x C905: Joint Restraint Harness; EBAA Iron Series 2800 or equal Flanges None Not allowed Couplings Dissimilar Pipe Materials Similar Pipe Materials Transition Coupling: Smith-Blair Style 413 or equal Ductile Iron Mechanical Joint Solid Sleeve END OF SECTION Project No. 18088080 1 of 1 40 23 39.42 Data Sheet Lake Lewisville WTP Dewatering Improvements Polyvinyl Chloride (PVC) Pipe and Fittings (DWV) SECTION 40 23 39.42 POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS (DWV) Item Size Description Pipe All Schedule 40 PVC: Type I, Grade I or Class 12454-B conforming to ASTM D2665 or F1866. Threaded Nipples: Schedule 40 PVC. Fittings All Schedule 40 PVC as specified above: Conforming to the requirements of ASTM D2665. Joints All Solvent socket-weld except where connection to valves and equipment may require future disassembly. Threaded joints shall not be used unless specifically approved by ENGINEER. Flanges All One piece, molded hub type PVC flat face flange in accordance with Fittings above, 125-pound ANSI B16.1-89 drilling. Bolting All Flat Face Mating Flange or In Corrosive Areas: ASTM A193/A193M Rev A-94 Type 316 stainless steel Grade B8M hex head bolts and ASTM A194/A194M-94 Grade 8M hex head nuts. With Raised Face Mating Flange: Carbon steel ASTM A307-94 Grade B square head bolts and ASTM A563-93 Grade A heavy hex head nuts. Gaskets All Flat Face Mating Flange: Full faced 1/8” thick. Raised Face Mating Flange: Flat ring 1/8” thick, with filler gasket between OD of raised face and flange OD to protect the flange from bolting moment. Gasket material shall be suitable for each service. Submit recommended gasket material for each service to ENGINEER. Solvent Cement All As recommended by the pipe and fitting manufacturer conforming to ASTM F493 Rev A. Solvent cement shall be rated for use with each service. Provide manufacturer’s certification that the solvent is appropriate for respective service. Thread Lubricant All Teflon Tape END OF SECTION Project No. 18088080 1 of 1 40 23 39.43 Data Sheet Lake Lewisville WTP Dewatering Improvements Polyvinyl Chloride (PVC) Pipe and Fittings SECTION 40 23 39.43 POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS Item Size Description Pipe All Schedule 80 PVC: Type I, Grade I or Class 23447-B conforming to ASTM D1785-05. Threaded Nipples: Schedule 80 PVC. Gravity Sewer and Gravity Process Drain Pipe: Use SDR-26 PVC: ASTM D-3034 as indicated in piping schedule. Fittings All Schedule 80 PVC as specified above: Conforming to the requirements of ASTM D2467. Joints All Solvent socket-weld except where connection to valves and equipment may require future disassembly. Threaded joints shall not be used unless specifically approved by ENGINEER Flanges All One piece, molded hub type PVC flat face flange in accordance with Fittings above, 125- pound ANSI B16.1-89 drilling. Bolting All Flat Face Mating Flange or In Corrosive Areas: ASTM A193/A193M Rev A-94 Type 316 stainless steel Grade B8M hex head bolts and ASTM A194/A194M-94 Grade 8M hex head nuts. With Raised Face Mating Flange: Carbon steel ASTM A307-94 Grade B square head bolts and ASTM A563-93 Grade A heavy hex head nuts. Gaskets All Flat Face Mating Flange: Full faced 1/8” thick. Raised Face Mating Flange: Flat ring 1/8” thick, with filler gasket between OD of raised face and flange OD to protect the flange from bolting moment. Gasket material shall be suitable for each service. Submit recommended gasket material for each service to ENGINEER. Solvent Cement All As recommended by the pipe and fitting manufacturer conforming to ASTM F493 Rev A. Solvent cement shall be rated for use with each service. Provide manufacturer’s certification that the solvent is appropriate for respective service. Thread Lubricant All Teflon Tape END OF SECTION Project No. 18088080 1 of 1 40 23 39.46 Data Sheet Lake Lewisville WTP Dewatering Improvements Chlorinated Polyvinyl Chloride (CPVC) Pipe and Fittings SECTION 40 23 39.46 CHLORINATED POLYVINYL CHLORIDE (CPVC) PIPE AND FITTINGS Item Size Description Pipe All Schedule 80 CPVC: Type IV, Grade I or Class 23447-B conforming to ASTM D1784 and ASTM DF441. Threaded Nipples: Schedule 80 PVC. Fittings All Schedule 80 CPVC as specified above: Conforming to the requirements of ASTM F439 Rev A for socket-weld type and ASTM F437 for threaded type Joints All Solvent socket-weld except where connection to valves and equipment may require future disassembly. Threaded joints shall not be used unless specifically approved by ENGINEER Flanges All One piece, molded hub type CPVC flat face flange in accordance with Fittings above, 125-pound ANSI B16.1-89 drilling. Bolting All Flat Face Mating Flange or In Corrosive Areas: ASTM A193/A193M Rev A-94 Type 316 stainless steel Grade B8M hex head bolts and ASTM A194/A194M-94 Grade 8M hex head nuts. With Raised Face Mating Flange: Carbon steel ASTM A307-94 Grade B square head bolts and ASTM A563-93 Grade A heavy hex head nuts. Gaskets All Flat Face Mating Flange: Full faced 1/8” thick. Raised Face Mating Flange: Flat ring 1/8” thick, with filler gasket between OD of raised face and flange OD to protect the flange from bolting moment. Gasket material shall be suitable for each service. Submit recommended gasket material for each service to ENGINEER. Solvent Cement All As recommended by the pipe and fitting manufacturer conforming to ASTM F493 Rev A. Solvent cement shall be rated for use with each service. Provide manufacturer’s certification that the solvent is appropriate for respective service. Thread Lubricant All Teflon Tape END OF SECTION Project No. 18088080 1 of 1 40 23 39.53 Data Sheet Lake Lewisville WTP Dewatering Improvements Copper and Copper Alloy Pipe Tubing and Fittings SECTION 40 23 39.53 COPPER AND COPPER ALLOY PIPE, TUBING, AND FITTINGS Item Description Tubing Seamless, conforming to ASTM B88 Rev A as follows: Buried………………………..Type K, soft or hard temper Exposed……………………. Type L, hard drawn P-trap priming service…… Type L, soft temper Fittings Commercially pure wrought copper, socket joint, conforming to ASTM B75, dimensions conforming to ANSI B16.22. Flanges Commercially pure wrought copper, socket joint, conforming to ASTM B75, faced and drilled 150-pound ANSI B16.24 standard. Bolting ASTM A307, carbon steel, Grade A hex head bolts and ASTM A563 Grade A hex head nuts. Gaskets Flanged, Water and Air Services: 1/16-inch thick, compressed inorganic fiber with nitrile binder, rated to 700 degrees F and 1,000 psi. Ring gaskets shall not be permitted. Blind flanges shall be gasketed covering the entire inside face with the gasket cemented to the blind flange. Solder 95-5 wire solder (95 percent tin, 5 percent antimony), conforming to ASTM B32 Grade 95TA. Do not use cored solder. END OF SECTION Project No. 18088080 1 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves SECTION 40 23 43 - PROCESS VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Basic requirements for Process Valves. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 60 00 – Product Requirements. 3. Section 01 78 23 – Operation and Maintenance Data. 4. Section 01 79 00 – Demonstration and Training. 5. Section 09 90 00 – Painting and Protective Coatings. 6. Section 22 05 53 – Mechanical Identification. 7. Section 40 23 39 – Process Piping - General. 8. Section 40 92 13 – Motorized Operators. 9. Section 40 92 16 – Manual Valve and Gate Operators. 10. Section 40 92 19 – Pneumatic Valve Actuators 1.2 GENERAL A. See Section 40 23 39, PROCESS PIPING - GENERAL, which contains information and requirements that apply to the work specified herein and are mandatory for this project. B. Certain valves are specified in Division 44 to be furnished by equipment manufacturer as part of their equipment package and/or system. These valves are to be installed by the Contractor as specified herein. In addition to installation, the Contractor shall be responsible for test, inspection, and assisting the equipment suppliers in start-up services as required to the place the valves into continuous, reliable operation. 1.3 SUBMITTALS A. Submittals shall be made as required in Section 01 33 00, SUBMITTALS. The following specific information shall be provided: 1. Shop Drawings: a. Product data sheets for make and model. b. Complete catalog information, descriptive literature, specifications, and identification of materials of construction. c. Refer to specific valve type for additional submittal requirements. 2. Quality Control Submittals: a. Tests and inspection data. b. Manufacturer’s Certificate of Proper Installation. c. Manufacturer’s printed installation instructions. d. Special shipping, storage and protection, and handling instructions. e. Suggested spare parts list to maintain the equipment in service for a period of 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. f. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance. 1.4 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, format, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. Project No. 18088080 2 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. PART 2 - PRODUCTS 2.1 GENERAL A. Valve to include operator, actuator, hand wheel, chain wheel, extension stern, floor stand, worm and gear operator, operating nut, chain, wrench, and accessories for a complete operation. For operator specifications, see sections 40 92 13 MOTORIZED OPERATORS, and 40 92 16 VALVE AND GATE OPERATORS. B. Valve shall be suitable for intended service. Renewable parts not to be of a lower quality than specified. C. Valve shall be the same size as adjoining pipe. D. Valve ends to suit adjacent piping. E. Valve shall open by turning counterclockwise unless otherwise specified. F. Operator, actuator, and accessories shall be factory mounted. G. EFFECTIVE JANUARY 4, 2014 ANY VALVE, PIPE, FITTING, SOLDER, OR FLUX USED OR IN CONTACT WITH POTABLE WATER MUST COMPLY WITH THE REDUCTION OF LEAD IN DRINKING WATER ACT, AN AMENDMENT TO SECTION 1417 OF THE SAFE DRINKING WATER ACT (SDWA). VALVES SPECIFIED IN THIS SECTION MAY NOT MEET REQUIRMENTS OF THIS ACT, HOWEVER THIS DOES NOT RELIEVE THE CONTRACTOR FROM PROVIDING A VALVE TO MEET REQUIREMENTS OF THE (SDWA) AND THE SAME FUNCTIONAL REQUIREMENTS OF THIS SPECIFICATION. 2.2 SCHEDULE A. Requirements relative to this section for certain type of actuated or process valves are shown on the Valve Schedules attached as Supplements to the related Sections. 2.3 MATERIALS A. Brass and bronze valve components and accessories that have surfaces in contact with water shall be alloys containing less than 16% zinc and 2% aluminum. B. Approved alloys are of the following ASTM designations: 1. B61, B62, B98 (Alloy UNS No.C65100, C65500, or C66100), B139 (Alloy UNS No.C51000), B584 (Alloy UNS No.C90300 or C94700), B164, B194, and B127. 2. Stainless steel, AISI Type 316 may be substituted for bronze. 2.4 FACTORY FINISHING A. Epoxy Lining and Coating: 1. In accordance with AWWA C550 unless otherwise specified. Coating shall be either two- part liquid material or heat-activated (fusion) material except only heat-activated material if specified as “fusion” or “fusion bonded” epoxy. 2. Minimum 7-mil dry film thickness except where limited by valve operating tolerances. B. Exposed Valves Field Finish: Project No. 18088080 3 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 1. Final paint coating shall be in accordance with Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. System and color shall match adjacent piping system. 2. Safety isolation valves and lockout valves with handles, hand wheels, or chain wheels “safety yellow.” 2.5 VALVES A. Gate Valves: 1. Type V140: Gate Valve, Less Than 3 Inches a. General: 1) Service: Aboveground, clean water and air. 2) 150 psi Class 3) Rising Stem type 4) Threaded ends 5) Conform to MSS-SP-80, Type 2 b. Materials: 1) Body & bonnet: Bronze, ASTM B62 alloy C83600 2) Disc: Bronze, ASTM B62 alloy C83600 3) Stem: ASTM B505 alloy C83600 or ASTM B371 alloy C69400 c. Manufacturers and Products: 1) Crane – Figure 431. 2) Jenkins – Figure 2810J 3) Nibco – T-131 2. Type V141: Buried Gate Valve, 3 Inches and Larger a. Valve shall be resilient wedge type, of non-rising stem design and rated for 250 psig cold water working pressure. b. Valve shall meet or exceed all requirements of the latest revision of AWWA C515. c. Valve shall have mechanical joint ends, except tapping valves may be flanged by mechanical joint. d. Stem shall be sealed by three O-Rings. O-Rings set in a cartridge shall not be allowed. e. Each valve shall have maker’s name, pressure rating, and year in which it was manufactured cast in the body. Country of origin to be clearly cast into body & cover castings. f. Valves 14” and larger shall be equipped with geared actuators. Valves to be installed in the standard vertical position shall have spur gear actuators. Valve to be installed in the horizontal position shall have bevel gear actuators. Valves shall only be installed in the horizontal position if noted on the plans or if instructed by the Engineer. g. Materials: 1) All cast ferrous components shall be ductile iron, ASTM A536. 2) The body, bonnet and O-ring plate shall be fusion-bonded epoxy coated, both interior and exterior on body and bonnet. Epoxy shall be applied in accordance with AWWA C550 and be NSF 61 Certified. 3) Wedge shall be ductile iron fully encapsulated in EPDM rubber. 4) Hardware shall be 304 stainless steel 5) Stems shall be cast copper alloy with integral collars in full compliance with AWWA. All stems shall operate with copper alloy stem nuts independent of wedge and of stem 6) Provide standard AWWA 2-inch operating nut, matching valve key, and valve box for operating stem. h. Manufacturers and Products: 1) M&H/Kennedy Valve Company. 2) Mueller. 3) American. Project No. 18088080 4 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 4) Crispin-Ludlow Valve. 3. Type V142: Exposed Gate Valve, 3 Inches and Larger a. Valve shall be resilient wedge type, of non-rising stem design and rated for 250 psig cold water working pressure. b. Valve shall meet or exceed all requirements of the latest revision of AWWA C515. c. Valve shall have flanged ends. d. Stem shall be sealed by three O-Rings. O-Rings set in a cartridge shall not be allowed. e. Each valve shall have maker’s name, pressure rating, and year in which it was manufactured cast in the body. Country of origin to be clearly cast into body & cover castings. f. Valves 14” and larger shall be equipped with geared actuators. Valves to be installed in the standard vertical position shall have spur gear actuators. Valve to be installed in the horizontal position shall have bevel gear actuators. Valves shall only be installed in the horizontal position if noted on the plans or if instructed by the Engineer. g. Materials: 1) All cast ferrous components shall be ductile iron, ASTM A536. 2) The body, bonnet and O-ring plate shall be fusion-bonded epoxy coated, both interior and exterior on body and bonnet. Epoxy shall be applied in accordance with AWWA C550 and be NSF 61 Certified. 3) Wedge shall be ductile iron fully encapsulated in EPDM rubber. 4) Hardware shall be 304 stainless steel 5) Stems shall be cast copper alloy with integral collars in full compliance with AWWA. All stems shall operate with copper alloy stem nuts independent of wedge and of stem 6) Provide handwheel, chainwheel, 2” nut, or actuator as noted on the drawings or specified in the valve schedule. h. Manufacturers and Products: 1) M&H/Kennedy Valve Company. 2) Mueller. 3) American. 4) Crispin-Ludlow Valve. 4. Type V145: Knife Gate Valve, 2 Inches to 36 Inches a. Suitable for service under pressures equal to and less than 150 pounds per square inch. b. Full round port, metal seated, raised face design. c. Flanged wafer design, drilled and tapped to ANSI Class 125/150 standard. d. Founded gate with beveled edge, finish-ground to 32 RMS, maximum, on both sides. e. Body to incorporate guides and jams to assist in seating. f. Materials: 1) Body: Cast or ductile iron or cast steel, with Type 316 stainless steel lining or cast Type 316 stainless steel. 2) Wetted Components (including gate): Type 316 stainless steel. 3) Yoke Sleeve: Acid resisting bronze or aluminum bronze. 4) Packing: PTFE. g. Outside screw and yoke (OS&Y) with handwheel operator. h. Manufacturers and Products: 1) DeZurik. 2) Fabri Valve. B. Globe Valves: 1. Type V200: Globe Valve, 3 Inches and Smaller a. General: Project No. 18088080 5 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 1) Service: Aboveground, clean water. 2) 150 psi Class 3) Rising Stem type 4) Union Bonnet 5) Threaded ends 6) Conform to MSS-SP-80, Type 2 b. Materials: 1) Body & bonnet: Bronze, ASTM B62 alloy C83600 2) Disc: PTFE 3) Stem: ASTM B505 alloy C83600 or ASTM B371 alloy C69400 c. Manufacturers and Products: 1) Stockham; B-22T, threaded end. 2) Crane. Co.; 7TF, threaded end. 3) Nibco: T-235-Y 2. Type V201: Angle Pattern Valve, 2 Inches and Smaller a. General: 1) Service: Aboveground, clean water. 2) 150 psi Class 3) Rising Stem type 4) Union Bonnet 5) Threaded ends 6) Conform to MSS-SP-80, Type 2 b. Materials: 1) Body & bonnet: Bronze, ASTM B62 alloy C83600 2) Disc: PTFE 3) Stem: ASTM B505 alloy C83600 or ASTM B371 alloy C69400 c. Manufacturers and Products: 1) Stockham; Figure B-222T. 2) Crane Co.; Cat. No. 17TF. 3) Nibco: T-335-Y 3. Type V235: Angle Type Hose Bibb Valve a. 3/4-inch NPT female inlet, 3/4-inch male hose thread outlet, heavy rough brass body rated 125 psi, lockshield bonnet, removable handle, atmospheric vacuum breaker conforming to ASSE Standard 1011 and IAPMO code. b. Manufacturers and Products: 1) Acorn; 8126, surface pipe mount valve, bent nose without flange: 2) Acorn; 8121, surface mount through wall valve, bent nose with flange. 3) Acorn; 8131, pipe and pedestal mounted valve located above 6 inches, straightnose. 4) Acorn; 8136, pedestal mounted valve located lower than 6 inches inverted nose. 4. Type V236: Angle Pattern Hose Valve, 1 Inch Through 3 Inches a. All-bronze, screwed ends, inside screw, rising stem, 'I'F±. disc, outlet of cast brass NST by NPT, male by male, nipple adapter with hexagonal wrench feature, rated 300 WOG. b. Manufacturers and Products: 1) Stockham; Figure B-222T. 2) Crane Co.; Cat. No. 17TF. 3) James Jones Co.: J-300 Series, angle fire hydrant valve with NPT inlet and National Hose thread outlet. 4) ITT Kennedy; Figure 936, angle fire hydrant valve with NPT inlet and National Hose thread outlet. Project No. 18088080 6 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves C. Ball Valves: 1. Type V300: Metal Body Ball Valve, Less than 6 Inches a. General 1) Type: Non-lubricated and capable of sealing in either flow direction. 2) End Connections: a) Threaded or solder ends for sizes 3-inch and smaller. b) Class 150 flanged for sizes larger than 3 inch. Flanges shall conform to ANSI/ASME B16.1 standards. 3) Stem Packing: Manually adjustable while valve is under pressure. 4) Shafts: Rigidly connected to the ball by a positive means. The connection shall be designed to transmit torque equivalent to at least 75 percent of the torsional strength of the shaft. 5) Handles: Stainless steel latch lock handle with vinyl grip and stainless steel nut designed to open and close the valve under operating conditions. 6) Temperature Limits: Suitable for operation between minus 20 and 350 degrees Fahrenheit. b. Materials: 1) Valves in Copper Lines: Bronze body 2) Valves in Steel and Ductile Iron Piping: Ductile iron or cast steel bodies. 3) Ball: Type 304 or 316 stainless steel. 4) Seats: PTFE. 5) Stem Seals: TFE or Viton 6) Bearings: Self-lubricated, corrosion resistant material that will not contaminate potable water. c. Manufacturers and Products: 1) Apollo. 2) Nibco. 3) Milwaukee Valve. 2. Type V302: Metal Body Ball Valve, 6 Inches and Larger a. General 1) Type: Non-lubricated and capable of sealing in either flow direction. 2) Conform to AWWA C 507. 3) Stem Packing: Manually adjustable while valve is under pressure. 4) ANSI B16.1, Class 125 flanged ends. b. Materials 1) Body: ASTM A48 cast iron and integrally cast bronze bushed trunnions. 2) Ball: Type 304 or Type 316 stainless steel. 3) Seats: TFE. 4) Stem Seals: TFE or Viton. c. Manually operated ball valves shall have self-locking worm gear type actuator with position indicator. Gearing shall be permanently lubricated. Provide adjustable screws to stop travel at both Open and Closed positions. d. Manufacturers and Products: 1) Henry Pratt. 2) McANNA/MARPAC 3. Type V303 Instrumentation Ball Valves a. Brass or stainless steel body ball valve, nylon handle. b. Manufacturers and Products: 1) Swagelok, 40G Series. 2) Imperial Eastman; Series 200. 4. Type V330 PVC Body Ball Valve a. General: 1) Type: Non-lubricated and capable of sealing in either flow direction. Project No. 18088080 7 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 2) End Connections: True union; solvent or heat welded to piping. 3) Operator Handle: Lever. 4) All ball valves on sodium hypochlorite lines and/or chlorine dioxide lines shall be venting type valves. b. Materials 1) Body: Polyvinyl chloride (PVC). 2) Ball: Polyvinyl chloride (PVC). 3) Seats: Teflon (TFE). 4) O-rings: Viton (FPM). c. Manufacturers and Products: 1) Asahi/America, Inc. 2) Nibco. D. Plug Valves: 1. Type V404: Eccentric Plug Valve, 1/2 Inch through 3 Inches a. Non-lubricating type rated 175 psig CWP, drip-tight shutoff with pressure from either direction, cast iron body, or stainless steel body where indicated, with threaded NPT full size inlets. Connection shall be hexagonal for a wrench connection. Plug cast iron with round or rectangular port of no less than 80% of connecting pipe area and coated with Buna-N or Hycar, seats nickel, stem bearing self-lubricating stainless steel, stem seal multiple V -rings or V-cups of nitrile rubber, grit seals on stem. b. Provide valves with wrench lever manual operator. c. Manufacturers and Products: 1) DeZurik. 2) Henry Pratt. 3) Val-Matic. 4) Crispin Valve 2. Type V405: Eccentric Plug Valve, 4 Inches through 12 Inches a. Non-lubricating type rated 175 psig CWP, drip-tight shutoff with pressure from either direction, cast iron body, or stainless steel body where indicated, with flanged ends or grooved ends in accordance with AWWA C606 for rigid joints, mechanical joint ends for buried valve. Plug cast iron with round or rectangular port of no less than 80% of connecting pipe area and coated with Buna-N or Hycar, seats nickel, stem bearing self-lubricating stainless steel, stem seal multiple V -rings or V-cups of nitrile rubber, grit seals on stem. b. 4” valve with wrench lever manual operator and 6 through 12” valve with totally enclosed, geared, manual operator with hand wheel, 2” nut, or chain wheel. c. Manufacturers and Products: 1) DeZurik. 2) Henry Pratt. 3) Val-Matic. 4) Crispin Valve. 3. Type V406: Eccentric Plug Valve, 14 Inches and Larger a. Non-lubricating type rated 150 psig CWP, drip-tight shutoff with pressure from either direction, cast iron body with flanged ends or grooved ends in accordance with AWWA C606 for rigid joints, mechanical joint ends for buried valve. Plug cast iron with round or rectangular port of no less than 80% of connecting pipe area and coated with Buna-N or Hycar, seats nickel, stem bearing self-lubricating stainless steel, stem seal multiple V -rings or V-cups of nitrile rubber, grit seals on stem. b. Provide with totally enclosed, geared, manual operator with hand wheel, 2” nut, or chain wheel. c. Manufacturers and Products: 1) DeZurik. 2) Henry Pratt. Project No. 18088080 8 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 3) Val-Matic. 4) Crispin Valve. E. Butterfly Valves: 1. General: Provide valves designed and manufactured in accordance with AWWA C504, Class 150B or Class 250B, AWWA C516, and the following requirements: a. Valve class shall meet the requirements of the connecting line or as indicated in valve schedule or as indicated on the drawings. b. Suitable for throttling operations and infrequent operation after periods of inactivity. c. Elastomer seats bonded to body shall have adhesive integrity of bond between seat and body assured by testing with minimum 75-pound pull in accordance with ASTM D429, Method B. Seat may be retained by mechanical means on valves 24-inches and larger. No epoxy attachment method will be allowed. d. Bubble-tight with rated pressure, or any pressure lower than rated, applied from either side with the valve mounted in any orientation. e. No travel stops for the disc on interior of the body. f. Shaft seal shall include V-type packing for self-adjusting and wear compensation. g. Isolate metal-to-metal thrust bearing surfaces from flow stream. h. Valves intended for air service shall meet ANSI B16.104 and ANSI B16.5. 2. Type V500: Butterfly Valve, 4 Inches and Larger a. Valve Style: Flanged end, short body type. b. Flanged end connections shall fully conform with ANSI B16.1 Class 125 or Class 250, or AWWA C207 Class D. c. Materials: 1) Body: Class 150B valve bodies shall be ASTM A126, Class B gray iron or ASTM A536 Grade 65-45-12 ductile iron. Class 250B valve bodies shall be ASTM A536 Grade 65-45-12 ductile iron. 2) Disc: Valve disc shall be made from cast iron ASTM A-126 Class B or stainless steel ASTM A351 in sizes 20" and smaller. Sizes 24" and larger shall be built from ductile iron in conformance to ASTM A-536. Disc shall be furnished with Type 316 stainless steel seating edge to mate with the rubber seat on the body. 3) Shafts: Shafts shall be Stainless Steel. ASTM A276 Type 304, or Type 316, or ASTM A564, grade 630. 4) Seat: Valve seat shall be Buna-N rubber located on the valve body. In sizes 20" and smaller, valves shall have bonded seats that meet test procedures outlined in ASTM D-429 Method B. Sizes 24" and larger shall be retained in the valve body by mechanical means without use of metal retainers or other devices located in the flow stream. 5) Bearings: Shall be sleeve type that is corrosion resistant and self-lubricating. 6) Manual Actuators: Shall be fully grease packed and have stops in the open/close position. The actuator shall have a mechanical stop which will withstand an input torque of 450 ft. lbs. against the stop. The traveling nut shall engage alignment grooves in the housing. The actuators shall have a built in packing leak bypass to eliminate possible packing leakage into the actuator housing. 7) Hardware: All seat retaining hardware shall be Type 316 stainless steel. d. Manufacturers and Products: 1) Henry Pratt /Mueller 2) DeZurik - AWWA Butterfly Valves (BAW) 150B or 250B 3) Crispin Valve 4) Val-Matic – American BFV 150B or 250B 3. Type V504: Buried Butterfly Valve, 4 Inches and Larger a. Valve Style: Mechanical joint end type b. Mechanical joint end connections shall fully conform to ANSI/AWWA C111/A21.11. Project No. 18088080 9 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves c. Valve position indicator at valve box locations. Indicator to be hermetically sealed and show valve disc position, direction of rotation, and number of turns from FULLY OPENED to FULLY CLOSED. d. Materials: 1) Body: Class 150B valve bodies shall be ASTM A126, Class B gray iron or ASTM A536 Grade 65-45-12 ductile iron. Class 250B valve bodies shall be ASTM A536 Grade 65-45-12 ductile iron. 2) Disc: Valve disc shall also be made from cast iron ASTM A-126 Class B in sizes 20" and smaller. Sizes 24" and larger shall be built from ductile iron in conformance to ASTM A-536. Disc shall be furnished with Type 316 stainless steel seating edge to mate with the rubber seat on the body. 3) Shafts: Shafts shall be Stainless Steel. ASTM A276 Type 304, or Type 316, or ASTM A564, grade 630. 4) Seat: Valve seat shall be Buna-N rubber located on the valve body. In sizes 20" and smaller, valves shall have bonded seats that meet test procedures outlined in ASTM D-429 Method B. Sizes 24" and larger shall be retained in the valve body by mechanicalmeans without use of metal retainers or other devices located in the flow stream. No epoxy attachment method will be allowed. 5) Bearings: Shall be sleeve type that is corrosion resistant and self-lubricating. 6) Manual Actuators: Shall be suitable for buried service. Shall be fully grease packed and have stops in the open/close position. The actuator shall have a mechanical stop which will withstand an input torque of 450 ft. lbs. against the stop. The traveling nut shall engage alignment grooves in the housing. The actuators shall have a built in packing leak bypass to eliminate possible packing leakage into the actuator housing. 7) Hardware: All seat retaining hardware shall be Type 316 stainless steel. e. Manufacturers and Products: 1) Pratt / Mueller 2) Henry Pratt - Class 150B - Groundhog 3) Class 250B - HP-250II 4) Mueller Co. - Class 150 B - Lineseal III 5) Class 250 B – Lineseal XP 6) DeZurik - AWWA Butterfly Valves (BAW) 150B or 250B 7) Crispin Valve 8) Val-Matic - American BFV 150B or 250B 4. Type V510: Lug Style Butterfly Valve, 2 Inches and Larger a. Cast iron ASTM A126 body, ASTM A351-CF8M discs, Type 18-8 stainless steel or Type 416 stainless steel one-piece stem/shaft, self-lubricating sleeve-type Teflon or bronze bearing, EPDM replaceable resilient seat, self-adjusting multi-ring V-type packing, suitable for temperatures up to 250°F, bubble-tight at 150 psi differential pressure. Flanges and/or mounting design shall be for ANSI B16.1 125- or 150- pound flanges. b. Manufacturers: 1) Henry Pratt – Series 397 2) DeZurik – BOS-CL 3) Bray Valve 5. Type V511: Wafer-Style Butterfly Valve, 2 Inches and Larger a. Cast iron body, cast iron or ductile iron discs, Type 18-8 stainless steel one-piece stem, self-lubricating sleeve type bearing, EPDM replaceable resilient seat, self- adjusting packing, suitable for temperatures up to 250 degrees F, bubble-tight at 50 psi differential pressure, valve body to fit between ANSI B16.1 flanges. b. Manufacturers: 1) Henry Pratt. 2) DeZurik Project No. 18088080 10 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 3) Bray Valve 6. Type V512: Plastic Body Butterfly Valve, 8 Inches and Smaller a. PVC or CPVC body, CPVC discs, 316 SS stem/shaft, Viton (FKM) seats and seals, suitable for pressures of up to 150 psi at 70°F. The liner seal shall be full seat design such that the disc and seat are the only wetted parts. Flanges and/or mounting design shall be for ANSI B16.5 or ANSI B16.10 bolt patterns b. Manufacturers 1) Asahi/America, Inc. F. Check and Flap Valve: 1. Type V600: Check Valve, 2 Inches and Smaller a. All-bronze, screwed ends and cap, swing type replaceable Buna-N disc, rated 125- pound SWP, 200-pound WOG. b. Manufacturers: 1) Stockham. 2) Milwaukee Valve. 2. Type V605: Resilient Seated Swing Check Valve, 3 Inches and Larger a. Valve Connections: Flanged in accordance with ANSI B16.1, Class 125 b. The valve shall be in conformance with AWWA C508 c. The valves used in potable water service shall be certified to NSF/ANSI 61 Drinking Water System Components – Health Effects, and certified to be Lead-Free in accordance with NSF/ANSI 372. d. The valve body shall be full flow equal to nominal pipe diameter at all points through the valve. The 4 in. (100mm) valve shall be capable of passing a 3 in. (75mm) solid. The seating surface shall be a minimum of 35 degree angle to minimize disc travel. A threaded port with pipe plug shall be provided on the bottom of the valve to allow for field installation of a backflow actuator or oil cushion device without special tools or removing the valve from the line. e. The top access port shall be full size, allowing removal of the disc without removing the valve from the line. The access cover shall be domed in shape to provide flushing action over the disc for operating in lines containing high solids content. A threaded port with pipe plug shall be provided in the access cover to allow for field installation of a mechanical, disc position indicator. f. The disc shall be of one-piece construction, precision molded with an integral O-ring type sealing surface and reinforced with alloy steel. The flex portion of the disc shall have no pentrations, contain nylon reinforcement and shall be warranted for twenty- five years. Non-Slam closing characteristics shall be provided through a short 35 degree disc stroke and a disc accelerator to provide a cracking pressure of 0.3 psig. g. The disc accelerator shall be of one piece construction and provide rapid closure of the valve in high head applications. The disc accelerator shall be enclosed within the valve and shall be field adjustable and replaceable without removal of the valve from the line. The disc accelerator shall be securely held in place captured between the cover and disc. It shall be formed with a large radius to allow smooth movement over the disc surface h. Materials: 1) Body: The valve body and cover shall be constructed of ASTM A536 Grade 65-45-12 ductile iron or ASTM A126 class B gray iron for 30 in. (800mm) and larger. The exterior and interior of the valve shall be coated with an NSF/ANSI 61 approved fusion bonded epoxy coating. 2) Disc: The disc shall be precision molded Buna-N (NBR), ASTM D2000-BG. 3) Hardware: All retaining hardware shall be Type 316 stainless steel. i. Manufacturers and Products: 1) Val-Matic - Surgebuster 2) Henry Pratt – RD-Series Project No. 18088080 11 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 3) DeZurik/APCO – Series 100 4) Crispin – RF/ASR 3. Type V608: Swing Check Valve, 2 Inches and Larger a. AWWA C508, flanged end, cast iron body, bronze mounted valve, solid bronze hinges, stainless steel hinge shaft. b. Valve 2” through 12” rated 175-pound and 14” through 36” rated 150-pound cold water, non-shock. Valve fitted with adjustable outside lever and spring. Increasing- pattern body valve may be used where increased outlet piping size is shown. c. Manufacturers: 1) Crispin Valve 2) Val-Matic. 3) DeZurik. 4. Type V612: Double Disc Swing Check Valve, 2 Inches and Larger a. Lug wafer style, spring loaded, cast or ductile iron body, aluminum-bronze or ductile iron doors, resilient seats, stainless steel hinge pin, stop pin spring. b. Valve 2 inches through 12 inches rated 200-pound cold water and valve 14 inches through 54 inches rated 150-pound cold water. c. Manufacturers: 1) Crispin Valve. 2) DeZurik. 5. Type V614: Stainless Steel Check Valve, 2 Inches and Smaller a. Type 316 stainless steel body, disc, cap, and trim. Screwed ends and cap, swing- type disc; Class 150. b. Manufacturers and Products. 1) Stockham. 2) Or equal. 6. Type V625: Slanting Disc Check Valve, 2 Inches and Larger a. Two-piece cast iron construction, Body shall be ASTM A126, Grade B cast iron. Disc shall be bronze ASTM B584. Pivot pins and bushing shall be stainless steel. The valve shall be provided with a bottom mounted hydraulic buffer. The buffer shall contact and control the sic closure rate. b. Manufacturer: 1) DeZurik. 2) Val-Matic. 3) Crispin Valve. 7. Type V631: CPVC Ball Check Valve, 4 Inches and Smaller a. ASTM D1784 Cell Class 23477B chlorinated polyvinyl chloride body, single or dual union socket weld ends, rated 150 psi at 73 °F, 110 psi at 140 °F, Viton seat and seal. b. Manufacturers: 1) Asahi/America, Inc. 2) Nibco. 3) Spears. 8. Type V632: CPVC Foot Valve with Strainer, 4 Inches and Smaller a. ASTM D1784 Cell Class 23477B chlorinated polyvinyl chloride body, single or dual union socket weld ends, rated 150 psi at 73 °F, 110 psi at 140 °F, CPVC screen, Viton seat and seal. b. Manufacturers: 1) Asahi/America, Inc. 2) Nibco. Project No. 18088080 12 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 3) Spears. 9. Type V635: Check Valve for Air Service, 2 Inches and Larger: a. Check valves for low pressure process air service shall be carbon steel type with 150# flanged ends, rated 150 psig at 300 °F. Valve shall have stainless steel split disc mounted on Type 316 stainless steel center post, such that wafer type butterfly valve can be mounted directly downstream of check valve when discs of both valves are in the OPEN position. b. Manufacturers: 1) Techno Corporation, Style 5003 2) Crane, Style H 10. Type V641: Double Check Valve Assembly, 2-1/2 Inches through 10 Inches a. General: 1) Regulatory Compliance: AWWA-C510-92, CSA B64.5, FCCHR of USC Section 10, ASSE 1048, IAPMO (UPC), SBCCI. 2) Valve Body: Bronze 3) End Connections: Flanged, ANSI B 16.1. 4) Maximum Working Pressure: 175 PSI, (350 Hydrostatic Test Pressure). 5) Temperature Range: 32 Degrees to 140 Degrees Fahrenheit. b. Manufacturers: 1) Febco. 2) Watts. 3) Hersey. 11. Type V642: Reduced Pressure Backflow Preventer, 3/4 Inches and Larger a. General, (3/4 Inches through 2 Inches): 1) Regulatory Compliance: AWWA-C510-92, CSA B64.5, FCCHR of USC Section 10, ASSE 1048, IAPMO (UPC), SBCCI. 2) Valve Body: Bronze 3) End Connection: Threaded, NPT ANSI/ASME B1.20.1 4) Maximum Working Pressure: 175 PSI, (350 Hydrostatic Test Pressure). 5) Temperature Range: 32 Degrees to 140 Degrees Fahrenheit. 6) Shut-off Valves: Full port resilient seated, bronze ball valves with bronze ball valve test cocks. 7) Size(s) and rating(s) as shown in the schedules following this Section. 8) Manufacturers: a) Febco. b) Watts. b. General, (2 Inches and Larger): 1) Regulatory Compliance: AWWA-C510-92, CSA B64.5, FCCHR of USC Section 10, ASSE 1048, IAPMO (UPC), SBCCI. 2) Valve Body: Ductile or Cast Iron, Class 125 3) End Connections: Flanged, ANSI B 16.1 4) Maximum Working Pressure: 175 PSI, (350 Hydrostatic Test Pressure). 5) Temperature Range: 32 Degrees to 140 Degrees Fahrenheit. 6) Shut-off Valves: Non-rising stem, resilient seated gate valves with bronze ball valve test cocks. 7) Accessories: Drain line with air gap. 8) Size(s) and rating(s) as shown in the schedules following this Section. 9) Manufacturers: a) Febco. b) Watts. 12. Type V650: Stainless Steel Flap Valve Project No. 18088080 13 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves a. General, (4 Inches and 6 Inches): 1) Valve Body: 316 stainless steel 2) End Connection: Flanged,125# ANSI B 16.1 3) Seat: buna-n seal 4) Manufacturers: a) Troy Valve. b) Golden Harvest. G. Self-Contained Automatic Valves: 1. Type V710: Pressure Regulating Valve, 2-1/2 Inches and Smaller a. General: 1) Maximum Inlet Pressure: 200 psig. 2) Outlet Pressure Ranges: 20 to 80 psig. 3) Maximum Allowable Outlet Pressure: 10% above spring setting, or 5 psig above setting, whichever is greater. 4) Maximum Operating Differential: 5 psi. 5) Maximum Operating Temperature: -20 Degrees to 150 Degrees Fahrenheit. b. Construction Materials: 1) Body: Bronze. 2) Spring Case: Cast Iron. 3) Valve Disk and Holder: Nitrile (NBR) and bronze. 4) Diaphragm: Nitrile (NBR) c. Manufacturers: 1) Fisher. 2) Mueller. 2. Type V711: High-Pressure Regulating Valve, 2 Inches and Smaller a. General: 1) Maximum Inlet Pressure: 300 psig. 2) Outlet Pressure Ranges: 5 to 150 psig. 3) Maximum Operating Temperature: 150 Degrees Fahrenheit. b. Construction Materials: 1) Body: Stainless Steel. 2) Spring Case: Stainless Steel. 3) Valve Disk and Holder: Nitrile (NBR) and bronze. 4) Diaphragm: Nitrile (NBR) c. Manufacturers: 1) Fisher. 2) Mueller. 3. Type V712: High-Pressure Regulating Valve, 3 Inches and Smaller a. General: 1) Maximum Inlet Pressure: 150 psig. 2) Outlet Pressure Ranges: 5 to 125 psig. 3) Maximum Operating Temperature: 140 Degrees Fahrenheit. b. Construction Materials: 1) Body: Machined PVC 2) Seals: Viton c. Manufacturers: 1) Plast-O-Matic Valves, Inc. 4. Type V713: Pressure Reducing Valve, 1 Inch through 4 Inches a. General: 1) Maximum Inlet Pressure: 250 psig (Cast Iron), 300 psig (Steel). 2) Droop: 10% of outlet pressure setting. Project No. 18088080 14 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 3) Maximum Differential Pressure: 150 psig or body rating limit, whichever is lower. 4) Body: Ductile Iron, Cast Steel, or Bronze. 5) Disc Retainer and Diaphragm Washer: Cast Iron, Cast Steel, or Bronze. 6) Stem, Nut and Spring: Stainless Steel 7) Diaphragm: Nylon Reinforced Buna-N Rubber b. Manufacturers: 1) Cla-Val. 2) Fisher. 3) Ross Valve. 5. Type V714: Pressure-Reducing Valve, 4 Inches and Larger a. Manufacturers: Where a manufacturer’s standard equipment name and/or model number is listed, the equipment system shall be provided as modified to conform to the performance, functions, features, and materials of construction as specified herein. 1) Materials, equipment, components and accessories specified in this section shall be, products of: a) Cla-Val b) Singer Valve c) Ross Valve b. Valve Size & Model c. Pressure Reducing Valves 1) Mfg. & Model: Cla-Val: 90-01/690-01 Pressure Reducing Valve 2) Mfg. & Model: Singer Valve: 106/206-PR Pressure Reducing Valve 3) Mfg. & Model: Ross Valve: D40WR d. Function 1) The pressure reducing valve shall maintain a constant downstream pressure regardless of changing flow rate and/or inlet pressure. e. Main Valve Design 1) The valve shall be hydraulically operated, single diaphragm-actuated, globe or angle pattern. The valve shall consist of three major components: the body, with seat installed; the cover, with bearings installed; and the diaphragm assembly. The diaphragm assembly shall be the only moving part and shall form a sealed chamber in the upper portion of the valve, separating operating pressure from line pressure. Packing glands and/or stuffing boxes are not permitted and there shall be no pistons operating the main valve or pilot controls. f. Main Valve Body 1) No separate chambers shall be allowed between the main valve cover and body. Valve body and cover shall be constructed of ASTM A536-65/45/12 ductile iron. The flanges shall be designed to ANSI Class 150 standards. Flange drilling to ANSI shall be standard. No fabrication or welding shall be used in the manufacturing process. 2) The valve cover shall have a separate stem cap on valves larger than 2 in giving access to the stem for alignment check, spring installation and ease of assembly. 3) On valve(s) 1in and larger, bonnets shall be accurately located to bodies utilizing locating pins. Locating pins shall eliminate corrosion resulting from the use of uncoated ductile iron to ductile iron surfaces. Valves with lipped spigot covers shall not be acceptable due to risk of rust and difficulty in assembly. 4) Valve(s) 3 in to 8 in shall have the AISI 316 Stainless Steel seat with integral bottom guide, bolted in place. The AISI 316 Stainless Steel seat ring shall be easily replaceable without special tools. Valves 10 in and larger shall incorporate a two-piece seat and bottom guide design. Project No. 18088080 15 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 5) The valve(s) shall form a drip-tight seal between the stationary stainless steel seat ring and the resilient disc, which has a rectangular cross-section and is retained by clamping on three and one half sides. The resilient disc shall be constructed of Buna-N for normal service conditions. 6) All external fasteners shall be AISI 18-8 Stainless Steel with AISI 18-8 Stainless Steel washers. Mild steel studs or bolts will not be acceptable. 7) 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 discs (circular, square, or quad type) shall be permitted as the seating surface. The disc guide shall be of the contoured type to permit smooth transition of flow and shall hold the disc firmly in place. The disc retainer shall be of a sturdy one-piece design capable of withstanding opening and closing shocks. It must have straight edge sides and a radius at the top edge to prevent excessive diaphragm wear as the diaphragm flexes across this surface. No hourglass-shaped disc retainers shall be permitted and no V-type or slotted type disc guides shall be used. 8) The stainless steel stem shall be provided with wrench flats on all valves 1 in to 16 in, for ease of assembly and maintenance. Wrench flats will be fully accessible when inner valve is assembled. 9) The valve cover shall have a separate stem cap on valves larger than 2 in giving access to the stem for alignment check, spring installation and ease of assembly. 10) On valve(s) 1 in and larger, bonnets shall be accurately located to bodies utilizing locating pins. Locating pins shall eliminate corrosion resulting from the use of uncoated ductile iron to ductile iron surfaces. Valves with lipped spigot covers shall not be acceptable due to risk of rust and difficulty in assembly. 11) Valve(s) 3 in to 8 in shall have the AISI 316 Stainless Steel seat with integral bottom guide, bolted in place. The AISI 316 Stainless Steel seat ring shall be easily replaceable without special tools. Valves 10 in and larger shall incorporate a two-piece seat and bottom guide design. 12) The valve(s) shall form a drip-tight seal between the stationary stainless steel seat ring and the resilient disc, which has a rectangular cross-section and is retained by clamping on three and one half sides. The resilient disc shall be constructed of Buna-N for normal service conditions. 13) All external fasteners shall be AISI 18-8 Stainless Steel with AISI 18-8 Stainless Steel washers. Mild steel studs or bolts will not be acceptable. 14) All repairs and maintenance shall be possible without removing the valve from the line. To facilitate easy removal and replacement of the inner valve assembly and to reduce unnecessary wear on the guide, the stem shall be vertical when the valve is mounted in a horizontal line. 15) Each valve shall be air tested prior to shipment. The standard test shall include leakage test, seat leakage test, and stroke test. Refer to IOM 622B for further details. Where the set-point is provided, the valve manufacturer will preset the pilot. 16) Valve(s) 6 in and larger shall provide smooth frictionless motion and maximum low flow stability. The diaphragms shall not be used as a seating surface. 17) Valve shall meet NSF-61/ANSI standards for drinking water contact. g. Valve Coating 1) Valve coating shall be NSF 61 and FDA approved, valve(s) shall have a protective fusion bonded epoxy coating internally and externally. The protective fusion bonded epoxy coating shall conform to the AWWA C116 (current version) specification. No machining of any external parts after final Project No. 18088080 16 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves coating will be acceptable to ensure a continuous coating surface throughout the entire valve. h. Pilot 1) The pilot shall have a spring range as specified in the schedule below 2) The pressure reducing pilot control shall be a direct-acting, adjustable, spring- loaded, normally open, diaphragm valve designed to permit flow when controlled pressure is less than the spring setting. The pilot control is held open by the force of the compression on the spring above the diaphragm, and it closes when the delivery pressure acting on the underside of the diaphragm exceeds the spring setting. 3) The pilot control system shall include a fixed orifice. No variable orifices shall be permitted. The pilot system shall include an opening speed control as standard equipment. 4) The pilot control shall have a second downstream sensing port which can be utilized to install a pressure gauge. 5) A direct factory representative shall be made available for start-up service, inspection and necessary adjustments. 6) Maximum working temperature: 180° F / 82° C 7) Maximum working pressure: 300 psi / 27.6 bar i. Pilot Tubing and Fittings 1) Shall have standard ASTM B16 brass pilot fittings with flexible stainless steel braided Teflon lined Pilot tubing. j. Flow Control Valves 1) Shall have brass or bronze body and stainless steel stem. 2) Shall control opening and closing speed of the main valve. 3) Shall have visible position markings. k. Isolation Valves 1) Shall be brass body ball valves with wing handle operator. 2) Shall be all stainless steel construction and shall a have a 40 mesh screen. 3) Strainers shall be provided at locations as necessary to protect the pilot and solenoid system from contaminates. l. Additional Provisions 1) Provide a pressure gauge on the inlet and outlet sides of the main valve. Pressure gauges shall be 0-300 psi range glycerin filled with 4” dial. Pressure gauges shall be provided with isolation valves to isolate gauges from pilot system. m. Warranty 1) The valve(s) shall be covered by a minimum three year (3) warranty against defects in materials and workmanship. The electrical components shall have a minimum one year (1) warranty. The stainless steel seat shall be covered by a lifetime replacement warranty. 6. Type V730: Pressure Relief Valve, 2 Inches and Smaller a. Direct diaphragm, spring controlled, Type 316 stainless steel body, spring case, Type 316 stainless steel diaphragm, stainless steel valve stem. b. Capable of opening when upstream-pressure reaches a maximum set point. c. Manufacturers: 1) Fisher. 2) Or equal. 7. Type V731: Pressure Relief Valve, 1/4 Inch through 2 Inches a. General: 1) Maximum Line Pressure: 150 psi 2) Setting Range: 15-150 psi b. Capable of opening when upstream-pressure reaches a maximum set point. c. Construction Materials: Project No. 18088080 17 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 1) Body: PVC, CPVC 2) Spring Case: PVC 3) Spring Keepers: PVC 4) Diaphragm: PVC, PTFE 5) Orifice Seal: EPDM, FKM 6) Adjustment Screw: 316 SS d. Manufacturers: 1) Primary Fluid Systems, Inc. 2) Or equal. 8. Type V732: Pressure Relief Valve, Pressure Sustaining Valve, 1 Inch and Larger a. Hydraulically operated, diaphragm, actuated, pilot controlled globe valve, cast iron body, ANSI B16.1 flanged ends, rated 175 psi, stainless steel trim, stainless steel stem, externally mounted strainers with cocks, to open when upstream pressure reaches a maximum set point. b. Manufacturers: 1) Cla-Val. 2) Or equal. 9. Type V733: Surge Anticipator Valve a. Manufacturers: Where a manufacturer’s standard equipment name and/or model number is listed, the equipment system shall be provided as modified to conform to the performance, functions, features, and materials of construction as specified herein. 1) Materials, equipment, components and accessories specified in this section shall be, products of: a) Singer Valve b) Cla-Val c) Ross Valve. b. Valve Size & Model c. Pump Station - Pump Control Valves 1) Mfg. & Model: Singer Valve: 106-RPS-L&H 2) Mfg. & Model: Cla-Val: 52-03 3) Mfg. & Model: Ross Valve: D50RWR-A 4) Size: As shown on the drawings or as recommended by valve manufacturer. 5) The valve manufacturer shall evaluate the pump station flow and hydraulics to determine the proper size of valve. The valve manufacturer shall submit their valve sizing calculations for review by the Engineer. d. Function 1) This 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. e. Main Valve Design 1) Shall be similar to V734 Pump Control Valve below f. Valve Coating 1) Valve coating shall be NSF 61 and FDA approved, valve(s) shall have a protective fusion bonded epoxy coating internally and externally. The protective fusion bonded epoxy coating shall conform to the AWWA C116 (current version) specification. No machining of any external parts after final coating will be acceptable to ensure a continuous coating surface throughout the entire valve. g. Pilot System 1) The pilot system shall be supplied with two pilots, a high pressure pilot to open the valve on excess pressure and a low pressure pilot to open the valve in anticipation of a surge wave. The high pressure pilot shall be, normally closed, Project No. 18088080 18 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves with a spring range of 100 psi to 300 psi. The low pressure pilot shall be, normally open, with a spring range of 20 psi to 80 psi. 2) The normally closed pilot shall be of brass and bronze construction with a spring to adjust the opening pressure. 3) The inner valve shall be of stainless steel 316 construction and the inner valve shall have Buna-N resilient compound for seating. The Buna-N compound must be bonded permanently to the inner valve and be ground flat and square to assure maximum performance. 4) The pilot shall be self-cleaning by locating the inlet directly into the seat area through the bottom of the pilot and the outlet ninety degrees to the inlet. 5) A separate port will sense pressure either upstream or downstream to open the pilot and therefore the main valve when system pressure exceeds the pilot set-point. 6) Maximum working temperature: 180° F / 82° C 7) Maximum working pressure: 400 psi / 27.6 bar h. Pilot Tubing and Fittings 1) Shall have standard ASTM B16 brass pilot fittings with flexible stainless steel braided Teflon lined Pilot tubing. i. Flow Control Valves 1) Shall have brass body and stainless steel stem. 2) Shall control opening and closing speed of the main valve. 3) Provide test valves to test main valve in-place. j. Isolation Valves 1) Shall be brass body ball valves with wing handle operator. k. Strainers 1) Shall be all stainless steel construction and shall a have a 40 mesh screen. 2) Strainers shall be provided at locations as necessary to protect the pilot system from contaminates. l. Additional Provisions 1) Provide a pressure gauge on the inlet and outlet sides of the main valve. Pressure gauges shall be 0-300 psi range glycerin filled with 4” dial. Pressure gauges shall be provided with isolation valves to isolate gauges from pilot system. m. Warranty 1) The valve(s) shall be covered by a minimum three year (3) warranty against defects in materials and workmanship. The electrical components shall have a minimum one year (1) warranty. The stainless steel seat shall be covered by a lifetime replacement warranty. 10. Type V734: Pump Control Valve a. Manufacturers: Where a manufacturer’s standard equipment name and/or model number is listed, the equipment system shall be provided as modified to conform to the performance, functions, features, and materials of construction as specified herein. 1) Materials, equipment, components and accessories specified in this section shall be, products of: a) Singer Valve b) Cla-Val c) Ross Valve. b. Valve Size & Model c. Pump Station - Pump Control Valves 1) Mfg. & Model: Cla-Val: 60-31 Pump Control Valve 2) Mfg. & Model: Singer Valve: 106-PG-BPC 3) Mfg. &Model: Ross Valve: 42WRS 4) Size: As shown on the drawings. d. Function Project No. 18088080 19 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 1) The pump control valve is designed for installation on the discharge of pumps to eliminate starting and stopping surges caused by the pump and to protect the pump and supply from damage cause by over pumping by acting as a back pressure valve. The valve shall be equipped with a built-in lift-type check feature to prevent reverse flow, operating independently of the solenoid control. e. Main Valve Design 1) Valve(s) shall be a hydraulically operated globe valve. The inner valve assembly shall be top and bottom guided by means bearing bushings. The inner valve assembly shall be the only moving part and shall be securely mounted on a AISI 316 Stainless Steel stem. Lower grades of stainless steel stems will not be acceptable. 2) The stainless steel stem shall be provided with wrench flats on all valves 1 in to 16 in, for ease of assembly and maintenance. Wrench flats will be fully accessible when inner valve is assembled. 3) All pressure containing components shall be constructed of ASTM A536-65 / 45 / 12 ductile iron. The flanges shall be designed to ANSI Class 150 standards. Flange drilling to ANSI shall be standard. 4) The valve cover shall have a separate stem cap on valves larger than 2 in giving access to the stem for alignment check, spring installation and ease of assembly. 5) On valve(s) 1 in and larger, bonnets shall be accurately located to bodies utilizing locating pins. Locating pins shall eliminate corrosion resulting from the use of uncoated ductile iron to ductile iron surfaces. Valves with lipped spigot covers shall not be acceptable due to risk of rust and difficulty in assembly. 6) Valve(s) 3 in to 8 in shall have the AISI 316 Stainless Steel seat with integral bottom guide, bolted in place. The AISI 316 Stainless Steel seat ring shall be easily replaceable without special tools. Valves 10 in and larger shall incorporate a two-piece seat and bottom guide design. 7) The valve(s) shall form a drip-tight seal between the stationary stainless steel seat ring and the resilient disc, which has a rectangular cross-section and is retained by clamping on three and one half sides. The resilient disc shall be constructed of Buna-N for normal service conditions. 8) All external fasteners shall be AISI 18-8 Stainless Steel with AISI 18-8 Stainless Steel washers. Mild steel studs or bolts will not be acceptable. 9) All repairs and maintenance shall be possible without removing the valve from the line. To facilitate easy removal and replacement of the inner valve assembly and to reduce unnecessary wear on the guide, the stem shall be vertical when the valve is mounted in a horizontal line. 10) Each valve shall be air tested prior to shipment. The standard test shall include leakage test, seat leakage test, and stroke test. Refer to IOM 622B for further details. Where the set-point is provided, the valve manufacturer will preset the pilot. 11) Valve(s) 6 in and larger shall provide smooth frictionless motion and maximum low flow stability. The diaphragms shall not be used as a seating surface. 12) Valve shall meet NSF-61/ANSI standards for drinking water contact. f. Valve Coating 1) Valve coating shall be NSF 61 and FDA approved, valve(s) shall have a protective fusion bonded epoxy coating internally and externally. The protective fusion bonded epoxy coating shall conform to the AWWA C116 (current version) specification. No machining of any external parts after final coating will be acceptable to ensure a continuous coating surface throughout the entire valve. g. Pilot Project No. 18088080 20 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 1) The pilot shall have a spring range of 20 psi to 200 psi. 2) The normally closed pilot shall be of brass and bronze construction with a spring to adjust the opening pressure. 3) The inner valve shall be of stainless steel 316 construction and the inner valve shall have Buna-N resilient compound for seating. The Buna-N compound must be bonded permanently to the inner valve and be ground flat and square to assure maximum performance. 4) The pilot shall be self-cleaning by locating the inlet directly into the seat area through the bottom of the pilot and the outlet ninety degrees to the inlet. 5) A separate port will sense pressure either upstream or downstream to open the pilot and therefore the main valve when system pressure exceeds the pilot set-point. 6) Maximum working temperature: 180° F / 82° C 7) Maximum working pressure: 400 psi / 27.6 bar h. Pilot Tubing and Fittings 1) Shall have standard ASTM B16 brass pilot fittings with flexible stainless steel braided Teflon lined Pilot tubing. i. Solenoid Valve 1) Shall be a three-way normally closed, 120VAC 60Hz solenoid valve, with a brass body and a NEMA 4X enclosure. j. Flow Control Valves 1) Shall have brass or bronze body and stainless steel stem. 2) Shall control opening and closing speed of the main valve. 3) Shall have visible position markings. k. Isolation Valves 1) Shall be brass body ball valves with wing handle operator. l. Limit Switch/Position Indicator Assembly 1) An adjustable limit switch assembly shall be mounted on the main valve, connected to the main valve stem. It shall be actuated by opening or closing of the valve and easily adjusted to operate at either point of the valve's travel. The limit switch will be used to complete the pump off cycle. The actuating point of the limit switch shall be adjustable. 2) Limit switches shall have NEMA 4X enclosures. 3) A direct factory representative shall be made available for start-up service, inspection, and necessary adjustments. 4) A position indicator column shall be mounted on the main valve, connected to the main valve stem. It shall have an indicator rod or sight tube indicating the position of the valve and shall be easily seen from two directions. m. Strainers 1) Shall be all stainless steel construction and shall a have a 40 mesh screen. 2) Strainers shall be provided at locations as necessary to protect the pilot and solenoid system from contaminates. n. Additional Provisions 1) Provide a pressure gauge on the inlet and outlet sides of the main valve. Pressure gauges shall be 0-300 psi range glycerin filled with 4” dial. Pressure gauges shall be provided with isolation valves to isolate gauges from pilot system. 2) Provide 3/8-in NPT isolation ball valves on inlet and outlet backside ports for future installation of pressure transducers. o. Warranty 1) The valve(s) shall be covered by a minimum three year (3) warranty against defects in materials and workmanship. The electrical components shall have a minimum one year (1) warranty. The stainless steel seat shall be covered by a lifetime replacement warranty. 11. Type V750: Well Service Air Valve, 1/2 Inch and Larger Project No. 18088080 21 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves a. Fully automatic float operated valve, suitable for vertical turbine pump discharge service, designed to exhaust air which is present in pump column on pump start-up and allow air to re-enter the column on pump shutdown or should a negative pressure occur. b. Valves used in potable water service shall be NSI/ANSI 61 certified. c. Valves 3” and smaller shall be equipped with a dual port throttling device to provide adjustable control of the exhaust rate and allow free air to flow into the valve through a separate inlet port. Valves 4” larger shall be equipped with a regulated exhaust device, which shall allow free airflow in and out of the valve, close upon rapid air exchange, and control the air exhaust rate to reduce pressure surges. d. Valve interiors and exteriors shall be coated with an NSF/ANSI 61 certified fusion bonded epoxy in accordance with AWWA C550. e. Connections: 1) Inlet-Valve sizes 3 in. and smaller shall have full size NPT inlets and outlets equal to the nominal valve size. The body inlet connection shall be hexagonal for a wrench connection. Valve sizes 4 in. and larger shall have bolted flange inlets equal to the valve size. Flanges shall be in accordance with ANSI B16.1 for Class 125 or Class 250 iron flanges and ANSI B16.42 for Class 300 ductile iron flanges. f. Outlets-Valve sizes 6 in. and smaller shall have NPT outlets; Valves 8 in. and larger shall have ANSI B16.1 Class 125 outlet flanges. The valve shall have two additional NPT connections for the addition of Air Release Valves, gauges, testing, and draining. g. Materials: The Well Service Air Valve body, cover, and baffle shall be constructed of ASTM A126 Class B cast iron for Class 125 and Class 250 valves. Class 300 ductile iron valves shall be constructed of ASTM A536 Grade 65-45-12 cast ductile iron. The float, guide shafts, and bushings shall be constructed of Type 316 stainless steel. Non-metallic guides and bushings are not acceptable. Resilient seats shall be Buna-N. h. Manufacturers: 1) Val-Matic. 2) DeZurik. 3) Crispin Valve. 12. Type V752: Wastewater Combination Air Valves, 2 Inch and Larger a. Valve shall be automatic float operated valve designed to exhaust large quantities of air during the filling of a piping system and close upon liquid entry. The valve shall open during draining or if a negative pressure occurs. The valve shall also release accumulated air from a piping system while the system is in operation and under pressure. b. Valve shall perform functions of both air release and Air/Vacuum valves and be furnished as a single body. c. Valve shall be suitable for use with domestic sewage. d. Valve body and structure shall be constructed of cast iron or ductile iron. Float, guide shafts and bushings shall be stainless steel. e. Manufacturers: 1) Val-Matic. 2) DeZurik. 3) Crispin Valve. 13. Type V755: Clean Water Combination Air Valve, 2 Inch and Larger a. Valve shall be automatic float operated valve designed to exhaust large quantities of air during the filling of a piping system and close upon liquid entry. Valve shall open during draining or if negative pressures occur. Valve shall also release accumulated air from a piping system while system is in operation and under pressure. Project No. 18088080 22 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves b. Valve shall perform functions of both air release and Air/Vacuum valves and be furnished as a single body. c. Valves used in potable water shall be NSF/ANSI certified. d. Valve body and structure shall be constructed of cast iron or ductile iron. Float, guide shafts and bushings shall be stainless steel. e. Manufacturers: 1) Val-Matic. 2) DeZurik. 3) Crispin Valve. 14. Type V780: Safety Relief Valve for Air Service, 1-1/2 Inch through 3 Inches a. Spring loaded, adjustable pressure relief valve for process air service, with stainless steel trim; seat material suitable for elevated temperatures above 300 °F, test pull ring or lever. b. Manufacturers: 1) Kunkle. 2) Apollo Valve 15. Type V785: Safety Relief Valve for Air Service a. Exposed spring, full nozzle with stainless steel trim, cast steel body, seat material suitable for elevated temperatures above 300 °F. b. Manufacturers: 1) Kunkle. H. Miscellaneous Valves: 1. Type V901: Diaphragm Valve, 1/2 Inch and Larger a. Diaphragm valves shall be weir type with solid CPVC body and bonnet. Provide with Type 316 stainless steel bushing bolts, and other integral metallic components (etc., sleeve and stem). All metallic components shall be isolated for contact with fluid and the surrounding atmosphere. Valves 1/2” through 2” shall have true union socket ends. Valves 2-1/2” and larger shall have ANSI flanged ends. Manual operator shall be indicating, rising stem type with hand wheel. Valve working pressure shall be 100 psig at 120 °F. Valve must also be suitable for testing at elevated pressure per respective flow stream as indicated in Piping Schedule. Diaphragm shall be PTFE or Viton. b. Manufacturers: 1). George Fisher. 2). Asahi/America, Inc. 2. Type V902: Pinch Valve a. Iron body, fanged ends, TFE Teflon sleeves, upper and lower pinch bars, and hand wheel operator. b. Manufacturer: 1). Red Valve Co. 3. Type V903: Anti-Siphon/Back Pressure Valves, 2 Inch and Smaller a. Spring controlled diaphragm, CPVC body, with a safety vent, to close when upstream pressure reaches a minimum set point and serve as an anti-siphon device. Rated 150 psi. The safety vent shall be connected to a leak containment system which shall include clear polyethylene tubing connecting to a vented, CPVC spill chemical neutralization bucket appropriate for the chemical service. b. Construction Materials: 1) Body: CPVC 2) Diaphragm: PTFE c. Manufacturers: 1) Plast-O-Matic Valves, Inc. Project No. 18088080 23 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 2) Or equal. 4. Type V910 Telescoping Valve, 4 Inches through 36 Inch a. Valve configuration shall be as shown on the Drawings and detailed within the Supplements following End of Section. b. Complete assembly consisting of rising stem, slip tube, seal flange, lifting bail, valve stand with indicator and motor, when required, and Type 316 stainless steel anchor bolts and mounting hardware. c. Slip tube shall be Type 304 stainless steel, manufactured from seamless pipe or tube, with a minimum wall thickness of 1/8” and must be of sufficient length to facilitate valve travel and maintain an appropriate insert depth. d. A stainless steel companion flange and neoprene slip seal gasket shall be provided. The gasket shall be a minimum 1/4-inch thick, mounted to allow sliding and shall be watertight throughout the travel of the slip tube. e. Lift shall be handwheel type and stem shall be of the rising type, stainless steel, thrust bearings, automatic self-locking, and provide infinite valve positioning. A clear plastic Butyrate stem cover shall be provided with a mylar strip type position indicator, calibrated in 1/4-inch increments to illustrate valve position. f. Manufacturers and Products: 1) Troy Valve 2) Waterman; TS-2. 3) Golden-Harvest 4) Amwell; Type RP. 5. Type V915: Mud Valve a. Cast iron body tapered seat, bronze disc and seat ring, frame flanged, nonrising type stem, bronze extension stem, 2” square operating nut for floor box operation, and stem guides for maximum unsupported stem length of 5 feet. b. Manufacturers and Products: 1) Waterman; MV11. 2) Clow; F-3075. 3) Troy Valve; A25600RB 6. Type V916: Mud Valve a. Type 316 stainless steel body tapered seat, disc and seat ring, frame flanged, nonrising type stem, stainless steel extension stem, 2” square operating nut for floor box operation, and stem guides for maximum unsupported stem length of 5 feet. b. Manufacturers and Products: 1) Waterman. 2) Clow. 3) Troy Valve 7. Type V940 Solenoid Valve, 2 Inches and Smaller a. Two-way internal pilot operated diaphragm type, brass body, resilient seat suitable for air or water, solenoid coil molded epoxy, NEMA Class A, 120 volts ac, 60-Hz, unless otherwise indicated. Solenoid enclosure NEMA 250, Type 4 unless otherwise indicated. Size and normal position (OPEN or CLOSED when de-energized) as indicated. b. Minimum operating pressure differential no less than 5 psig, maximum operating pressure differential no greater than 125 psig. c. Manufacturers and Products: 1) ASCO 2) Skinner 8. Type V941 Plastic Body Solenoid Valve, 2 Inches and Smaller Project No. 18088080 24 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves a. Two-way internal pilot operated diaphragm type, PVC body, resilient seat suitable for air or water, solenoid coil molded epoxy, NEMA 4X, 120 volts ac, 60-Hz, unless otherwise indicated. Solenoid enclosure NEMA 250, Type 4 unless otherwise indicated. Size and normal position (OPEN or CLOSED when de-energized) as indicated. b. Minimum operating pressure differential no less than 5 psig, maximum operating pressure differential no greater than 140 psig. c. Manufacturers and Products: 1) Plast-O-Matic Valves, Inc. 2) Or Equal. 2.6 TAGGING REQUIREMENTS A. See Section 22 05 53, MECHANICAL IDENTIFICATION. B. The tags shall be attached to the valves by soldered split key rings so that ring and tag cannot be removed. The tag shall bear the 1/4” die-stamped equipment identification number as indicated in the Contract Documents. 2.7 ACCESSORIES A. T-Handled Operating Wrench: 1. 2 each galvanized operating wrenches, 4 feet long. 2. Manufacturers and Products: a. Mueller; No. A-24610. b. Clow No.; F-2520. 3. 2 each galvanized operating keys for cross handled valves. B. Cast Iron Valve Box: Designed for traffic loads, sliding type, with minimum of 6” ID shaft. 1. Box: Cast iron with minimum depth of 9”. 2. Lid: Cast iron, minimum depth 3”, marked for the appropriate service. 3. Extensions: Cast iron. PART 3 - EXECUTION 3.1 SHIPPING, STORAGE, HANDLING, AND PROTECTION A. As specified in Section 01 60 00, PRODUCT REQUIREMENTS. 3.2 INSTALLATION A. Flange Ends: 1. Flanged valve bolt holes shall straddle vertical centerline of pipe. 2. Clean flanged faces, insert gasket and bolts, and tighten nuts progressively and uniformly. B. Screwed Ends: 1. Clean threads by wire brushing or swabbing. 2. Apply joint compound. C. Valve Orientation: 1. Install operating stem vertical when valve is installed in horizontal runs of pipe having centerline elevations 4’ 6” or less above finished floor, unless otherwise shown. 2. Install operating stem horizontal in horizontal runs of pipe having centerline elevations between 4’ 6” and 6’ 9” above finish floor, unless otherwise shown. Project No. 18088080 25 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves 3. Orient butterfly valve shaft so that unbalanced flows or eddies are equally divided to each half of the disc, i.e., shaft is in the plane of rotation of the eddy. 4. If no plug valve seat position is shown, locate as follows: a. Horizontal Flow: The flow shall produce an “unseating” pressure, and the plug shall open into the top half of valve. b. Vertical Flow: Install seat in the highest portion of the valve. D. Install a line size ball valve and union upstream of each solenoid valve, in-line flow switch, or other in-line electrical device, excluding magnetic flow meters, for isolation during maintenance. E. Install safety isolation valves on compressed air. F. Locate valve to provide accessibility for control and maintenance. Install access doors in finished walls and plaster ceilings for valve access. G. Extension Stem for Operator: Where the depth of the valve is such that its centerline is more than 3 feet below grade. Furnish an operating extension stem with 2”operating nut to bring the operating nut to a point 6” below the surface of the ground and/or box cover. H. Torque Tube: Where operator for quarter-turn valve is located on floor stand. Furnish extension stem torque tube of a type properly sized for maximum torque capacity of the valve. I. Floor Box and Stem: Steel extension stem length shall locate operating nut in floor box. 3.3 TESTS AND INSPECTION A. Valve may be either tested while testing pipelines, or as a separate step. B. Test that valves open and close smoothly with operating pressure on one side and atmospheric pressure on the other, in both directions for two-way valve and applications. C. Inspect air and vacuum valves as pipe is being filled to verify venting and seating is fully functional. D. Count and record number of turns to open and close valve; account for any discrepancies with Manufacturer’s data. E. Set, verify, and record set pressures for all relief and regulating valves. F. Automatic valve to be tested in conjunction with control system testing. G. Test hydrostatic relief valve seating; record leakage. Adjust and retest to maximum leakage of 0.1 gpm per foot of seat periphery. 3.4 MANUFACTURER’S SERVICES A. A Manufacturer’s representative for the equipment specified herein shall be present at the jobsite for the minimum person-days listed for the services herein under, travel time excluded: 1. 2 person-days for installation assistance, inspection, and certification of the installation. Provide certificate. 2. 2 person-days for functional and performance testing. 3. 2 person-days for pre-startup classroom or jobsite training of OWNER’S personnel. B. Training of OWNER’S personnel shall be at such times and at such locations as requested by OWNER. Project No. 18088080 26 Section 40 23 43 Lake Lewisville WTP Dewatering Improvements Process Valves C. See Section 01 79 00, demonstration and training. 3.5 MANUFACTURER’S CERTIFICATE(S) A. Provide Manufacturer’s certificate(s) in accordance with Section 01 79 00. 3.6 SUPPLEMENTS A. The supplements listed below, following “END OF SECTION,” are a part of this Specification. 1. Power Operated Valve Schedule. END OF SECTION Project No. 18088080 1 of 1 Section 40 23 43 Supplement 1 Lake Lewisville WTP Dewatering Improvements Power Operated Valve Schedule 40 23 43: PROCESS VALVES POWER OPERATED VALVE SCHEDULE FLOW VALVE BODY FAIL TYPICAL OPERATING RANGE FLOW PRESSURE P&ID STREAM TYPE OPERATION SIZE ACTION MAX FLOW / MAX/MIN TAG NO. DRAWING ID (NOTE 1) (NOTE 2) (IN) (NOTE 3) MIN FLOW UNITS PRESSURE UNITS 75CV01 08-I751 TR V405 OC 6 FLP 250/160 GPM 15/0 PSI 75CV02 08-I751 TR V405 OC 6 FLP 250/160 GPM 15/0 PSI 75CV03 08-I751 TR V405 OC 6 FLP 250/160 GPM 15/0 PSI 75CV04 08-I751 TR V405 OC 6 FLP 250/160 GPM 15/0 PSI 75CV05 08-I751 TR V405 OC 6 FLP 250/160 GPM 15/0 PSI 75CV06 08-I751 TR V405 OC 6 FLP 250/160 GPM 15/0 PSI 75CV07 08-I751 TR V405 OC 6 FLP 250/160 GPM 15/0 PSI 75CV08 08-I751 TR V405 OC 6 FLP 250/160 GPM 15/0 PSI NOTES: 1. See Section 40 23 43 PROCESS VALVES, for valve type description. 2. MOD - Modulating OC - Open/Close operation OCS - Open/Close/Stop operation 3. FO - Fail Open FC - Fail Close FLP - Fail Last Position FLP/FC - Fail Last Position and Fail Close (selector switch) 4. Division 40 includes certain Powered Operated Valves, in addition to the valves specified above, that shall be provided as specified and shown on the Drawings. 5. See Section 40 92 13 MOTORIZED OPERATORS for motorized valve requirements. Project No. 18088080 1 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties SECTION 40 24 00 - PROCESS PIPING SPECIALTIES PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Basic requirements for Process Piping Specialties. B. Related sections: 1. Section 01 60 00 – Product Requirements. 2. Section 03 30 00 – Cast-In-Place Concrete. 3. Section 09 90 00 – Painting and Protective Coatings. 4. Section 22 05 29 – Process Supports and Anchors. 5. Section 40 23 39 – Process Piping – General. 1.2 REFERENCES A. The following is a list of standards which may be referenced in this section: 1. American National Standards Institute (ANSI): a. B16.1, Cast Iron Pipe Flanges and Flanged Fittings. b. B16.5, Pipe Flanges and Flanged Fittings. 2. American Society for Testing and Materials (ASTM): a. A153, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. b. A276, Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes. 3. National Fire Protection Association (NFPA): 24, Standard for the Installation of Private Fire Service Mains and Their Appurtenances. 1.3 SUBMITTALS A. Shop Drawings: Manufacturer’s data on materials, construction, end connections, ratings, overall lengths, and live lengths (as applicable). PART 2 - PRODUCTS 2.1 GENERAL A. Provide required piping specialty items, whether shown or not shown on the Drawings, as required by applicable codes and standard industry practice. B. Rubber ring joints, mechanical joints, flexible couplings, and proprietary restrained ductile iron pipe joints are considered flexible joints; welded pipe joints are not. 2.2 CONNECTORS A. Teflon Bellows Connector: 1. Type: Two convolutions unless otherwise shown, with metal reinforcing bands. 2. Flanges: Ductile iron, drilled 150 psi ANSI B16.5 standard. 3. Working Pressure Rating: 140 psi, minimum, at 120 ° F. 4. Thrust Restraint: Limit bolts to restrain the force developed by the specified test pressure. 5. Manufacturers and Products: a. Garlock; Style 214. b. Resistoflex; No. R6904. Project No. 18088080 2 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties B. Elastomer Bellows Connector: 1. Type: Fabricated spool, with single filled arch. 2. Materials: Nitrile tube and neoprene cover. 3. End Connections: Flanged, drilled 125-pound ANSI B16.1 standard, with full elastomer face and steel retaining rings. 4. Working Pressure Rating: 140 psig, minimum, at 180° F for sizes 12” and smaller. 5. Thrust Restraint: Control rods to limit travel of elongation and compression. 6. Manufacturers and Products: a. Goodall Rubber Co.; Specification E-1462. b. Garlock; Style 204. C. Sleeve Type Coupling Manufacturers: 1. Dresser. 2. Rockwell. D. Closure Collar Concrete: As specified in Section 03 30 00, CAST-IN-PLACE CONCRETE. 2.3 EXPANSION JOINTS A. Elastomer Bellows: 1. Type: Reinforced, molded wide-arch. 2. End Connections: Flanged, drilled 125-pound ANSI B16.1 standard with split galvanized steel retaining rings. 3. Washers: Over the retaining rings to help provide a leak proof joint under test pressure. 4. Thrust Protection: Control rods to protect the bellows from overextension. 5. Bellows Arch Lining: Buna-N, nitrile, or butyl. 6. Rated Temperature: 250° F. 7. Rated Deflection and Pressure: a. Lateral Deflection: 3/4” minimum. b. Burst Pressure: Four times the working pressure. c. Compression deflection and minimum working pressure as follows: Size Deflection Pressure (inch) (inch) (psig) 2-1/2 to 12 1.06 150 14 1.65 130 16 to 20 1.65 110 8. Manufacturers and Products: a. General Rubber Corp.; Style 1015 Maxijoint. b. Mercer; Flexmore Style 450. c. Goodall Rubber Co.; Specification E-711. B. Teflon Bellows: 1. Type: Three convolutions, with metal reinforcing bands. 2. Flanges: Ductile iron, drilled 150 psi ANSI B 16.5 standard. 3. Working Pressure Rating: 100 psig, minimum, at 120° F. 4. Thrust Restraint: Limit bolts to restrain the force developed by the specified test pressure. 5. Manufacturers and Products: a. Garlock; Style 215. b. Resistoflex; No. R6905. C. Copper Pipe Expansion Compensator: 1. Material: All bronze. 2. Working Pressure Rating: 125 psig, minimum. Project No. 18088080 3 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties 3. Accessories: Anti-torque device to protect the bellows. 4. Manufacturers and Products: a. Flexonics; Model HB. b. Hyspan; Model 8509 or 8510. D. Galvanized and Black Steel Pipe Expansion Compensator: 1. Material: Carbon steel with stainless steel bellows. 2. Working Pressure Rating: 150 psig, minimum. 3. Accessories: Anti-torque device to protect the bellows. 4. Manufacturers and Products: a. Flexonics; Model H. b. Hyspan; Model 8503. E. Flexible Metal Hose: 1. Type: Close pitch, annular corrugated with single braided jacket. 2. Material: Stainless steel, ASTM A276, Type 321. 3. End Connections: a. 3” and Larger: Shop fabricated flanged ends to match mating flanges. b. 2-1/2” and Smaller: Screwed ends with one union end. 4. Minimum Burst Pressure: 600 psig at 70° F for 12” and smaller. 5. Length: Provide hose live-length equal to the lengths shown on the Drawings. 6. Manufacturers and Products: a. Flexonics; Series 401M. b. Anaconda; BWC21-1. F. Bellows Type Expansion Joints: 1. Expansion joints: Flexible bellows type with equalizing rings, or as otherwise specified or indicated on the Drawings. 2. Manufacturers: a. Expansion joints: One of the following or equal: 1) Senior Flexonics Pathway, Inc., Controlled Flexing Expansion Joint. 2) Flex-Weld, Inc., Keflex, Series 308. 3) Victaulic Depend-o-Lok, Omniflex stainless bellows expansion joint. b. Pipe alignment guides: One of the following or equal: 1) Senior Flexonics Pathway, Inc. 2) Flex-Weld, Inc. c. Intermediate supports: Provide with protective saddles. One of the following or equal: 1) Unistrut Corporation, Roller-type. 2) Bergen-Paterson Pipe Support Corp. 3. Design: a. Expansion joint rating: 150 pounds per square inch gauge, at 300 degrees Fahrenheit. b. Bellows: Multi-ply stainless steel, equipped with a self-draining liner guide. c. Axial travel of expansion joints: Not less than 1.50 inches. d. Ends: 150 pound ASME flanges, Victaulic Depend-o-Lok Airmaster/Fluidmaster coupled ends, or plain suitable for welding connections, as required for piping in which installed. 2.4 FLEXIBLE PIPE CONNECTIONS TO EQUIPMENT A. Manufacturers and Products: 1. Flexonics; Model TCS, with tie bolts. 2. Keflex;Type 152-TR, with tie bolts. Project No. 18088080 4 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties 2.5 SERVICE SADDLES A. Double-Strap Iron: 1. Pressure Rating: Capable of withstanding 150 psi internal pressure without leakage or over stressing. 2. Run Diameter: Compatible with the outside diameter of the pipe on which the saddle is installed. 3. Taps: Iron pipe threads. 4. Materials: a. Body: Malleable or ductile iron. b. Straps: Galvanized steel. c. Hex Nuts and Washers: Steel. d. Seal: Rubber. 5. Manufacturers and Products: a. Smith-Blair; Series 313 or 366. b. Dresser; Style 91. B. Nylon-Coated Iron: 1. Pressure Rating: Capable of withstanding 150 psi internal pressure without leakage or over stressing. 2. Run Diameter: Compatible with the outside diameter of the pipe on which the saddle is installed. 3. Materials: a. Body: Nylon-coated iron. b. Seal: Buna-N. c. Clamps and Nuts: Stainless steel. 4. Manufacturer and Product: a. Smith-Blair; Style 315 or 317. 2.6 INSULATING FLANGES, COUPLINGS, AND UNIONS A. Materials: 1. In accordance with the applicable piping material specified in the Pipe Data Sheets. 2. Galvanically compatible with piping. B. Union Type: 1. 2” and Smaller: Screwed or solder-joint. 2. 2-1/2” and Larger: Flanged, complete with bolt insulators, dielectric gasket, bolts, and nuts. C. Working Pressure Rating: Suitable for specified system working pressure. D. Manufacturers and Products: 1. Dielectric Flanges and Unions: a. Epco Sales, Inc. b. Capitol Insulation Unions. 2. Insulating Couplings: a. Dresser; STAB-39. b. R. H. Baker; Series 216. 2.7 WALL PIPES A. Ductile Iron Wall Pipe: 1. For penetrations through concrete walls, floors, slabs, or roofs that are to be watertight. 2. Diameter and Ends: Same as connecting ductile iron pipe. Project No. 18088080 5 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties 3. Thickness: Equal to or greater than remainder of pipe in line. 4. Fittings: In accordance with applicable Pipe Data Sheet. 5. Thrust Collars: a. Provide for all wall pipes. b. Rated for thrust load developed at 250 psi. c. Safety Factor: 2, minimum. d. Material and Construction: Ductile iron or cast iron, cast integral with wall pipe wherever possible. Fabricate welded attachment of ductile iron thrust collar to pipe where casting impossible. Perform in pipe manufacturer’s shop by qualified welders. Electric arc welds of ductile iron with NI-55 or FC-55 nickel-iron-carbon weld rod. Con- tinuously weld on each side all around. 6. Manufacturers: American Cat Iron Pipe Co.; U.S. Pipe and Foundry Co. 7. Coating After Fabrication: Prepare and coat wall pipe in accordance with and as specified in Section 09 90 00, PAINTING AND PROTECTIVE COATINGS, System No. 2 B. Steel or Stainless Steel Wall Pipe: 1. Same material and thickness as connecting pipe, except 1/4-inch minimum thickness. 2. Lining: Same as connecting pipe. 3. Thrust Collar: Unless otherwise shown, 3 inches greater than outside diameter of wall pipe. Continuously fillet weld on each side all around. 4. Coating After Fabrication: Prepare and coat wall pipe in accordance with and as specified in Section 09 90 00, PAINTING AND PROTECTIVE COATINGS, System No. 2 5. Restraint: Provide lugs for use with thrust ties as specified. 2.8 PIPE SLEEVES A. Steel Pipe Sleeve: 1. Material: 3/16” minimum thickness steel pipe. 2. Seep Ring: a. 3/16” minimum thickness center steel flange for water stoppage on sleeves in exterior or water-bearing walls. b. Outside Diameter: 3” greater than pipe sleeve outside diameter. c. Continuously fillet weld on each side all around. 3. Factory Finish: a. Galvanizing: Hot-dip applied, meeting requirements of ASTM A153. Electroplated zinc or cadmium plating is unacceptable. b. Shop Lining and Coating: Factory prepare, prime, and finish coat in accordance with Section 09 90 00, PAINTING AND PROTECTIVE COATINGS, System No.2. B. Insulated and Encased Pipe Sleeve: 1. Manufacturer: Pipe Shields, Inc.; Models WFB, WFB-CS and -CW Series, as applicable. C. Modular Mechanical Seal: 1. Type: Interconnected synthetic rubber links shaped and sized to continuously fill annular space between pipe and wall sleeve opening. 2. Fabrication: Assemble interconnected rubber links with ASTM A276, Type 316 stainless steel bolts, nuts, and pressure plates. 3. Size: According to Manufacturer’s instructions for the size of pipes shown to provide a watertight seal between pipe and wall sleeve opening, and to withstand a hydrostatic head of 40 feet of water. 4. Manufacturer: Thunderline Link-Seal. Project No. 18088080 6 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties 2.9 MISCELLANEOUS SPECIALTIES A. Strainers for Process Water Service, 2” and Smaller: 1. Type: Bronze Body, Y-Pattern, 200 psi non-shock rated, with screwed gasketed bronze cap. 2. Screen: Heavy gauge Type 304 stainless steel or Monel, 20-mesh 3. Manufacturers: a. Armstrong International, Inc.; Model F b. Mueller Steam Specialty; Model 351M. B. Strainers for CPVC, Plastic Piping Systems, 4” and Smaller: 1. Type: Y-pattern CPVC body, 150 psi non-shock rated, with screwed CPVC cap; and PTFE Teflon seals as recommended by manufacturer for service. 2. End Connections: Screwed or solvent weld, 2” and smaller. Class 150 ANSI flanged, 1- 1/2” and larger. 3. Screen: Heavy-gauge CPVC, 1/32” mesh, minimum 2 to 1 screen area to pipe size ratio. 4. Manufacturers and Products: Hayword; Series 85/80, or equal. C. Spray Nozzles: 1. Design: a. Operating pressure 10 pounds per square inch gauge, at which pressure each nozzle discharges not less than 3.5 gallons per minute. 1) Spray: Flat, heavy sheet, fan with uniform distribution. 2) Fan spray angle: 105 degrees. 3) Spray deflection with a replaceable deflector insert free to rotate away from the orifice opening and mechanically locked in place and counterweighted. b. Spray nozzles structurally suitable for pressure up to 200 pounds per square inch gauge. c. Nozzles, easy flush type. d. Provide split eyelet connectors or weld-0-lets for nozzle connections. 2. Materials: a. Spray Nozzles: Brass. b. Nozzles provided with ¼ inch national pipe thread, and the orifice diameter not less than ¼ inch. c. Replaceable Spray Deflector: Neoprene rubber. 3. Manufacturers: a. Spray Nozzles: Spray System Co, Model 22561, or approved equal. b. Split eyelet connectors: Spray Systems Co, Series 8370 and Series 15475, or approved equal. D. Quick Couplings: 1. Provide female NPT by male quick-connect hose adaptors. All adapters and couplers shall satisfy dimensional requirements of MIL-C-27487E and shall be cast iron and sized shown on the Drawings. 2. Manufacturers and Products: Swagelock; Series QH. E. Quick Disconnect Cam Operating Couplings for Chemical Service: 1. Type: Twin cam arm actuated, male and female, locking, for chemical loading and transfer. 2. Material: Glass-filled polypropylene and PVDF with Teflon gaskets and as recommended for the service by Manufacturer. 3. End Connections: NPT threaded or flanged to match piping connections. 4. Hose shanks for chemical installations. 5. Plugs and Caps: Female dust cap for each male end, male dust plug for each female end. 6. Pressure Rating: 125 psi, minimum at 70° F. Project No. 18088080 7 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties 7. Manufacturers: a. OPW; Kamlock b. Ryan Herco; 1300 Series c. Goodall; Basic Eight F. Chemical Injection Quills: 1. Retractable injection quill, service rated for 250 psi, including stainless steel check valve, ball valve, solution tube adaptor, packing nut, restraint system, and limit chains, and 300 Series O-ring gaskets. 2. Manufacturer and Products: SAF-T-FLO; or equal. PART 3 - EXECUTION 3.1 SHIPPING, STORAGE, HANDLING, AND PROTECTION A. As specified in Section 01 60 00, PRODUCT REQUIREMENTS. B. Install process piping specialties in accordance with manufacturer's directions, and as specified herein. 3.2 PIPING FLEXIBILITY PROVISIONS A. General: 1. Install thrust protection. 2. Install flexible couplings to facilitate piping installation, in accordance with approved shop drawings. B. Flexible Joints at Concrete Backfill or Encasement: Install within 18” or one-half pipe diameter, whichever is less, from the termination of any concrete backfill or concrete encasement. C. Flexible Joints at Concrete Structures: 1. Install 18” or less from the face of structures; joint may be flush with face. 2. Install a second flexible joint, whether or not shown. a. Pipe Diameter 18” and smaller: Within 18” of the first joint. b. Pipe Diameter Larger than 18”: Within one pipe diameter of the first joint. 3.3 PIPING TRANSITION A. Applications: 1. Provide complete closure assembly where pipes meet other pipes or structures. 2. Pressure Pipeline Closures: Plain end pieces with double flexible couplings, unless otherwise shown. 3. Restrained Joint Pipe Closures: Install with thrust tie-rod assemblies as shown or in accordance with NFPA 24. 4. Gravity Pipe Closures: As specified for pressure pipelines, or concrete closures. 5. Concrete Closures: Use to make connections between dissimilar pipes where standard rubber gasketed joints or flexible couplings are impractical, as approved. 6. Elastomer sleeves bonded to pipe ends are not acceptable. B. Installation: 1. Flexible Transition Couplings: Install in accordance with coupling Manufacturer’s instructions to connect dissimilar pipe and pipes with a small difference in outside diameter. 2. Concrete Closures: Project No. 18088080 8 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties a. Locate away from structures so that there are at least two flexible joints between the closure and pipe entering the structure. b. Clean pipe surface before closure collars are placed. c. Wet non-metallic pipe thoroughly prior to pouring collars. d. Prevent concrete from entering pipe. e. Extend collar a minimum of 12” on each side of joint with minimum thickness of 6” around outside diameter of pipe. f. Make entire collar in one placement. g. After concrete has reached initial set, cure by covering with well moistened earth. 3.4 PIPING EXPANSION A. Piping Installation: Allow for thermal expansion due to differences between installation and operating temperatures. B. Expansion Joints: 1. Grooved Joint and Flanged Piping Systems: Elastomer Bellows Expansion Joint. 2. Nonmetallic Pipe: Teflon Bellows Expansion Joint. 3. Screwed and Soldered Piping Systems: Copper or Galvanized and Black Steel Pipe Expansion Compensator, as applicable. 4. Pipe Run Offset: Flexible Metal Hose. C. Bellows Type Expansion joints: 1. Install bellows type expansion control joints at piping connections to mechanical equipment to prevent damaging stresses due to normal expansion and contraction with temperature changes in piping and connected equipment. 2. Install bellows type expansion joints so as to allow 2-1/4 inch expansion per 100 linear feet of piping. 3. Install expansion joints adjacent to an anchor, and provide 1 concentric guide on piping within 12 pipe diameters, but not more than 5 feet, from the end of the joint opposite the anchor. a. Locate a similar guide approximately 30 diameters but not more than 10 feet from the first. 4. For expansion joints not installed adjacent to an anchor provide 2 concentric guides similarly located at each end of the joint. 5. Space intermediate supports a minimum of 10 feet, and tack weld the protective saddles to the pipe. D. Anchors and Anchor Walls: Install as specified in Section 22 05 29, PROCESS SUPPORTS AND ANCHORS, to withstand expansion thrust loads and to direct and control thermal expansion. 3.5 SERVICE SADDLES AND THRUST TIES A. Service Saddles: 1. Ferrous Metal Piping (except stainless steel): Double-strap iron. 2. Plastic Piping: Nylon-coated iron. B. Thrust Ties: 1. Install where shown and where required to restrain the force developed by the specified test pressure. 2. Steel Pipe: Attach with fabricated lugs. 3. Ductile Iron Pipe: Attach with socket clamps against a grooved joint coupling or flange. 4. Flanged Coupling Adapters: For exposed installations, install Manufacturer’s anchor studs through the coupling sleeve. Project No. 18088080 9 Section 40 24 00 Lake Lewisville WTP Dewatering Improvements Process Piping Specialties C. Installation: Install in accordance with Manufacturer’s written instructions. 1. Before coupling, clean pipe holdback area of oil, scale, rust, and dirt. 2. Remove pipe coating if necessary to present smooth surface. 3.6 FLEXIBLE PIPE CONNECTIONS TO EQUIPMENT A. Tie Bolts: Tighten snug prior to applying any pressure to the system. 3.7 INSULATING FLANGES, COUPLINGS, AND UNIONS A. Applications: 1. Copper to ferrous metal piping connections. 2. Cathodically protected piping penetration to buildings and watertight structures. 3. Submerged to un-submerged metallic piping connections. 4. Where required for electrically insulated connection. B. Installation of Insulating Kits: Drill oversize to accommodate insulating sleeves through the bolt holes, assuming standard bolt sizes. C. Pipe Installation: 1. Insulating joints connecting immersed piping to non-immersed piping shall be installed above maximum water surface elevation. 2. All submerged carbon steel, ductile iron, or galvanized piping in reinforced concrete basins shall be isolated from the concrete reinforcement steel. 3.8 WALL PIPES A. Applications: 1. As specified in Section 40 23 39, PROCESS PIPING - GENERAL 2. Watertight and Below Ground Penetrations: a. Wall pipes with thrust collars. b. Provide taps for stud bolts in flanges to be set flush with wall face. c. Existing Walls: Rotary drilled holes. 3. Wall Pipe Installation: a. Isolate embedded metallic piping from concrete reinforcement. b. Support wall pipes securely by formwork to prevent contact with reinforcing steel and tie-wires. 3.9 PIPE SLEEVES A. Application: 1. As specified in Section 40 23 39, PROCESS PIPING - GENERAL. 2. Above Grade in Non-submerged Areas: Hot-dip galvanized after fabrication. 3. Below Grade or in Submerged or Damp Environments: Shop-lined and coated. B. Installation: 1. Support non-insulating type securely in form work to prevent contact with reinforcing steel and tie-wires. 2. Caulk joint with rubber sealant or seal with wall penetration seal. 3.10 MISCELLANEOUS SPECIALTIES A. Install in accordance with manufacturer's instructions. END OF SECTION Project No. 18088080 1 Section 40 50 41.01 Lake Lewisville WTP Dewatering Improvements Rubber Hose SECTION 40 50 41.01 - RUBBER HOSE PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Hose. B. Related sections: 1. The Contract Documents are complementary; what is called for by one is as binding as if called for by all. 2. It is the CONTRACTOR’s responsibility for scheduling and coordinating the Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work. 1.2 SUBMITTALS A. Product data: Manufacturer's data indicating service type, sizes, materials, and required accessories. PART 2 - PRODUCTS 2.1 HOSE A. Hose material: Neoprene or acceptable oil resistant material suitable for a working pressure of minimum 50 pounds per square inch, gauge. B. Size as indicated on the Drawings fit ends with appropriate combination clamped nipples and threaded ends as indicated on the Drawings. C. Hose larger than 1-1/2 inches in size: Industrial fire hose. Provide one 50-foot long hose for each utility station (hose bib and hose rack) provided. 1. Manufacturers: One of the following: a. Goodyear Rubber Products Corp. b. Uniroyal, Inc. c. Goodall Rubber Company. D. Hose 1/2 inch through 1-1/2 inch nominal diameter: General purpose hose. Provide one 75-foot long hose (or length as indicated on the Drawings) for each utility station (hose bib/hydrant and hose rack) provided. 1. Manufacturers: One of the following: a. Goodyear Rubber Products Corp. b. Uniroyal. c. Goodall Rubber Company. E. Equip and fit hose ends with appropriate combination clamped nipples and threaded ends to make up the assembly indicated on the Drawings. PART 3 - EXECUTION 3.1 INSTALLATION A. Install hose in accordance with manufacturer's published instructions. Project No. 18088080 2 Section 40 50 41.01 Lake Lewisville WTP Dewatering Improvements Rubber Hose END OF SECTION Project No. 18088080 1 Section 40 91 23.33 Lake Lewisville WTP Dewatering Improvements Magnetic Flow Meter SECTION 40 91 23.33 – MAGNETIC FLOW METER PART 1 - GENERAL 1.1 SUMMARY A. This specification section covers the work necessary to furnish all materials for one (1) complete and operable flow monitoring systems. B. Flow meter components shall be of the same manufacturer to obtain standardization of performance, operation, spare parts, maintenance and manufacturer's services. 1.2 GENERAL A. Like items of equipment provided hereinafter shall be the end products of one manufacturer to achieve standardization of appearance, operation, maintenance, spare parts, and manufacturer services. B. Unit Responsibility: The Work requires that the clamp-on flow meter, complete, with all accessories and appurtenances be the end product of one responsible system manufacturer or system supplier. The supplier shall furnish and/or coordinate all components and accessories as necessary to place equipment in operation in conformance with the specified performance, features, and functions indicated. 1.3 SUBMITTALS A. Submittals shall be made as required in Section 01 33 00, SUBMITTALS of Division 01, GENERAL REQUIREMENTS. 1. Shop Drawings: a. Make, model, and weight of each equipment assembly. b. Complete catalog information, descriptive literature, specifications, and identification of materials of construction. c. Detailed mechanical and electrical drawings showing the equipment dimensions, size, components, and locations of connections. d. Power and control wiring diagrams, including terminals and numbers. 2. Manufacturer’s Instructions: Written or published information that documents Manufacturer’s recommendations, guidelines, and procedures for receiving, storing, installing, operating, and maintaining the magnetic flow meter and accessories. 3. Quality Control Submittals: a. Special shipping, storage and protection, and handling instructions. b. Manufacturer’s printed installation instructions. c. Manufacturer’s Certificate of Proper Installation. d. Unit Process Start-Up Form. e. Suggested spare parts list to maintain the equipment in service for a period of 2 year and 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. f. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance. 1.4 OPERATIONAL AND MAINTENANCE DATA A. The Manufacturer/Supplier shall be responsible for supplying written instruction, which shall be sufficiently comprehensive to enable the operator to service and operate the meter and all equipment supplied by the manufacturer. Project No. 18088080 2 Section 40 91 23.33 Lake Lewisville WTP Dewatering Improvements Magnetic Flow Meter B. Operation and maintenance instruction shall be specific to the equipment supplied in accordance with these specifications. Instruction manuals applicable to many different configurations and meters, and which require the operator to selectively read portions of the instructions shall not be acceptable. C. O&M Manuals: Content, format, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. D. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.5 DELIVERY, STORAGE, HANDLING A. Equipment shall be delivered to the Contractor completely factory assembled. Individual equipment components shall be crated in structurally adequate packing containers to prevent damage during shipping facilitate easy of handling and to provide suitable protection from weather for extended storage at the jobsite prior to installation. Packing containers shall be permanently labeled with appropriate equipment identification, shipping address and return address. Packing list shall be provided with equipment at time of delivery. B. Electrical equipment shall be kept thoroughly dry at all times and shall be stored indoors. Equipment storage shall be protected and maintained in accordance with the manufacturer's recommendations. Equipment shall not be stored directly on the ground. C. The Contractor shall utilize equipment and tools of adequate size suitable for unloading, transporting, storing and supporting the equipment during installation. Caution shall be employed to prevent equipment damage resulting from abrupt contact with other materials or equipment. 1.6 WARRANTY A. The manufacturer shall warrant the equipment to be of quality construction, free from defects in materials and workmanship. The warranty shall become effective upon acceptance by the Owner or Owner's authorized agent. B. The equipment, apparatus, and parts furnished shall be warranted for a period of one (1) year, excepting only those items that are normally consumed in service, such as fuses, oil, grease, packing, gaskets, O-rings, etc. The manufacturer shall be solely responsible for the warranty of the equipment and all components. C. Upon request from the Engineer and/or the Owner, the manufacturer shall demonstrate proof of financial responsibility with respect to performance and delivery date. In addition, the manufacturer shall provide proof of evidence of facilities, equipment, and skills required to produce the equipment specified herein and provide technical service and replacement parts. D. Components failing to perform as specified by the Engineer, or as represented by the manufacturer, or proven defective in service during the warranty period, shall be replaced, repaired, or satisfactorily modified by the manufacturer without cost of parts or labor to the Owner. E. The manufacturer shall provide an application performance guarantee with submittals. 1.7 DESCRIPTION A. Dimensional Information Project No. 18088080 3 Section 40 91 23.33 Lake Lewisville WTP Dewatering Improvements Magnetic Flow Meter 1. Belt Filter Press- 6” PART 2 - PRODUCTS 2.1 MANUFACTURERS A. The flow meters furnished under this contract shall be as manufactured by Krohne, Isco, Foxboro, or equal. B. Approval for an equivalent flowmeter will be considered if the proposed equivalent flowmeter meets the specifications as described herein and an actual one (1) week on-site flowmeter demonstration is performed. The flow meter manufacturer shall submit the flow data collected during the one (1) week demonstration to the Engineer and Owner for review and consideration. 2.2 DESCRIPTION A. The flow meter shall operate on electromagnetic induction principle and give an output signal directly proportional to the liquid rate of flow. B. Each meter shall have a stainless steel metering tube and a non-conductive liner of hard rubber or polyurethane, suitable for the liquid being metered. End connections shall be steel flanged for sizes 1/2” and greater, ANSI Class 150#, for meter sizes up to 24" and AWWA Class B or D for meters larger than 24". The housing shall be epoxy coated steel welded at all joints. C. There shall be no electronic components on the primary flowhead. Coil drive power shall be supplied by an integral or remote converter. Output signal from the primary shall be fed through ‘DS’ proprietary cable supplied with the meter for remote signal converters. D. The flowmeter shall have the ability to indicate flow rate, flow velocity, signal strength, liquid sonic velocity, Reynolds Number and liquid aeration level. The flow meter shall provide self and application diagnostics to isolate any fault conditions to either equipment failure or abnormal process conditions. The flow meter shall have full HELP menu routines corresponding to all leveles of programming and interrogation. E. The primary flowhead shall be housed in a weatherproof NEMA 4X and NEMA 6 Enclosure. F. The magnetic inductive flow converter shall be integral or remote mounted and provide precisely controlled and regulated, bi-polar DC primary field excitation pulses at a keyed frequency of either 2, 1 1/3, 2/3, 1/2, 1/4, 1/6, 1/8, 1/12, 1/18, 1/36, or 1/50 of line frequency (50 Hz or 60 Hz), digitally selectable. It shall convert the primary flowmeter signal into a standard linear analog or pulse/frequency output directly proportional to the flow rate or flow total. The convertor shall be capable of up to (4) inputs or outputs with selectable combinations of: -Standard 4-20 mA DC -Totalized pulses, with each pulse representing a fixed volume or mass -Frequency output of 0-10 kHz -Control Input -Alarm/Status Output G. The converter shall be capable of monitoring all common modes of failure of magnetic inductive flowmeters, complying with VDI/VDE/WIB/NAMUR Guideline 2650. This capability allows the Project No. 18088080 4 Section 40 91 23.33 Lake Lewisville WTP Dewatering Improvements Magnetic Flow Meter converter to verify 100% check of flowmeter software and hardware components, 100% check of accuracy and linearity, and 100% check of process conditions that may adversely affect flow measurement uncertainty. The converter shall provide local display of detected errors, as well as the ability to assign any or all errors to outputs. H. The converter shall be microprocessor based and be completely interchangeable with other converters of the same type. I. The flowmeter shall have an accuracy of +/- 0.2% of actual flow rate +/- 1 mm/sec. Repeatability shall be +/-0.15% of flow sensitivity of 0.001 fps at any flow rate including no flow conditions. PART 3 - EXECUTION 3.1 INSTALLATION A. The Contractor shall assume full responsibility for coordination of the entire project, including verification that all electronic systems and equipment components are compatible. The general contractor shall initially operate each equipment system, and shall make all necessary adjustments so that each system is placed in proper operation condition. B. Equipment and materials utilized or supplied for this project must be approved by the Engineer prior to installation. Approval for installation or incorporation in this project will be made only after submittal of manufacturer's shop and installation drawings, test results or other data as required and as specified herein. C. Installation of equipment shall be in full conformance with the manufacturer shop drawings and requirements as approved by the Engineer. Wherever a conflict arises between manufacturer’s instructions and the contract documents, the contractor shall follow the Engineer's decision at no additional cost to the owner. 3.2 WORKMANSHIP A. The Contractor shall install equipment and materials furnished under this bid in a workmanlike manner utilizing craftsmen skilled in the particular trade. The finished installation shall portrait a neat, plumb and clean appearance. 3.3 MANUFACTURERS SERVICES A. Provide the services of a representative of the meter manufacturer to assist in adjusting and testing the equipment, to supervise initial operation, and to assist in making final adjustments and the tests specified, or which may be necessary to assure the Engineer and Owner that the equipment is in satisfactory operating conditions. This service shall be a minimum of one (1) trip, each consisting of one (1) four (4) hour day on the jobsite. B. See Section 01 60 00, PRODUCT REQUIREMENTS, and Section 01 79 00, DEMONSTRATION AND TRAINING. C. Provide MANUFACTURER’s Certificate(s) in accordance with DIVISION 01, GENERAL REQUIREMENTS. END OF SECTION Project No. 18088080 1 Section 40 92 13 Lake Lewisville WTP Dewatering Improvements Motorized Operators SECTION 40 92 13 - MOTORIZED OPERATORS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Motorized gate and valve operators and mechanical, gear type limit switches. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 60 00 – Product Requirements. 1.2 GENERAL A. Certain operators are specified in Division 44 to be furnished by equipment manufacturer as part of their equipment package and/or system. These operators are to be installed by the CONTRACTOR as specified herein. In addition to installation, the CONTRACTOR shall be responsible for test, inspection, and assisting the equipment suppliers in start-up services as required to the place the operators into continuous, reliable operation. 1.3 SCHEDULES A. Operator schedules are contained within the Process Valve Schedules. 1.4 REFERENCES A. American Water Works Association (AWWA). B. National Electrical Manufacturer’s Association (NEMA) 1.5 SUBMITTALS A. Submittals shall be made as required in Section 01 33 00, SUBMITTALS of Division 01, GENERAL REQUIREMENTS. The following specific information shall be provided: 1. Design Data: a. Product data sheets for make and model. b. Complete catalog information, descriptive literature, specifications, and identification of materials of construction. c. Operating torque calculations for each valve size and class. d. Maximum starting and normal operating torques for the operators supplied. Size operator for maximum starting torque. 2. Quality Control Submittals: a. Tests and inspection data. b. Manufacturer’s Certificate of Proper Installation. c. Manufacturer’s printed installation instructions. d. Special shipping, storage and protection, and handling instructions. e. Suggested spare parts list to maintain the equipment in service for a period of 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. f. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance. 1.6 QUALITY ASSURANCE A. Ascertain that the valve manufacturer provides limit switches with the valves. Project No. 18088080 2 Section 40 92 13 Lake Lewisville WTP Dewatering Improvements Motorized Operators B. Actuator/operator manufacturer shall coordinate with the valve manufacturer and submit calculations showing the maximum and normal operating torques for the valves and operators supplied. PART 2 - PRODUCTS 2.1 MOTORIZED OPERATOR A. Manufacturers: Motorized operators for gates and valves shall be the product of a single supplier for each type of gate or valve. Products shall be furnished by one of the following, or ENGINEER approved equal: 1. AUMA 2. Limitorque Company, Model MX. 3. EIM Company. B. Design: 1. Sized to move gates or valves from full open to closed position at minimum 12 inches per minute, plus or minus 10 percent, under maximum load. a. Measure rate of closure for butterfly valve discs at disc edge on diameter at right angle to valve shaft. 2. Actuator: Provide with built-in device to allow motor to reach full speed before engaging valve load; in manual operating mode when motor is not energized; in electrical operating mode when motor is energized. 3. Handwheels for Manual Operation: Metallic with arrows to indicate “open” rotation; incapable of rotation during motor operation; unaffected by fused motor; maximum 80 pound pull on rim when rotating. 4. Declutch Lever: Padlockable, capable of mechanically disengaging motor and related gearing positively when motor is deenergized and freeing handwheel for manual operation. C. Actuator Gearing: 1. Valve Actuator Gearing: Multiple reduction type with hardened alloy steel spur or helical gears and self-locking, alloy bronze worm gear set in drive train to maintain valve position. 2. Gate Actuator Gearing: Multiple reduction type with hardened alloy steel spur gear, bevel pinion and bevel gears; self-locking to maintain gate position. 3. Power Gearing: Hardened alloy steel; accurately cut to assure minimum backlash; anti- friction bearing with caged balls or rollers throughout. 4. Stem Nuts: High tensile manganese bronze; accurately machined and mounted in heavy ball or roller bearings; minimum 2-1/4 times stem diameter for length of thread in lift nuts. 5. Actuator Gear Housing: Ductile iron. 6. Lubrication: Rotating power train components immersed in grease with provisions for inspection and re-lubrication without disassembly. a. Lubricants: Suitable for ambient conditions of minus 20 degrees Fahrenheit to plus 150 degrees Fahrenheit. b. Provide seals on shafting. D. Motors: 1. Type: Specifically designed for valve actuator service with high starting torque, totally enclosed non-ventilated construction. 2. Motor Insulation: Minimum NEMA Class F, with a maximum continuous temperature rating of 155 degrees Centigrade, rise plus ambient. 3. Motor Windings: Epoxy treated. 4. Size: Sufficient to open and close valves at maximum stated torque. 5. Voltage Tolerance: Capable of operating at within 10 percent of specified voltage. Project No. 18088080 3 Section 40 92 13 Lake Lewisville WTP Dewatering Improvements Motorized Operators 6. Motor Duty Ratings: 15 minute duty rating for open and close service; continuous duty rating for modulating service. 7. Accessories: Internal thermal contacts, heaters in motor and switch compartment, and ground lug. 8. Power Supply: As scheduled or as indicated on the Drawings. 9. Enclosures for Motors, Switches, and Other Electrical Compartments: a. Where explosion-proof construction is indicated on the Drawings, provide NEMA 7 enclosures. b. Other Locations: Provide NEMA 4X enclosures. E. Controls: 1. Voltage Transformer: As required to step down power supply to control voltage. 2. Control Station: a. Integral with operator or mounted in separate enclosure. 1) Where explosion-proof construction is indicated on the Drawings, provide NEMA 7 enclosure. 2) For other locations, provide NEMA 4X enclosure. b. Provide with additional contacts for remote indication of hand switch position where indicated on the Drawings. c. Provide with the following devices: 1) Lock-out HAND-OFF-AUTO selector switch. 2) OPEN, STOP, CLOSE pushbuttons. 3) OPEN and CLOSE indicating lights. 3. Limit switches and associated gearing shall be integral with valve actuator. a. Gearing: Intermittent type; bronze or stainless steel; grease lubricated; totally enclosed. b. Contacts: Heavy duty and silver plated with wiping action. c. Remote Indication Contacts: As indicated on the Drawings. d. Switches: Adjustable; allowing for trip points from fully open to closed positions of valve travel; not subject to breakage or slippage due to over-travel; permits visible verification of switch position without disassembly. 4. Torque Limit Switch: a. Capable of interrupting control circuit in both opening and closing when valve torque overload occurs. b. Silver plated contacts. c. Graduated dials for both open and close directions of travel, each independently adjustable. d. Positive means to limit adjustability to avoid exceeding actuator output torque capability with Belleville activating spring pack. e. Permits visible verification of switch position without disassembly. F. Operation: 1. Open-Close Service: a. Operators shall operate automatically by remote signal specified and as indicated on the Drawings. b. When the selector switch is in the AUTO position, the self-contained electromechanical reversing starter shall cause valve or gate to open or close on receiving a remote signal. c. When the selector switch is in the HAND position, the local control station will control the motorized operator. 2. Modulating Service: a. Actuator Controller: Microprocessor based and using proportional-integral derivative algorithm to calculate actuator response. b. Controller shall compare 4 to 20 milliampere direct-current analog command signal to analog feedback signal and move actuator accordingly. Project No. 18088080 4 Section 40 92 13 Lake Lewisville WTP Dewatering Improvements Motorized Operators c. A microprocessor-based controller shall control the integrally mounted solid state reversing starter. 3. Where indicated on the Drawings, provide 4 to 20 milliampere direct-current analog output signal for continuous remote monitoring of position. 4. Controller System: Rated for continuous duty. G. Valve Limit Switches: 1. Type: Mechanical cam gear for remote operation, indication, and other control; compatible with associated operation and suitable for service intended; for valves specified and indicated on the Drawings; with racks, gears, cam, linkage mountings, and accessories. 2. Mechanical Limit Switches: 2-pole, 3-pole, or 4-pole; gang-mounted in required multiples, and with necessary mechanical linkage. 3. Contact Ratings: 120 volt alternating current, 20 amperes at 75 to 100 percent power factor, and 24 volt direct current, 5 amperes minimum. 4. Enclosures: Watertight and oil tight for normal service. 5. Valve box: Large enough to contain and to allow easy adjustment of limit switch without switch’s removal. PART 3 - EXECUTION 3.1 SHIPPING, STORAGE, HANDLING, AND PROTECTION A. As specified in Section 01 60 00, PRODUCT REQUIREMENTS. 3.2 INSTALLATION A. Install operators in accordance with Manufacturer’s instructions. B. Locate valve boxes where indicated on the Drawings. END OF SECTION Project No. 18088080 1 Section 40 92 16 Lake Lewisville WTP Dewatering Improvements Valve and Gate Operators SECTION 40 92 16 - VALVE AND GATE OPERATORS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: 1. Valve and Gate Operators. 2. Handwheel Operators. 3. Key Operated Valves. 4. Bench Stands. 5. Floor Stands. 6. Accessory Equipment and Floor Boxes B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 60 00 – Product Requirements. 3. Section 01 78 23 – Operation and Maintenance Data. 1.2 GENERAL A. Certain valve operators are specified in Division 44 to be furnished by equipment manufacturer as part of their equipment package and/or system. These valve operators are to be installed by the CONTRACTOR as specified herein. In addition to installation, the CONTRACTOR shall be responsible for test, inspection, and assisting the equipment suppliers in start-up services as required to the place the valve operators into continuous, reliable operation. 1.3 SCHEDULES A. Operator schedules are combined with Process Valve Schedules 1.4 REFERENCES A. Aluminum Association (AA) 1. DAF-45 – Design for Aluminum Finishes 1.5 SUBMITTALS A. Submittals shall be made as required in Section 01 33 00, SUBMITTALS of Division 01, GENERAL REQUIREMENTS. The following specific information shall be provided: 1. Shop Drawings: a. Product data sheets for make and model. b. Complete catalog information, descriptive literature, specifications, and identification of materials of construction. c. Power and control wiring diagrams, including terminals and numbers. d. Complete motor nameplate data. e. Open/close and throttle actuators sizing calculations including factor of safety used and final torques used for actuation selection. f. Refer to specific valve type for additional submittal requirements. 2. Quality Control Submittals: a. Special shipping, storage and protection, and handling instructions. b. Suggested spare parts list to maintain the equipment in service for a period of 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. Project No. 18088080 2 Section 40 92 16 Lake Lewisville WTP Dewatering Improvements Valve and Gate Operators c. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance. 1.6 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, format, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.7 QUALITY ASSURANCE A. Provide valve operators integral with the valve or gate, except for valve operators utilizing T- wrenches or keys, and portable operators intended to operate more than one valve. B. Provide all similar operators by one manufacturer. C. Provide gates and hand operating lifts by one manufacturer. D. Provide hydraulic gate lifts by one manufacturer. E. Provide hydraulic valve operators and motorized operators by one manufacturer. 1.8 MAINTENANCE A. Extra materials: 1. Key operated Valve Keys or Wrenches: Furnish a minimum of four keys with 4-foot shafts and 3-foot pipe handles or wrenches with 4-foot shafts and 3-foot handles for operating key operated valves. PART 2 - PRODUCTS 2.1 GENERAL A. Size operator to operate valve for the full range of pressures and velocities. B. Valve to open by turning counterclockwise. C. Factory-mount the operator, actuator, and accessories. 2.2 VALVE OPERATORS A. Manual Operator: 1. General: a. Operator force not to exceed 40 pounds under any operating condition, including initial breakaway, and gear reduction operator when force exceeds 40 pounds. b. Operator self-locking type or equipped with self-locking device. c. Position indicator on quarter-turn valves. d. Worm and gear operators one-piece design worm-gears of gear bronze material. Worm hardened alloy steel with thread ground and polished. Traveling nut type operators, threader steel reach rods with internally threaded bronze or ductile iron nut. 2. Exposed Operator: a. Galvanized and painted hand wheels. Project No. 18088080 3 Section 40 92 16 Lake Lewisville WTP Dewatering Improvements Valve and Gate Operators b. Lever operators allowed on quarter-turn valves 8” and smaller. c. Cranks on gear type operators. d. Chain wheel operator with tiebacks, extension stem, floor stands, and other accessories to permit operation from normal operation level. e. Valve handles to take a padlock, and wheels a chain and padlock. 3. Buried Operator: a. Buried service operators on valves larger than 2-1/2” shall have a 2” AWWA operating nut. Buried operators on valves 2” and smaller shall have cross handle for operation by forked key. Enclose moving parts of valve and operator in housing to prevent contact with the soil. b. Design buried service operators for quarter-turn valves to withstand 450 foot- pounds of input torque at the FULLY OPEN or FULLY CLOSED positions, grease packed and gasketed to withstand a submersion in water to 10 psi. c. Buried valves shall have extension stems, bonnets, and valve boxes. 2.3 VALVE AND GATE OPERATORS A. Stem Covers: 1. Aluminum pipe; threaded cap on top; bolted aluminum flange on bottom; 1 by 12 inch slots cut at 18 inches on center in front and back of pipe; capable of covering threaded portion of greased stems that project above operators when gates or valves are opened or closed. B. Stem Cover Flanges, Pipes and Caps: 1. Etched and anodized to produce chemical finishes in accordance with AA C 22, medium matte finish, and AA A 41 clear anodic coating, or described in AA publication 45, after fabrication C. Gate Stem Covers: Concentric with stem D. Position Indicators: 1. Tail rods on hydraulic cylinders, or dial indicators with clear full-open and closed position indicators, calibrated in number of turns or percentage of opening. E. Manual or Power Operator Size: 1. Sized to deliver maximum force required under most severe specified operating condition, including static and dynamic forces, seat and wedge friction, and seating and unseating forces with safety factor of five, unless otherwise specified. F. Operator Size: Capable of supporting weight of suspended shafting unless carried by bottom thrust bearings; shaft guides with wall mounting brackets. G. Provisions for Alternate Operation: Where specified or indicated on the Drawings, position and equip crank- or handwheel-operated geared valve operators or lifts for alternate operation with tripod mounted portable gate operators. H. Operation: Counterclockwise to open with suitable and adequate stops, capable of resisting at least twice normal operating force to prevent overrun of valve or gate in open or closed position. I. Open Direction Indicator: Cast arrow and legend indicating direction to rotate operator on handwheel, chain wheel rim, crank, or other prominent place. J. Buried Operator Housing: Oil and watertight, specifically designed for buried service, factory packed with suitable grease, completely enclosed space between operator housing and valve Project No. 18088080 4 Section 40 92 16 Lake Lewisville WTP Dewatering Improvements Valve and Gate Operators body so that no moving parts are exposed to soil; provide operators with 2 inch square AWWA operating nut. K. Worm Gear Operators: Provide gearing on worm gear operators that is self-locking with gear ratio such that torque in excess of 160 foot-pounds will not need to be applied to operate valve at most adverse conditions for which valve is designed. L. Traveling Nut Operators: Capable of requiring maximum 100 foot-pounds of torque when operating valve under most adverse condition; limit stops on input shaft of manual operators for fully open and closed positions; non-moving vertical axis of operating nut when opening or closing valve. 2.4 HANDWHEEL OPERATORS A. Manufacturers: One of the following, or equal: 1. Rodney Hunt Company. 2. Waterman Industries, Incorporated. B. Mounting: Floor stand or bench stand. Unless otherwise indicated on the Drawings position operator 36 inches (nominal) above top of walkway surface. C. Bearings above and below Finished Threaded Bronze Operating Nut: Ball or roller. D. Wheel Diameter: Minimum 24-inch. E. Indicator: Counterclockwise opening with arrow, and word OPEN cast on top of handwheel indicating direction for opening. F. Pull to Operate: Maximum 40 pounds pull at most adverse design condition. G. Stem Travel Limiting Device: Setscrew locked stop nuts above and below lift nut. H. Grease Fittings: Suitable for lubrication of bearings. 2.5 HAND-CRANKED GEARED OPERATORS A. Type: Single removable crank; fully enclosed. B. Mounting: Floor and Bench Stand. Unless otherwise indicated on the Drawings, position the operator 36-inches (nominal) above the top of the walkway surface. C. Operating Nut: When scheduled for portable operators. D. Geared Lifts: 2-speed with minimum ratio of 4 to 1. E. Teeth on Gears, Spur Pinions, Bevel Gears, and Bevel Pinions: Cut. F. Lift Nuts: Cast manganese bronze. G. Exterior Surfaces on Cast Iron Lift Parts: Smooth. H. Bearings above and below Flange on Lift Nuts: Ball or roller; capable of taking thrust developed by opening and closing of gates under maximum operating head; with bronze sleeve bearings and sufficient grease fittings for lubrication of moving parts, including bearings and gears. Project No. 18088080 5 Section 40 92 16 Lake Lewisville WTP Dewatering Improvements Valve and Gate Operators I. Crank Rotation Indicator: Cast arrow with word OPEN in prominent, readily visible location indicating correct rotation of crank to open gate. J. Hand Cranks: 15 inch radius; requiring maximum 25 pounds pull to operate gate at maximum operating head with: 1. Revolving brass sleeves. 2. Gears, spur pinions, bevel gears, and bevel pinions with cut teeth. 3. Cast manganese bronze lift nuts. 4. Cast iron lift parts with smooth exterior surfaces. K. Indicator: Dial position type mounted on gear operator; enclosed in cast-iron or aluminum housing with clear plastic cover; marked with fully open, 3/4, 1/2, 1/4, and closed positions. 2.6 FLOOR BOX AND STEM A. Manufacturers: One of the following, or equal: 1. Waterman Industries, Inc. 2. Neenah Foundry; R 7506. 3. Clow; No. F5690. B. Floor Boxes: Cast iron with: 1. Plain type, for support of non-rising type stem. 2. Complete with stem, operating nut, and stem guide brackets. 3. Stem Guide: Space such that stem UR ratio does not exceed 200. 4. Anchor Bolts: Type 304 SST. 5. Counter type indicator. 6. Hinged, lockable lid with directional arrow. 7. 2-inch square AWWA operating nut. 8. Packing gland providing drip-tight seal around valve shaft. 2.7 FLOOR STAND AND EXTENSION STEM A. Manufacturers: One of the following, or equal: 1. Clow; Figure F-5515. 2. Mueller, Figure A-26426. 3. Rodney Hunt Company. 4. Waterman Industries, Incorporated. B. Floor Stand Assemblies: Heavy-duty cast iron, suitable for mounting specified operator. 1. Nonrising, indicating type. 2. Complete with stem, coupling, hand wheel, stem guide brackets, and yoke attachment. 3. Stem Guide: Space such that stem UR ratio does not exceed 200. 4. Anchor Bolts: Type 304 SST. 2.8 BENCH STANDS A. Manufacturers: One of the following, or equal: 1. Rodney Hunt Company. 2. Waterman Industries, Incorporated. B. Bench Stands: Handwheel operators or hand crank, geared operators conforming to hand- cranked geared operator requirements, except capacity to be mounted on haunch, wall bracket, or self-contained gate yoke. Project No. 18088080 6 Section 40 92 16 Lake Lewisville WTP Dewatering Improvements Valve and Gate Operators 2.9 ACCESSORY EQUIPMENT A. T-Handled Operating Wrench: 1. 2 each galvanized operating wrenches, 4 feet long. 2. Manufacturers and Products: a. Mueller; No. A-24610. b. Clow No.; F-2520. 3. 2 each galvanized operating keys for cross handled valves. B. Extension Bonnet for Valve Operator: Complete with stem and accessories for valve and operator. 1. Manufacturers and Products: a. Metallic Valves: 1) Pratt. 2) Allis-Chalmers. b. Plastic Valves: ASAHI/America. C. Chain Wheel and Guide: 1. Install chain wheel and guide assemblies or chain lever assemblies on manually operated valves over 6’ 9” above finished floor. Use appropriate “L” type tie-back anchors where chains hang in normally traveled areas. Hand wheel direct-mount type. 2. Complete with chain. 3. Galvanized or cadmium-plated. 4. Manufacturers and Products: a. Clow Corp.; Figure F-5680. b. Walworth Co.; Figure 804. c. DeZurik Corp.; Series W or LWG. D. Wall Brackets or Haunches: As indicated on the Drawings. E. Stems: Stainless steel; sized to match output of operator; minimum gate or valve operating stem diameter; maximum 200 slenderness ratio. F. Stem Couplings: Stainless steel; internally threaded to match stem; lockable to stem by set screw. G. Stem Guides: Cast iron with silicon bronze bushing; maximum 200 slenderness ratio; capable of being mounted with a wall bracket; adjustable in 2 directions. H. Wall Brackets: Cast iron, capable of withstanding the output of the operator; adjustable in 2 directions. I. Stem Stuffing Boxes: Cast iron, with adjustable gland and packing. J. Fasteners and Anchor Bolts: 316 stainless steel. K. Geared Valve Operators: Provided with cut gears, either spur or worm; sized to operate valves at most adverse design condition; with maximum 40 pound pull at handwheel or chain wheel rim. L. Geared Valve Traveling Nut Operators: Acceptable only where specified or indicated on the Drawings. M. Accessory Equipment for Valves and Gates Requiring Remote Operators: Operating stems, stem couplings, stem guides, wall brackets, and stem stuffing boxes. Project No. 18088080 7 Section 40 92 16 Lake Lewisville WTP Dewatering Improvements Valve and Gate Operators PART 3 - EXECUTION 3.1 SHIPPING, STORAGE, HANDLING, AND PROTECTION A. As specified in Section 01 60 00, PRODUCT REQUIREMENTS. 3.2 INSTALLATION A. Install floor boxes in concrete floor with lid flush with floor. B. After installation of gate and stem covers, mark stem covers at point where top of stems are at full-open position and at closed position. C. Attach floor stand to structure with anchor bolts. D. Install stem stuffing boxes where operating stems pass through intermediate concrete floor slabs. 3.3 SCHEDULES A. Geared Operators: Provide geared operators for following valves: 1. Butterfly valves larger than 6 inches, nominal size, on liquid service. 2. Butterfly valves larger than 10 inches, nominal size, on gas and air service. 3. Plug valves 6 inches, nominal size, and larger. B. Handwheel operators: Provide handwheel operators for valves mounted at 6 feet or less above floors. C. Chain Wheel Operators; Provide chain wheel operators for valves mounted more than 6 feet to centerline above floors. END OF SECTION DIVISION 41 MATERIAL PROCESSING AND HANDLING EQUIPMENT Project No. 18088080 1 Section 41 12 13 Lake Lewisville WTP Dewatering Improvements Dumpster-Veyor Patented Container Handling System SECTION 41 12 13 – DUMPSTER-VEYOR PATENTED CONTAINER HANDLING SYSTEM PART 1 - GENERAL 1.1 SUMMARY A. Design / Manufacturer 1. The Dumpster-Veyor is designed to provide the operator a means to evenly distribute material into a roll-off container being deposited from a conveyor or chute. The system has a rated capacity of 20 tons. 2. The components of the Dumpster-Veyor include two (2) runs of runway track with anchors, two (2) drive tracks, one 1) idler articulating carriers, one (1) drive articulating carrier, one (1) positive control dual directional closed loop drive system with controls and one (1) return sheave. 3. The Dumpster-Veyor shall be manufactured by D. R. Cordell & Associates, Inc., Chalfont, PA 18914, (215) 822-9345, www.cordellmfg.com B. Related sections: 1. Section 01 33 00 – Submittal Procedures 2. Section 01 60 00 – Product Requirements 3. Section 01 78 23 – Operation and Maintenance Data 4. Section 01 79 00 – Demonstration and Training 5. Section 05 50 00 – Metal Fabrications 6. Section 09 90 00 – Painting and Protective Coatings 7. Section 26 05 15 – Electrical Motors 8. Division 26 – Electrical Sections 1.2 GENERAL A. Like items of equipment provided hereinafter shall be the end products of one manufacturer to achieve standardization of appearance, operation, maintenance, spare parts and manufacturer’s services. B. Unit Responsibility: The Work requires that the provided equipment, local control panels, instruments, and components complete with all accessories and appurtenances be the end product of one responsible system manufacturer or responsible system supplier. Unless otherwise indicated, the Contractor shall obtain each system from the responsible supplier of the equipment. The supplier shall furnish all components and accessories of the system to enhance compatibility, ease of operation and maintenance, and as necessary to place the equipment in operation in conformance with the specified performance, features, and functions without altering or modifying the Contractor's responsibilities under the Contract Documents. The Contractor is responsible to the Owner for providing the equipment systems as specified herein. C. General Requirements: See Division 01, GENERAL REQUIREMENTS, which contains information and requirements that apply to the work specified herein and are mandatory for this project. 1.3 SUBMITTALS A. General: Administrative, shop drawings, samples, quality control, and contract closeout submittals shall conform to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES. B. In addition to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES, submit the following additional specific information: 1. Shop Drawings: Project No. 18088080 2 Section 41 12 13 Lake Lewisville WTP Dewatering Improvements Dumpster-Veyor Patented Container Handling System a. All drawings to be generated using a 3D Computer Aided Drafting program including but not limited to Autodesk Inventor, PTC ProEngineer, Dassault Systèmes SOLIDWORKS, or equal. b. Make, model, weight, and horsepower of each component. c. Manufacturer's catalog information, descriptive literature, specifications, and identification of materials of construction. d. Detailed mechanical, and electrical drawings showing the equipment fabrications and interface with other items. Include dimensions, size, and details of anchorage and of connections to other work, and weights of associated equipment. e. All material and drawings to be provided in Imperial system. Any metric material sizes, drawing dimensions, or hardware are unacceptable. This ensures replacement parts are easily obtained in North America. f. Flight diameter, thickness, and pitch of each screw. g. Trough diameter for each screw. h. Rotating speed of each screw. i. Percentage of active trough area filled under design capacity for each screw. j. Spiral strength calculations for spring (spiral) compression and elongation showing the supplied spiral meets or exceeds spring effect intent herein k. Conveyor torque requirement calculations. l. Torque calculations for the gear reducer and reducer motor. m. External utility requirements (quantity and connection details) such as air, water, power, drain etc., for each component. n. Motor nameplate data, motor manufacturer, and any motor modifications. o. Wiring diagrams for motors, including terminals and numbers. p. Suggested spare parts list to maintain the equipment in service for a period of 1 year and 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. q. List of special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance. r. Instrumentation and Control Submittals: In conformance with Division 26. 2. Quality Control Submittals: a. Manufacturer's Certificate of Compliance: Commercial products, including painting/coating systems. b. Special shipping, storage and protection, and handling instructions. c. Test and work procedures. Manufacturer shall carry a current, valid certificate of ISO-Certification or equal as approved by the ENGINEER. d. Test results, reports, and certifications. e. Manufacturer's Certificate of Proper Installation. f. Operation and maintenance manual. 3. Contract Closeout Submittals: Service records for maintenance performed during construction. 4. Support and Anchorage Calculations: Manufacturer must supply calculations for support and anchorage design accounting for wind, seismic, and worst-case product load considerations including 100% fill level. Calculations must be validated and P.E. stamped by a third party engineering firm licensed in the state of Texas. 1.4 QUALITY CONTROL A. Balancing: Rotating elements of equipment, except small, commercially packaged equipment, shall be statically and dynamically balanced at the factory prior to final assembly. The Contractor shall furnish certified copies of all test results. Project No. 18088080 3 Section 41 12 13 Lake Lewisville WTP Dewatering Improvements Dumpster-Veyor Patented Container Handling System 1.5 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, format and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.6 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer will promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. 1. PART 2 - PRODUCTS 2.1 COMPONENTS A. Runway and Drive Tracks 1. The runway track shall be manufactured using 304 stainless steel and be a built up fabricated section, providing a track system on which the drive and idler carts operate. Tracks shall be positioned under a discharge point so that the track extends in either direction from the discharge point as shown on the drawings. Track length shall be as indicated on the drawings spaced at approximately 7'-6" 2. Track joints are spliced using a lap joint. Ends of adjoining tracks manufactured to allow the square bar to overlap the base plate. Track ends are shop fabricated to permit smooth transition from track section to track section during carrier travel. No field welding at track joints is required. The base plate is drilled at regular intervals for mounting to a flat concrete surface using expandable anchors or an epoxy anchor system. 3. The drive track shall be manufactured using a UHMW guide channel bolted directly to the concrete floor. The guide channel is drilled at regular intervals for mounting to a flat concrete surface using an expandable anchoring system or the epoxy system. Two tracks running from the drive winch to the idler sheave are required spaced at approximately 9" apart. The drive chain rides in the guide channel. B. Idler Carriers 1. One (1) low profile, heavy duty 304 stainless steel idler carrier having a capacity of 10 tons, and a nominal plan size of 8'-3" by 2'-8" shall be provided for the container handling system. The idler carrier shall be assembled to prevent skewing and racking and to accurately accept the articulating wheel assemblies. 2. The carriers shall be drilled to ensure articulating axle alignment. The axles shall be held in place by retainer plates which are easily removable to allow component inspection. Dual wheel stops shall be provided to prevent wheel overload and container roll off when traveling. Stops shall be factory welded and located to clear any obstruction on the underside of the container. 3. The idler carrier shall be equipped with eight (8) double flanged, 304 stainless steel wheels assembled into articulating trolley assemblies. Articulating trolley assemblies are designed to maintain equal wheel loading at all times during carrier travel. Wheels shall interface with the runway track to allow easy tracking and eliminate binding during travel. Project No. 18088080 4 Section 41 12 13 Lake Lewisville WTP Dewatering Improvements Dumpster-Veyor Patented Container Handling System C. Drive Carrier 1. One (1) low profile, heavy duty 304 stainless steel drive carrier having a capacity of 10 tons and a nominal plan size or 8'-3" by 2'-8" shall be provided for the container handling system. The unit shall be assembled to prevent skewing and racking and to accurately accept the articulating wheel assemblies. 2. The carriers shall be drilled to ensure articulating axle alignment. The axles shall be held in place by retainer plates which are easily removable to allow component inspection. Dual wheel stops shall be provided to prevent wheel overload and container roll off when traveling. Stops shall be factory welded and located to clear any obstructions on the underside of the container. 3. Center portion of the drive carrier shall be equipped with steel welded lugs for connection of drive chain and swiveling clevis connectors. 4. The drive carrier shall be equipped with eight (8) double flanged, 304 stainless steel wheels assembled into articulating trolley assemblies. Articulating trolley assemblies are designed to maintain equal wheel loading at all times during carrier travel. Wheels shall interface with the runway track to allow easy tracking and eliminate binding during travel. D. Articulating Trolley Assemblies 1. Each articulating trolley assembly shall consist of 304 stainless steel top pivoting shaft, two (2) 304 stainless steel heavy duty side plates, two (2) 304 stainless steel double flanged wheels with stainless steel sealed bearings and two (2) 304 stainless steel wheel axles. The top pivoting shaft shall secure the assembly in place on the carrier frame and allow articulating motion for equal wheel loading. 2. Wheels shall be double flanged, 5" tread diameter for operation of 1-1/2" bar track, with sealed roller bearings. Wheels to be manufactured from 304 stainless steel. Wheels are to be mounted on the free floating axles and mounted in the heavy duty side plates. All components are easily removable for inspection and replacement if required. E. Closed Loop Winch 1. A single speed, base mounted, positive control, dual directional electric motor driven carrier puller shall be furnished with the drive carrier. The puller shall operate at a speed to move the container at approximately 18 FPM unless otherwise indicated. 2. The puller base frame shall be a fabricated steel weldment designed for easy access to motor, gearbox and drive wheel. 3. The electric motor shall be single speed, 30 min duty rated with high starting torque characteristics. Motor shall be C-Face mounted design with minimum class B insulation. Enclosure shall be NEMA 7. 4. The gearbox shall be cycloidal type design providing high reduction with minimal space requirements. Cycloidal drive shall be Sumitomo, with grease lubrication. Bearings shall be rated for 5000 hours, L-10 bearing life. 5. A Zinc plated steel chain seated in a type 304 stainless steel pocket wheel mounted to the output shaft on the cycloidal gearbox shall connect to the idler sheave, also having a 304 stainless steel pocket wheel. The drive sheave and idler sheave shall be mounted in the horizontal plane for a low profile configuration. Drive chain shall run in UHMW guide channel described previously in this specification. 6. The electric motor shall be TENV 30 min. duty rating, 2 HP, single speed with high starting torque characteristics. Motor shall be C-face mounted design with minimum class B insulation. Motor shall operate on 460 volts, 3 phase, 60 hertz, and control voltage to be reduced to 120 volt single phase. 7. Two magnetically operated travel limit switches shall be provided to stop carrier movement at extreme ends of the track. Steel lugs are welded to the drive and idler carriers. The steel lugs trip magnetically activated proximity switches, one mounted at each end of the track length. F. Return Idler Sheave Project No. 18088080 5 Section 41 12 13 Lake Lewisville WTP Dewatering Improvements Dumpster-Veyor Patented Container Handling System 1. The return idler sheave shall be mounted horizontally inside a heavy duty 304 stainless steel weldment designed for low profile and able to withstand truck traffic. Idler sheave is a stainless steel pocket wheel operating on roller bearings. The heavy duty steel housing includes holes for mounting the unit to concrete floors. 2.2 INSTRUMENTATION AND CONTROL SYSTEM A. General 1. The container handling system manufacturer shall design, furnish and shop wall mounted control station for control of system movement. Controls shall include a 3 phase power circuit controlled by a single phase control circuit with step down transformer. The control system shall be designed to handle the expected duty cycle of the container handling system. Power supply is 460 volts 3 phase 60 hertz and the control circuit will be 120 volts 1 phase 60 hertz. 2. Control schematic shall include a variable frequency drive (VFD) used for smooth acceleration and deceleration. The inverter detects over-torque situations and opens the directional circuit, and provides dynamic braking to stop carrier movement. Other control features include a warning horn, warning light, power on indicating light and on off switch. 3. All controls are to be located in a NEMA 7 enclosure for Class 1, Division 2 hazardous environment. Heaters shall be included in control enclosures. Push buttons for control of the system movement shall be mounted in the enclosure door, with indicating lights for “power on”, “power off”. Enclosure shall be wall mounted and located as directed by the engineer. 4. A warning horn and light shall be included with the control system. The warning horn shall sound for 15 seconds prior to the system moving, and shall be activated by the forward and reverse buttons. The warning light shall flash during horn signal, and stay flashing during system movement. Light and horn shall be mounted and located as directed by the engineer. B. AutoFILL 1. Provide Dumpster-Veyor AutoFILL feature designed to automatically fill the container evenly. AutoFILL shall include all hardware, software and programming necessary to allow automatic filling and movement of the Dumpster-Veyor. 2. Elevation Sensors positioned around the fill source shall detect piles created inside the dumpster and activate container movement when activated. 3. Container sensors are positioned in the area to confirm the presence of a container prior to AutoFILL execution 4. Elevation and container sensors are mounted in the area directly adjacent to the container loading bay, and are field adjustable up, down and left, right for optimal performance. 5. The control panel shall include an AutoFILL / Off / Manual three position selector switch. When in AutoFILL, the elevation sensors will detect when a pile reaches a determined height, and activate system movement for a timed distance. Prior to movement the horn and light will sound. 6. Movement will only occur if the container sensors are providing the necessary feedback indicating the presence of a container. 7. When the container is full throughout the length, a container sensor will signal such an event and terminate the AutoFILL sequence. C. Control Panels (77DCP01 and 77DCP02) 1. Enclosure: NEMA 4X stainless steel 2. Control panel shall be designed with a SCCR rating of 18kA at 480VAC minimum and labeled as such unless otherwise specified. 3. All terminals utilized in the main panel shall be 600V rated terminals and 20% spare terminal space shall be provided for any potential future revisions. 4. The control panel shall include the following at a minimum: a. Main disconnect circuit breaker interlocked with door handle. Project No. 18088080 6 Section 41 12 13 Lake Lewisville WTP Dewatering Improvements Dumpster-Veyor Patented Container Handling System b. VFD for dumpster-veyor motor. VFD shall be rated for 50 deg C ambient operating temperature. c. Modicon M340 PLC. d. Surge arrestor. e. Control power transformer. f. Control relays. g. Enclosure space heater. h. Alarm beacon and horn. i. Terminal points for interconnection with ancillary equipment. 5. The control panel shall meet U.L. requirements and shall be U.L. 508A listed as a complete assembly. The control panel shall be completely pre-wired and factory tested prior to shipment. 6. Control Panel Operator Interfaces: At a minimum, provide the following functions on the front of the panel: a. Hand Switches and Other Controls: 1) LOCAL-OFF-AUTOFILL three position switch. 2) Push/Pull Emergency Stop. 3) Reset pushbutton. b. Alarms: The following alarms shall be provided on the front of the panel: 1) VFD Fault light 2) General alarm light c. Status: The following status shall be indicated on the front of the panel: 1) Control power on light 2) Running forward light 3) Running reverse light 4) Auto indication light 7. Control Panel External Interfaces: Provide the following interfaces between the control panel and items outside the system package: a. Dry Contact Outputs: 1) Running indication 2) General alarm indication 3) VFD fault indication 4) E-STOP indication 5) Dumpster full indication 6) Dumpster in auto indication PART 3 - EXECUTION 3.1 PAINTING A. General 1. Stainless steel surfaces shall not be painted. The motor shall be provided with the manufacturer’s standard finish. Surfaces shall be hand cleaned with a wire brush and wiped with solvent prior to painting equipment. 2. Equipment shall be touch painted in the filed after installation. All marks and abrasions shall be primed if required, and finish coated. 3.2 INSTALLATION A. General 1. Installation shall be in accordance with the manufacturer’s recommendations, and performed with qualified persons. Tracks shall be anchored to the building floor with stainless steel threaded rod and Epcon Epoxy System, or expansion anchors depending on surface conditions. 2. The Epcon mounting system incorporates a leveling nut under track to set elevation of track along the length. After installation, grout shall be installed under track along the entire Project No. 18088080 7 Section 41 12 13 Lake Lewisville WTP Dewatering Improvements Dumpster-Veyor Patented Container Handling System length. Drive winch and idler sheave shall be installed the same way if the Epcon system is used. 3. The concrete floor shall have a constant slope in one direction, not exceeding 1/4" per 10’- 0” of run for run-off purposes. Trench drains running perpendicular to the tracks at intervals dictated by the engineer is the preferred method for drainage in a new facility. 4. Track, guide channel, drive and idler shall be installed at the same elevation (+-) 1/4". Care should be taken to ensure alignment of guide track to drive chain during installation. 3.3 TESTING AND START-UP A. General 1. The container handling system shall be tested for proper operation prior to being put into service. All controls, lights, horns, limit switches and stops shall be tested in a no-load situation. 2. A container to be provided by others can be used to perform a partial load test. The container, delivery of the container and removal of the container is to be provided by the owner. An operational and partial load test will be performed with an empty container. The owner is responsible for obtaining a loaded container to perform a full load test. 3. Tests shall include operating the equipment the full length of the tracks, checking travel limit switches and carrier operation. END OF SECTION DIVISION 43 PROCESS GAS AND LIQUID HANDLING, PURIFICATION AND STORAGE EQUIPMENT Project No. 18088080 1 Section 43 21 43 Lewisville Lake WTP Dewatering Improvements Washwater Equalization Sump Pump SECTION 43 21 43 – SUMP PUMPS 1.1 WORK INCLUDED A. This section covers the Work necessary to furnish and install, complete, the Sump Pumps specified herein, and as further specified in the Sump Pump Data Sheets hereinafter. 1.2 GENERAL A. Equipment Numbers: See supplemental data sheet(s) at end of section. B. Like items of equipment provided hereunder shall be the end products of one Manufacturer in order to achieve standardization for appearance, operation, maintenance, spare parts, and Manufacturer’s service. C. See CONDITIONS OF THE CONTRACT, and Division 01, GENERAL REQUIREMENTS, which contain information and requirements that apply to the work specified herein and are mandatory for this project. D. Unit Responsibility: The Work requires the Sump Pumps complete with all accessories and appurtenances including, but not necessarily limited to, Pump, Motor, spare parts, start-up, and testing be the end product of one responsible Manufacturer. Unless otherwise indicated, the Contractor shall obtain each system from the Manufacturer of the equipment, which Manufacturer shall provide all components of the system to enhance compatibility, ease of construction, and efficient operation and maintenance, and as necessary to place the equipment in operation and its intended functions without altering or modifying the Contractor’s responsibilities under the Contract Documents. The Contractor is responsible to the Owner for performance of all equipment systems as indicated. E. The equipment specified herein is included in the Manufacturer/Subcontractor Form. Refer to the Bid Form and the Instructions to Bidder for additional requirements. 1.3 SUBMITTALS A. Submittals shall be made as required in Section 01 33 00, SUBMITTAL PROCEDURES of Division 01, GENERAL REQUIREMENTS .The following specific information shall be provided: 1. Shop Drawings: Shop drawings shall include descriptive information as required to fully describe the Pumps, Controls, Motors, and overall performance and shall identify any deviations from the specified requirements. 2. Special handling instructions, in accordance with Section 01 60 00, PRODUCT REQUIREMENTS. 3. Requirements for storage and protection prior to installation, in accordance with Section 01 60 00, PRODUCT REQUIREMENTS. 4. Requirements for routine maintenance required prior to plant startup, in accordance with Section 01 60 00, PRODUCT REQUIREMENTS. 5. List of all requested exceptions to the Contract Documents. 6. Motor information to be submitted in accordance with Division 26, ELECTRICAL. 7. Quality control submittals as listed in Section 01 33 00, SUBMITTAL PROCEDURES of Division 01, GENERAL REQUIREMENTS. 8. Instrumentation and control submittals as listed in Section 26 09 00, INSTRUMENTATION AND CONTROLS. 9. Factory Test Reports (Balance & Vibration). 10. Contract Closeout Submittals: a. Service records for maintenance performed during construction. b. Warranty Project No. 18088080 2 Section 43 21 43 Lewisville Lake WTP Dewatering Improvements Washwater Equalization Sump Pump 1.4 QUALITY CONTROL Balancing: Rotating elements of equipment, except small, commercially packaged equipment, shall be statically and dynamically balanced at the factory prior to final assembly. The Contractor shall furnish certified copies of all test results. 1.5 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, format, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.6 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer will promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. The use of a Manufacturer’s name and model or catalog number is for the purpose of establishing the standard of quality and general configuration. Where a manufacturer’s standard equipment name or model number is listed, the equipment system shall be provided and modified as required to conform to the performance, functions, features and materials of construction as specified herein. B. Each pump shall be of the sealed submersible type, incorporating features normally found in pumps furnished for the residential market. These features include: 1. The pump volute, motor and seal housing shall be high quality gray cast iron, ASTM A- 48, Class 30. 2. The pump inlet shall be open and clear, without screening to provide access for effluent and septic tank solids. 3. All external mating parts shall be machined and Buna N, O-Ring sealed. 4. All fasteners exposed to the pumped liquid shall be 300 series stainless steel. 5. All power cords shall be water resistant UL or CSA approved, with double insulation and sized as a function of Amp. Draw. C. Manufacturers and models of components and accessories specified herein shall be as follows: 1. Liberty 2. Hydromatic 2.2 SUPPLEMENTS A. See supplemental data sheet(s) to this section for additional equipment system product, component and accessory information and requirements. Project No. 18088080 3 Section 43 21 43 Lewisville Lake WTP Dewatering Improvements Washwater Equalization Sump Pump 2.3 SERVICE CONDITION A. The Submersible Sump Pump(s) shall be of a non-clog design capable of pumping area and process drainage. B. As specified in Sump Pump Data Sheet(s) located at the end of this section as a supplement. 2.4 PERFORMANCE REQUIREMENTS A. As specified in Sump Pump Data Sheet(s) located at the end of this section as a supplement. 2.5 MOTOR AND SHAFT A. The stator, rotor and bearings shall be mounted in a sealed submersible type housing. Single phase motors shall be split phase with solid state switch and start capacitor. Three phase motors shall be Polyphase. Full Load and Locked Rotor Amps as well as Start and Run winding resistance shall be tabulated for each pump. 2.6 BEARINGS AND SHAFT A. A thrust bearing shall be required. It shall be heavy duty single row ball bearings which are permanently and continuously lubricated and cooled by the dielectric oil which fills the motor housing. The motor shaft shall be stainless steel and sealed from the pumped liquid with a carbon ceramic mechanical seal. 2.7 SEALS A. The rotor and stator in the motor housing shall be separated and protected from the pumped liquid by an oil filled housing incorporating two type 21 carbon ceramic mechanical seals mounted in tandem. 2.8 IMPELLER A. The Impeller shall be high capacity, two vane, high head design with pump out vanes on the back side. These vanes wash out grit and stringy material that will damage the shaft and mechanical seal. 2.9 PUMP ACCESSORIES A. Equipment Identification Plate: A 16-gauge stainless steel identification plate shall be securely mounted on each pump in a readily visible location. The plate shall bear the 1/4” die-stamped equipment identification number name that is assigned to each pump in the Sump Pump Data Sheets and shown on the Drawings. B. Lifting Lugs: Equipment weighing over 100 pounds shall be provided with lifting lugs. C. Painting: Provide touch-up painting for post-installation. D. See Sump Pump Data Sheet(s) following this Section. E. Spare Parts and Special Tools: See Submersible Pump Data Sheets for spare parts and special tools required for each pump or set of pumps. Project No. 18088080 4 Section 43 21 43 Lewisville Lake WTP Dewatering Improvements Washwater Equalization Sump Pump 2.10 ELECTRICAL AND CONTROL SYSTEMS A. Electrical products and execution required to complete the Work under this section shall conform to the applicable requirements of Division 26, ELECTRICAL. B. Labeling: All electrical materials, devices, appliances, and equipment used shall be indicated as acceptable by established standards. Indication shall be by a valid label affixed to the item. Panels that consist of multiple components shall be listed and labeled as a unit in addition to any other requirements. C. Sump pump shall operate automatically using an integral float switch. PART 3 - EXECUTION 3.1 SHIPPING, STORAGE, HANDLING, AND PROTECTION A. As specified in Section 01 60 00, PRODUCT REQUIREMENTS. B. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers or bundles bearing the name of the manufacturer. C. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. D. Protection of Equipment: Equipment shall be boxed, crated or otherwise protected from damage and moisture during shipment, handling and storage. Equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Pumps, motors, drives, electrical equipment and other equipment with anti-friction or sleeve bearings shall be stored in weathertight and heated storage facilities prior to installation. For extended storage periods, plastic equipment wrappers shall not be used to prevent accumulation of condensate in gears and bearings. 3.2 INSTALLATION A. Install in strict accordance with manufactured directions and recommendations. B. Lubricants: The installation includes oil and grease for initial operation. C. Work shall be as specified in Section 01 60 00, PRODUCT REQUIREMENTS. 3.3 PAINTING AND COATING A. All cast iron parts shall be painted before assembly with a water reducible alkyd air dried enamel. The paint shall be applied in one coat with a minimum thickness of 3 to 4 mils. 3.4 FACTORY TESTS A. All pumps shall be individually tested to include the following: 1. The pump and power cord shall be visually inspected for imperfections, cuts or nicks. 2. The pump shall have a ground continuity check and the motor chamber shall be Hi- potted to test for moisture content and/or insulation defects. 3. The motor and volute housing shall be pressurized and a 10 second air leak decay test run. 4. Oil is added, and the pump is run, voltage and current are monitored visually electronically and the tester listens for any noise or malfunction. Project No. 18088080 5 Section 43 21 43 Lewisville Lake WTP Dewatering Improvements Washwater Equalization Sump Pump 3.5 FIELD TESTS A. Functional Test: Prior to plant startup, all equipment described herein and in the Sump Pump Data Sheets following shall be inspected for proper alignment, quiet operation, proper connection, and satisfactory performance by means of a functional test. Provide certification of test results. Tests and certification shall be as specified in Section 01 79 00, DEMONSTRATION AND TRAINING. 3.6 MANUFACTURER’S SERVICES A. Provide representative for one (1) days on-site to verify correct installation, equipment testing, equipment certification, and personnel training. 3.7 MANUFACTURER’S CERTIFICATE(S) A. Provide Manufacturer’s certificate(s). In accordance with Section 01 79 00, DEMONSTRATION AND TRAINING. 3.8 SUPPLEMENTS A. The supplements listed below, and provided following “END OF SECTION,” are part of this specification. 43 21 43.1-DS Washwater Equalization Sump Pump END OF SECTION Project No. 18088080 Lewisville Lake WTP Dewatering Improvements 1 of 1 43 21 43.2 Data Sheet Washwater Equalization Sump Pump Section 43 21 43.1 – SUMP PUMP DATA SHEET PROJECT: LAKE LEWISVILLE WTP DEWATERING IMPROVEMENTS OWNER: CITY OF DENTON EQUIPMENT NAME(S): WASHWATER EQUALIZATION SUMP PUMP EQUIPMENT TAG NUMBER(S): 68SUP01 CONTROL PANEL(S): TOTAL PUMPS REQUIRED: 1 MANUFACTURERS MODEL Liberty 281 Wide-Angle Float Or equal SERVICE CONDITIONS Liquid Pumped: Wash Water (0.0 – 1.0% solids) Explosion Proof (Y/N): Y Specific Gravity at 60 deg F: 0.99 – 1.10 Pumping Temperature (°F): 60 - 95 Largest dia. Solid pump shall be capable of passing: 3/4 inch Installation Configuration: Submerged Min. NPSH available: 13 ft. PERFORMANCE REQUIREMENTS Variable Frequency Drive (Y/N): N Rated Design Point Maximum Pump Speed (RPM): 3450 Pump Speed (RPM): 3450 Minimum Pump Speed (RPM): NA Flow (gpm): 45 Variable Frequency Drive (Y/N): N Head (ft.): 17 Shutoff Pressure (ft.): 37 EQUIPMENT DESCRIPTION Casing Material: Cast Iron, ASTM A-48, Class 35B Installation: Submerged Casing Ring Material: Stainless Steel or Cast Iron Guide Rail Material: NA Impeller Type: 2 Vane Non-Clog Lifting Chain Material: NA Impeller Material: Cast Iron (ASTM A-48, Class 40) Pump Removal Hoist (Y/N): N Impeller Wear Ring Shaft Material: Stainless Steel Material: Bronze Double Mechanical Seal (Y/N): Y MOTOR DATA Type: Squirrel-cage induction meeting requirements of NEMA MG1. Manufacturer: For multiple units of the same type of equipment, furnish motors and accessories of a single manufacturer. Hazardous Location: Furnish motors for hazardous (classified) locations that conform to UL 674 and have an applied UL listing marking Motor Horsepower: 0.50 (max) Mounting Type: Horizontal Vertical Voltage: 115 Enclosure Type: Sub / oil filled Phase: 1 Material: Cast Iron, A48 Class 35B or Class 30 Frequency: 60 Hz Load Class: Synchronous Speed: 3450 rpm Multispeed, Two speed: rpm Service Factor: 1.0 1.15 Variable Speed Drive: See Division 26, ELECTRIC. Provide Inverter Duty Rated Motors. Windings: One Two Thermal protection embedded in windings. Motor nameplate horsepower shall not be exceeded at any operational point. x Provide Space Heater Oversize main terminal (conduit) box for motors Moisture detection switches. SPECIAL FEATURES / NOTES DIVISION 44 POLLUTION CONTROL EQUIPMENT Project No. 18088080 1 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps SECTION 44 42 56.23 VERTICAL TURBINE PUMPS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work necessary to furnish and install a complete and functional, vertical turbine pumps including all related equipment, material, and appurtenances. B. Related Sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 60 00 – Product Requirements. 3. Section 01 78 23 – Operation and Maintenance Data. 4. Section 01 79 00 – Demonstration and Training. 5. Section 05 50 00 – Metal Fabrications. 6. Section 09 90 00 – Painting and Protective Coatings. 7. Division 26 – Electrical. 1.2 GENERAL A. Equipment Numbers: See supplemental data sheet(s) at the end of the section. B. PUMP SIZES AND FITTING SIZES MAY BE DIFFERENT FROM THOSE SHOWN ON THE PLANS DEPENDING ON THE PUMP MANUFACTURER SELECTED. IT IS THE CONTRACTORS RESPONSIBILITY TO VERIFY THE DIMENSIONS REQUIRED TO INSTALL THE PUMPS CORRECTLY. C. Like items of equipment provided hereinafter shall be the end products of one manufacturer to achieve standardization of appearance, operation, maintenance, spare parts, and manufacturer’s services. D. Unit Responsibility: The Work requires that the vertical turbine pumps, motors, instruments, and components, complete with all accessories and appurtenances, be the end product of one responsible system manufacturer or responsible system supplier. Unless otherwise indicated, the Contractor shall obtain each system from the responsible supplier of the equipment. Supplier shall furnish all components and accessories of the system to enhance compatibility, ease of operation and maintenance, and as necessary to place the equipment in operation in conformance with the specified performance, features, and functions without altering or modifying the Contractor's responsibilities under the Contract Documents. The Contractor is responsible to the Owner for providing the equipment systems as specified herein. E. General Requirements: See Division 01, GENERAL REQUIREMENTS, which contains information and requirements that apply to the work specified herein and are mandatory for this project. 1.3 REFERENCES A. Terminology pertaining to pumping unit performance and construction shall conform to the ratings and nomenclature of the Hydraulic Institute Standards. 1.4 SUBMITTALS A. General: Administrative, shop drawings, samples, quality control, and contract closeout submittals shall conform to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES. Project No. 18088080 2 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps B. In addition to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES, submit the following additional specific information: 1. Shop Drawings: a. Make, model, weight, and horsepower of each equipment assembly. b. Complete catalog information, descriptive literature, specifications, and identification of materials of construction. c. Hydraulic Shop Testing: Performance data curves showing head, capacity, horsepower demand, and pump efficiency over the entire operating range of the specific pump, from shutoff to maximum capacity. Indicate separately the head, capacity, horsepower demand, overall efficiency, and minimum submergence required at the guarantee point. d. Pump maximum downthrust or upthrust in pounds. 1) Structural slab and beams as shown on drawings are designed for 4,000 lbf thrust. Pumps exceeding 4,000 lbf thrust will require structural modifications. Contractor must submit any structural modifications and design calculations for pumps exceeding 4,000 lbf of thrust. Structural modifications for additional pump thrust will be no additional cost to the Owner. e. Detailed mechanical and electrical drawings showing the equipment dimensions, size, and locations of connections and weights of associated equipment. f. Power and control wiring diagrams, including terminals and numbers. g. Complete motor nameplate data, as defined by NEMA, motor manufacturer, and including any motor modifications. h. Factory finish system. 2. Quality Control Submittals: a. Factory Functional and Performance Test Reports. b. Manufacturer’s Certification of Compliance that the factory finish system is identical to the requirements specified herein. c. Special shipping, storage and protection, and handling instructions. d. Manufacturer’s printed installation instructions. e. Manufacturer’s Certificate of Proper Installation. f. Suggested spare parts list to maintain the equipment in service for a period of 1 year and 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. g. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance. h. Operation and Maintenance manual. 3. Contract Closeout submittals: Service records for maintenance performed during construction. 1.5 QUALITY CONTROL A. Factory Inspections: Inspect control panels for required construction, electrical connection, and intended function. B. Factory Tests and Adjustments: Test all equipment and control panels actually furnished. C. Factory Test Report: Include test data sheets, curve test results, and performance test logs. D. Functional Test: Perform manufacturer’s standard pump test on equipment. Include vibration test, as follows: 1. Dynamically balance rotating parts of each pump and its actual driving unit before final assembly. 2. Limits: a. Driving Unit Alone: Less than 80 percent of NEMA MG 1 limits. Project No. 18088080 3 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps b. Complete Rotating Assembly Including Coupling, Drive Unit, and Motor: Less than 90 percent of limits established in the Hydraulic Institute Standards at all operating speeds. 3. Shop Performance Test: a. Conduct on each pump with actual motor furnished. b. Perform under simulated operating conditions. c. Test for a continuous 3-hour period without malfunction. d. Test Log: Record the following for each flow head condition: 1) Total head. 2) Capacity. 3) Horsepower requirements. 4) Flow measured by factory instrumentation and storage volumes. 5) Average distance from suction well water surface to pump discharge centerline for the duration of the test. 6) Pump discharge pressure converted to feet of liquid pumped and corrected to pump discharge centerline. 7) Calculated velocity head at the discharge flange. 8) Field head. 9) Driving motor voltage and amperage measured for each phase. 4. Adjust, realign, or modify units and retest in accordance with Hydraulic Institute Standards, if necessary. 5. Motor Test: Provide NEMA short commercial test. Document guaranteed efficiency by providing certified test report for test conducted on actual motor furnished. 1.6 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, form, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.7 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer shall promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Where a manufacturer’s standard equipment name and/or model number is listed, the equipment system shall be provided as modified to conform to the performance, functions, features, and materials of construction as specified herein. B. Materials, equipment, components, and accessories specified in this section shall be, products of: 1. Fairbanks Morse. 2. Layne/Verti-line. 3. Goulds. Project No. 18088080 4 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps 4. Patterson. 5. Peerless. 2.2 GENERAL REQUIREMENTS A. All pump system components shall be supplied by the pump manufacturer and including but not limited to motor, bowl assembly, column assembly, discharge head, and all necessary appurtenances for a complete pumping unit. B. Coordinate pump requirements with motor manufacturers and be responsible for pump and motor requirements. 2.3 SUPPLEMENTS A. See supplemental data sheets to this section for additional equipment system product, component and accessory information and requirements. 2.4 PUMPS A. Specific requirements for the pumps are attached to this section as supplements. B. Any modifications to the mechanical, structural, electrical, instrumentation and control, and other portions of the work that may be required to adapt the general layout and detail shown on the Plans and the equipment actually furnished shall be at no additional cost to the Owner. All necessary design revisions shall be made at the Contractor’s sole expense. All redesign information prepared by the Contractor shall be submitted for review prior to incorporating the redesign into the work. C. Rotation 1. Pump rotation shall be counterclockwise when viewed from the driver end looking at the pump. D. Impeller 1. Impellers shall be of one-piece construction, single suction, enclosed radial flow design. 2. The waterways through the pump shall have extremely smooth contours, devoid of sharp corners, to promote maximum efficiency. 3. The impeller shall be balanced and secured to the shaft by means of stainless steel collet for bowl shafts 1-15/16” and smaller. For bowl shafts larger than 1-15/16” impeller shall be secured to the shaft using a combination of thrust washer, key and/or snap rings. 4. Impeller shall be adjustable by means of top shaft-adjusting nut. E. Bowls 1. Castings shall be free from blowholes, sand holes and shall be accurately machined and fitted to close dimensions. 2. Bowls with nominal diameter of 8” and above shall be flanged connected. Bowls smaller than 8” nominal diameter may use either flanged or threaded connections. 3. Bowls shall be designed with smooth passages to ensure efficient. 4. The casing shall be hydrostatically tested to 1.5 times the design head or 1.25 times the shutoff head whichever is greater. F. Suction 1. The suction bell of bowl shall be provided with a non-soluble grease packed bearing. A sand collar shall be provided to protect this bearing from abrasives in the pumping fluids. The bearing housing shall have sufficient opening at the bottom for easy removal of the bearing. Project No. 18088080 5 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps 2. It shall have a net inlet area equal to at least three times the impeller inlet area. The maximum opening shall not be more than seventy-five percent (75%) of the maximum opening of the water passage through the bowl or impeller. G. Impeller Shaft 1. Impeller shaft shall be of stainless steel construction conforming to ASTM A582 (416 stainless steel). 2. The shaft shall be supported by bronze or neoprene bearings located on both sides of each impeller. 3. The impeller shaft coupling shall be of stainless steel construction conforming to ASTM A582 (416 stainless steel). H. Wear Rings 1. Wear rings shall be provided on both the impellers and bowls on bowls of nominal diameter of 8” or larger so that the clearances can be maintained throughout the life of the rings and minimize recirculation. Bowls smaller than 8” shall incorporate bowl wear rings only. 2. Impeller wear rings shall be of the radial-type. 3. Wear rings shall be attached to the impellers and bowls using interface fit and Loctite. I. Column 1. Column pipe in sizes 4” through 12” diameter shall be provided in interchangeable sections not over 10 feet in length, and shall be connected with threaded, sleeve-type couplings. Column pipe 14” diameter and larger shall be flanged and provided in interchangeable sections not over 10 feet in length. 2. Pump with speeds between 2200 RPM and 3600 RPM shall have intermediate column length and bearing spacing no greater than 5 feet. The length of the top and bottom sections shall not be more than 5 ft. 3. Column joints are to be butted to insure perfect column alignment after assembly. 4. The pipes shall be of ASTM A53 grade B steel pipe and the weight shall be not less than schedule 30. The end of the pipe shall be with 8 threads per inch with 3/16” taper per foot thread and faced parallel to butt against the centering spiders of ASTM B584 Silicon Bronze to form accurate alignment. 5. All column flange faces shall be parallel and machined for rabbet fit to permit accurate alignment. 6. The inside diameter of the pipe shall be such that the head losses shall not be more than 5 feet per 100 feet of pipe or the flow velocity not to exceed 3 ft/sec based on rated flow of the pump. J. Lineshafts 1. Lineshafting shall be of ample size to transmit the torque and operate the pump without distortion or vibration. 2. Lineshaft shall be furnished in interchangeable section not over 10 feet in length. 3. Lineshafting shall be coupled with extra-long threaded steel couplings machined from solid steel bar. 4. Lineshafting shall be fitted with stainless steel replaceable sleeves at each bearing and shall conform AISI 304 material. K. Discharge Head Assembly 1. Discharge head shall be fabricated steel construction or cast iron construction with ANSI 125# discharge flange. 2. Discharge head shall be of sufficient design to support the entire weight of pump and driver plus thrust forces. 3. A drive shaft of the same material as the lineshaft shall extend through the sealing assembly of the discharge head and be coiled to a vertical hollow shaft driver. If mechanical seals are used a spacer type coupling shall be used to permit easy field removal of the mechanical seal. Project No. 18088080 6 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps 4. Packing box shall be rated for 175 psi. 5. Discharge heads shall be fitted with guards to prevent access to the rotating shaft and/or coupling. 2.5 ACCESSORIES A. Equipment Identification Plate: 16-gauge stainless steel with 1/4-inch die-stamped equipment tag number securely mounted in a readily visible location. B. Lifting Lugs: Shall be provided on all modular section, including but motor, discharge head, and all column sections. Lugs shall be adequate to lift two times the equipment weight. C. Base Flange Bolts: Sized by equipment manufacturer and as specified in Division 05, METALS. D. Vibration Sensor Switch: 1. Pump manufacturer shall provide vibration switches on the motor factory mounted such that the axis of sensitivity extends radially from pump and motor housing. The vibration switch shall meet the following specifications: Limits Limit #1: 10-100% of Limit #2 Limit #2: 0.1 to 2.75 in/sec peak Velocity Range 0.1 to 2.75 in/sec peak Frequency Range 2 to 1000 Hz (120 to 60,000 rpm) Limit Outputs (2) Form C SPDT Relay – 5A at 125Vac, 5A at 28Vdc Analog Output 4-20 mA Features Remote reset, remote mute Enclosure NEMA 4 Suppliers Balmac Model 550 or approved equal Scope Refer to Plans 2.6 MOTOR REQUIREMENTS A. As specified in Section 26 05 15, ELECTRIC MOTORS B. Shall have shaft ground rings and insulated bearings. 2.7 ELECTRICAL COMPONENTS AND ACCESSORIES A. General: 1. Conform to Division 26, ELECTRICAL. 2. Provide all necessary electrical components and wiring for a complete, functional system. 3. Where indicated, motor starters for constant-speed, 460-volt motors shall be provided in a separate motor control center specified in Division 26, ELECTRICAL. Provide all necessary control functions to properly interface with this motor starter. B. Wiring: The Drawings and Specifications indicate the anticipated wiring for the equipment provided under this section. If additional wiring is required, or if required wiring does not match what is indicated, the Contractor shall make the necessary modifications to the electrical wiring and documentation as part of the lump sum price. Wiring shall meet the requirements of Division 26, ELECTRICAL, and NFPA 70. Insulation shall be rated 600 volts, minimum. Low-voltage (24V) signals shall be run in twisted, shielded pair cable. Project No. 18088080 7 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps C. Electrical Raceways: Electrical wiring shall be installed in conduit meeting the requirements of Division 26, ELECTRICAL. Raceways shall be installed in accordance with Division 26, ELECTRICAL, and NFPA 70. D. Non-Reverse Ratchet: Motor shall be equipped with non-reversing ratchet to prevent reverse rotation of rotating elements. 2.8 INSTRUMENTATION AND CONTROLS A. All instrumentation and control components shall be provided in accordance with the requirements of Division 26, ELECTRICAL. 2.9 TOOLS AND SPARE PARTS A. Tools: The work includes furnishing two complete set of special tools recommended by the manufacturer for maintenance and repair of each separate type of equipment; tools shall be stored in tool boxes, and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box. B. Spare Parts: 1. All equipment shall be furnished with the specified manufacturers spare parts as indicated in the individual equipment sections. 2. Spare parts shall be tagged by project equipment number and identified as to part number, equipment manufacturer and subassembly component (as appropriate). Spare parts subject to deterioration such as ferrous metal items and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts with individual weights less than 50 pounds and dimensions less than 2 feet wide, or 18 inches high, or 3 feet in length shall be stored in a wooden box with hinged wooden cover and locking clasp. Hinges shall be strap type. The box shall be painted and identified with stenciled lettering stating the name of the equipment, equipment numbers and the words “spare parts.” A neatly typed inventory of spare parts shall be taped to the underside of the cover. 3. Provide at a minimum, the following spare parts for the equipment: a. Complete set packing or replacement mechanical seal. b. Complete set pump bearings. c. Complete set gaskets and O-ring seals. d. Complete set of shaft sleeves. e. Complete set keys, dowels, pins, etc. f. Impeller. g. Impeller shaft. h. Impeller wear ring. i. Head shaft. j. One complete set of any special tools required to dismantle pump. 2.10 FABRICATION A. Shop Assembly: The system shall be factory assembled and tested. B. Shop/Factory Finishing: Shop prime coatings shall conform to the requirements of Section 09 90 00, PAINTING AND PROTECTIVE COATINGS; coordinate color with Owner. Project No. 18088080 8 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps PART 3 - EXECUTION 3.1 ASSSEMBLY AND PREPARATION FOR SHIPMENT A. Coordination shall include space and structural requirements, clearances, utility connections, signals, outputs and features required by the manufacturer including safety interlocks. 3.2 PRODUCT DELIVERY, STORAGE AND HANDLING A. Comply with Section 01 60 00, PRODUCT REQUIREMENTS. B. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. C. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. D. Protection of Equipment: Equipment shall be boxed, crated or otherwise protected from damage and moisture during shipment, handling, and storage. Equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Pumps, motors, drives, electrical equipment and other equipment with anti-friction or sleeve bearings shall be stored in weather tight and heated storage facilities prior to installation. For extended storage periods, plastic equipment wrappers shall not be used to prevent accumulation of condensate in gears and bearings. 3.3 INSTALLATION A. Install in accordance with manufacturer’s printed instructions. B. Coordinate installation of pump mounting flange with pump manufacturer. C. Adjust pump assemblies such that the driving units are properly aligned, plumb, and level with the driven units and all interconnecting shafts and couplings. Do not compensate for misalignment by use of flexible couplings. D. Connect discharge piping without imposing strain to pump discharge head. E. Anchor Bolts: Provide templates and specify bolts for furnishing by Contractor. 3.4 FIELD QUALITY CONTROL A. Functional Tests: Conduct on each pump. 1. Alignment: Test complete assemblies of actual pump with motors furnished for correct rotation, proper alignment and connection, and quiet operation. 2. Vibration Test: a. Test with units installed and in normal operation, and discharging to the connected piping systems at rates between the low discharge head and high discharge head conditions specified, and with the actual building structures and foundations provided shall not develop vibration exceeding limits specified in HIS 9.6.4 at all operating speeds. b. If units exhibit vibration in excess of the limits specified adjust or modify as necessary. Units which cannot be adjusted or modified to conform as specified shall be replaced. 3. Flow Output: Measured by pump station instrumentation. Project No. 18088080 9 Section 44 42 56.23 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps 4. Operating Temperatures: Monitor bearing areas on pump and motor for abnormally high temperatures. B. Performance Test: In accordance with Hydraulic Institute Standards, latest standard. 3.5 MANUFACTURER’S SERVICES A. A manufacturer’s representative for the equipment specified herein shall be present at the job site for the minimum person-days listed for the services hereinunder, travel time excluded: 1. Installation, Startup, and Testing Services: a. 1 person-day for installation assistance, inspection, and Certificate of Proper Installation. b. 1 person-day for functional and performance testing. c. Provide Qualifications of Manufacturer's Representative. 2. Training Services: a. 1 person-day of prestart classroom or jobsite training of Owner’s personnel. b. Training of Owner’s personnel shall be at such times and at such locations as required and approved by the Owner. B. See Section 01 79 00, DEMONSTRATION AND TRAINING. 3.6 MANUFACTURER’S CERTIFICATES A. Provide Manufacturer’s certificate(s) in accordance with Section 01 79 00, DEMONSTRATION AND TRAINING. 3.7 SUPPLEMENT A. The supplement listed below, following “End of Section,” is a part of this Specification. 1. Vertical Turbine Pump Data Sheet. END OF SECTION Project No. 18088080 1 Section 44 42 56.23.1 Lake Lewisville WTP Dewatering Improvements Vertical Turbine Pumps Supplement Section 44 42 56.23:VERTICAL TURBINE PUMPS DATA SHEET PROJECT: Lewisville Lake Water Treatment Plant Improvements OWNER: City of Denton EQUIPMENT NAME(S): Vertical Turbine Pump #1 and #2 EQUIPMENT TAG NUMBER(S): 69VTP01, 69VTP02 TOTAL PUMPS REQUIRED: 2 MANUFACTURERS SUGGESTED MODEL Goulds VIT 12GHC (2-Stage) Patterson Peerless Layne Verti-Line Fairbanks-Morse (Pentair) 12M-SS (1-Stage) SERVICE CONDITIONS PERFORMANCE REQUIREMENTS Liquid Pumped: Filter Backwash and Sedimentation Blowdown The pump shall perform as specified at the following flow rates: Largest solid: 0.30” Design Flow Rate (Min.): 1150 gpm Liquid Temperature: 40°-70° F Design TDH: 75 ft Minimum Efficiency @ Design Flow: 77 % Shutoff Head (Min.): 92 ft EQUIPMENT DESCRIPTION Pump Type: Vertical Turbine Lineshaft: 416 Stainless Steel Column: 8 in. dia. Max, Threaded Lineshaft Bearings: Neoprene Wear Rings: Bronze ASTM B505, C93200 Lubrication: Open Lineshaft (Product Lubrication) Impeller: Bronze or Stainless Steel Discharge Head Assembly: Above ground, fabricated steel Bowl: Cast Iron ASTM A48 CL 30 Stages (Max): 2 Impeller Shaft: 416 Stainless Steel ASTM A582 Seals: Field replaceable mechanical seal MOTOR DATA Type: Squirrel-cage induction meeting requirements of NEMA MG1. Manufacturer: For multiple units of the same type of equipment, furnish motors and accessories of a single manufacturer. Hazardous Location: ܆܆ Furnish motors for hazardous (classified) locations that conform to UL 674 and have an applied UL listing marking. Motor Horsepower: 35 (max) Mounting Type ܆܆ Horizontal ܈܈ Vertical Voltage 460 Enclosure Type WP I Phase 3 Material Cast Iron/Steel Frequency 60 Hz Load Class: Variable Torque Synchronous Speed 1800 rpm max ܆܆ Multispeed, Two Speed:__________ rpm Service Factor:܆܆1.0 ܈܈1.15 Windings:܆܆One ܆܆Two ܈܈ Thermal protection embedded in windings. ܈܈ See Division 26, ELECTRIC. Provide Inverter Duty Rated Motors. Provide ܈܈ Space Heater ܈܈ Oversize main terminal (conduit) box for motors ܆܆ Moisture detection switches Additional Motor Requirements: See Section 26 05 15, ELECTRIC MOTORS SPECIAL FEATURES / NOTES Suggested models are for reference only. Other models meeting the design criteria will be considered. Project No. 18088080 1 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps SECTION 44 42 56.29 – WET-PIT SUBMERSIBLE PUMPS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: All work necessary to furnish, install and place into operation the electrical submersible pump(s) required to complete this project. This section includes electric submersible pump(s) to be supplied with motor, close coupled volute, cast iron discharge elbow, guide bar brackets, power cable and accessories as specified herein, and as further specified in the Submersible Pump Data Sheets hereinafter. B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 60 00 – Product Requirements. 3. Section 01 78 23 – Operation and Maintenance Data. 4. Section 01 79 00 – Demonstration and Training. 5. Section 09 90 00 – Painting and Protective Coatings. 6. Section 26 90 00 – General Instrumentation and Controls. 7. Section 26 90 10 – Process and Analytical Instruments. 8. Section 41 22 17 – Davit Cranes. 1.2 GENERAL A. Like items of equipment provided hereunder shall be the end products of one Manufacturer in order to achieve standardization for appearance, operation, maintenance, spare parts, and Manufacturer’s service. B. Unit Responsibility: The Work requires the Submersible Pumps complete with all accessories and appurtenances (including, but not necessarily limited to, pump, motor, base elbow, guiderails, guiderail mount accessories, lift chains or cables, spare parts, start-up, testing, and personnel training) be the end product of one responsible Manufacturer. Unless otherwise indicated, the Contractor shall obtain each system from the Manufacturer of the equipment. Manufacturer shall provide all components of the system to enhance compatibility, ease of construction, and efficient operation and maintenance, and as necessary to place the equipment in operation and its intended functions without altering or modifying the Contractor's responsibilities under the Contract Documents. The Contractor is responsible to the Owner for performance of all equipment systems as indicated. 1.3 SUBMITTALS A. Submittals shall be made as required in Section 01 33 00, SUBMITTAL PROCEDURES. The following specific information shall be provided: 1. Shop Drawings: Shop drawings shall include descriptive information as required to fully describe the Pumps, Controls, Motors, and overall performance and shall identify any deviations from the specified requirements. 2. For pumps equipped with variable frequency drives. Provide a VFD analysis showing single pump operation, and parallel pump operation at increments not greater than 5 Hz between 35 Hz and 60 Hz or the minimum safe operating frequency, whichever is greater. Each increment shall include flow, head, and pump efficiency. 3. Special handling instructions, in accordance with Section 01 60 00, PRODUCT REQUIREMENTS. 4. Requirements for storage and protection prior to installation, in accordance with Section 01 60 00, PRODUCT REQUIREMENTS. Project No. 18088080 2 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps 5. Requirements for routine maintenance required prior to plant startup, in accordance with Section 01 60 00, PRODUCT REQUIREMENTS. 6. List of all requested exceptions to the Contract Documents. 7. Motor information to be submitted in accordance with Division 26, ELECTRICAL. 8. Quality control submittals as listed in Section 01 33 00, SUBMITTAL PROCEDURES. 9. Instrumentation and control submittals as listed in Section 26 90 00, GENERAL INSTRUMENTATION AND CONTROLS. 10. Factory Test Reports (Balance & Vibration). 1.4 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, format, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.5 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer will promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. PART 2 - PRODUCTS 2.1 GENERAL REQUIREMENTS A. Furnish and install submersible non-clog wastewater pump(s). Each pump shall be equipped with a submersible electric motor, connected for operation on 460 volts, 3 phase, 60 hertz, with 70 feet of submersible cable (SUBCAB) suitable for submersible pump applications. The power cable shall be sized according to NEC and ICEA standards and also meet with P-MSHA Approval. See supplement data sheets for specific pump information. B. The use of a Manufacturer’s name and model or catalog number is for the purpose of establishing the standard of quality and general configuration, but modifications shall be made to ensure all requirements specified herein are met. Specific pump models are suggested and other models meeting the service and duty requirements will be considered. 2.2 MANUFACTURERS A. Where a manufacturer's standard equipment name and/or model number is listed, the equipment system shall be provided and modified as required to conform to the performance, functions, features, and materials of construction as specified herein. B. Materials, equipment, components, and accessories specified in this section shall be, products of: 1. Xylem Flygt 2. KSB 3. Or Engineer Approved Equal Project No. 18088080 3 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps 2.3 PUMP A. GENERAL 1. The pump shall be supplied with a mating cast iron discharge connection and be capable of delivering flow as specified in supplement data sheet(s). The pump(s) shall be automatically and firmly connected to the discharge connection, guided by no less than two guide bars extending from the top of the station to the discharge connection. There shall be no need for personnel to enter the wet-well. Sealing of the pumping unit to the discharge connection shall be accomplished by a machined metal to metal watertight contact. Sealing of the discharge interface with a diaphragm, O-ring or profile gasket will not be acceptable. No portion of the pump shall bear directly on the sump floor. Each pump shall be fitted with 25 feet of stainless steel lifting chain. The working load of the lifting system shall be 50% greater than the pump unit weight. 2. Major pump components shall be of grey cast iron, ASTM A48, Class 35B, with smooth surfaces devoid of blow holes or other irregularities. The lifting handle shall be of stainless steel. All exposed nuts or bolts shall be of stainless steel construction. All metal surfaces coming into contact with the fluid, other than stainless steel or brass, shall be protected by a factory applied spray coating of acrylic dispersion zinc phosphate primer with a polyester resin paint finish on the exterior of the pump. 3. Sealing design shall incorporate metal-to-metal contact between machined surfaces. Critical mating surfaces where watertight sealing is required shall be machined and fitted with Nitrile rubber O-rings. Fittings will be the result of controlled compression of rubber O- rings in two planes and O-ring contact of four sides without the requirement of a specific torque limit. 4. Rectangular cross sectioned gaskets requiring specific torque limits to achieve compression shall not be considered as adequate or equal. No secondary sealing compounds, elliptical O-rings, grease or other devices shall be used. B. PUMP SHAFT 1. The pump and motor shaft shall be a single piece unit. The pump shaft is an extension of the motor shaft. Shafts using mechanical couplings shall not be acceptable. The shaft shall be 420 or 431 stainless steel. Shaft sleeves will not be acceptable. C. IMPELLER 1. The impeller shall be of ASTM A48, Class 35B gray iron or ASTM A532 Type II or III abrasion resistant cast iron as specified in supplemental data sheet. Impeller shall be dynamically balanced, semi-open or closed, multi-vane, non-clog design. The leading edges of the gray iron impeller shall be hardened to Rc 45 and shall be capable of handling solids, fibrous materials, heavy residuals and other matter normally found in wastewater. D. VOLUTE / SUCTION COVER 1. The pump volute shall be a single piece gray cast iron, ASTM A48, Class 35B, non- concentric design with smooth passages of sufficient size to pass any solids that may enter the impeller. The volute shall have a replaceable wear ring cast of ASTM A48, Class 35B gray iron or ASTM A-532 Type II or III abrasion resistant cast iron and provide effective sealing between the impeller and the volute housing. 2.4 BEARINGS A. The integral pump/motor shaft shall rotate on two bearings. The motor bearings shall be sealed and permanently grease lubricated with high temperature grease. The upper motor bearing shall be a two row angular contact ball bearing. The lower bearing shall be a two row angular contact ball bearing to handle the thrust and radial forces. The minimum L10 bearing life shall be 50,000 hours at any usable portion of the pump curve. Project No. 18088080 4 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps 2.5 MECHANICAL SEALS A. Each pump shall be provided with a positively driven dual, tandem mechanical shaft seal system consisting of two seal sets, each having an independent spring. The rotating seal ring shall have small back-swept grooves laser inscribed upon its face to act as a pump as it rotates, returning any fluid that should enter the dry motor chamber back into the lubricant chamber. All seal rings shall be individual solid sintered rings. Each seal interface shall be held in place by its own spring system. The seals shall not depend upon direction of rotation for sealing. Mounting of the lower seal on the impeller hub is not acceptable. Shaft seals without positively driven rotating members or conventional double mechanical seals containing either a common single or double spring acting between the upper and lower seal faces are not acceptable. The seal springs shall be isolated from the pumped media to prevent materials from packing around them, limiting their performance. B. Each pump shall be provided with a lubricant chamber for the shaft sealing system. The lubricant chamber shall be designed to prevent overfilling and shall provide capacity for lubricant expansion. The seal lubricant chamber shall have one drain and one inspection plug that are accessible from the exterior of the motor unit. The seal system shall not rely upon the pumped media for lubrication. C. The area about the exterior of the lower mechanical seal in the cast iron housing shall have cast in an integral concentric spiral groove. This groove shall protect the seals by causing abrasive particulate entering the seal cavity to be forced out away from the seal due to centrifugal action. D. A separate seal leakage chamber shall be provided so that any leakage that may occur past the upper, secondary mechanical seal will be captured prior to entry into the motor stator housing. Such seal leakage shall not contaminate the motor lower bearing. The leakage chamber shall be equipped with a float type switch that will signal if the chamber should reach 50% capacity. 2.6 ACCESSORIES A. Discharge Base and Elbow 1. Materials: Same as pump casing. 2. Features: a. Structurally capable of firmly supporting guide rails, discharge piping and pumping unit under operating conditions. b. One or more integral support legs or pads with provisions for bolting to sump floor. c. Incorporates 90 degree flanged elbow that receives horizontal flow from pump and discharges flow vertically. 3. Discharge Interface: a. Sealing of the pumping unit to the discharge connection shall be accomplished by a machined metal to metal watertight contact. b. Self-aligning without having to enter the wet well. c. Discharge elbow to mate to pump discharge and transition to discharge piping. B. Guide rails, brackets, fasteners, and lifting chain for each pump 1. Material: Type 316 stainless steel, with the following features: a. Dual pipes or dual rails that extend from discharge base to upper bracket unless scheduled otherwise. b. Rail wall thickness sufficient to suspend pump unit between brackets plus minimum 50 percent safety factor. c. Sized to fit discharge base and sliding bracket of pump. d. Integral, self-aligning, guide rail sliding brackets that seal pump to discharge base under operating conditions. e. Upper guide rail bracket. Project No. 18088080 5 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps f. Intermediate guide rail brackets where indicated on the Drawings or at 10-foot maximum intervals. g. Lifting chain of sufficient strength and length to permit safe removal of pump unit from sump. h. For setting greater than 15 feet, provide double harness rings in chain or cable every 15 feet and a hook to support pump and chain from concrete wall at ground surface. 2.7 PAINTING AND COATING A. Shop prime and field finish paint ferrous metal in accordance with and as specified in Section 09 90 00 PAINTING AND PROTECTIVE COATINGS. B. Exposed metal surfaces of motors, gear reducers, and drive assemblies shall be factory prepared and primed and field finish coated in accordance with Section 09 90 00 PAINTING AND PROTECTIVE COATINGS Division 09, FINISHES. 2.8 PUMP ACCESSORIES A. Equipment Identification Plate: A 16-gauge stainless steel identification plate shall be securely mounted on each pump in a readily visible location. The plate shall bear the 1/4” die-stamped equipment identification number name that is assigned to each pump in the Submersible Pump Data Sheets and shown on the Drawings. B. Lifting Lugs: Equipment weighing over 100 pounds shall be provided with lifting lugs. C. Painting: Provide touch-up painting for post-installation. D. See Submersible Pump Data Sheet(s) following this Section. E. Spare Parts and Special Tools: See Submersible Pump Data Sheet(s) for spare parts and special tools required for each pump or set of pumps. 2.9 MOTOR REQUIREMENTS A. Motor shall be selected in accordance with the pump’s non-overloading performance characteristics. Motor horsepower rating shall be chosen in keeping with the pump’s possible peak horsepower requirements. B. The motor shall be mounted with the pump at the pump manufacturer’s plant and shipped as one unit. C. Each pump motor shall be sufficiently cooled by submergence in the pumped media. D. The cable entry seal design shall preclude specific torque requirements to insure a watertight and submersible seal. The cable entry shall consist of dual cylindrical elastomer grommets, flanked by washers, all having a close tolerance fit against the cable outside diameter and the entry inside diameter. The grommets shall be compressed by the cable entry unit, thus providing a strain relief function. The assembly shall provide ease of changing the cable when necessary using the same entry seal. The cable entry junction chamber and motor shall be sealed from each other, which shall isolate the stator housing from foreign material gaining access through the pump top. Epoxies, silicones, or other secondary sealing systems shall not be considered equal. E. The pump motor shall be a NEMA B design, induction type with a squirrel cage rotor, shell type design, housed in an air filled, watertight chamber. The stator windings shall be insulated with moisture resistant Class H insulation rated for 180°C (356°F). The stator shall be insulated by the Project No. 18088080 6 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps trickle impregnation method using Class H monomer-free polyester resin resulting in a winding fill factor of at least 95%. The motor shall be inverter duty rated in accordance with NEMA MG1, Part 31.The stator shall be heat-shrink fitted into the cast iron stator housing. The use of multiple step dip and bake-type stator insulation process is not acceptable. The use of pins, bolts, screws or other fastening devices used to locate or hold the stator and that penetrate the stator housing are not acceptable. The motor shall be designed for continuous duty while handling pumped media of up to 104°F. The motor shall be capable of no less than 30 evenly spaced starts per hour. The rotor bars and short circuit rings shall be made of aluminum. Three thermal switches shall be embedded in the stator end coils, one per phase winding, to monitor the stator temperature. These thermal switches shall be used in conjunction with and supplemental to external motor overload protection and shall be connected to the motor control panel. F. The junction chamber shall be sealed off from the stator housing and shall contain a terminal board for connection of power and pilot sensor cables using threaded compression type terminals. The use of wire nuts or crimp-type connectors is not acceptable. The motor and the pump shall be produced by the same manufacturer. G. The motor service factor (combined effect of voltage, frequency and specific gravity) shall be 1.15. The motor shall have a voltage tolerance of +/- 10%. The motor shall be designed for continuous operation in up to an ambient temperature of 40°C ambient and shall have a NEMA Class B maximum operating temperature rise of 80°C. A motor performance chart shall be provided upon request exhibiting curves for motor torque, current, power factor, input/output kW and efficiency. The chart shall also include data on motor starting and no-load characteristics. H. Motor horsepower shall be sufficient so that the pump is non-overloading throughout its entire performance curve, from shut-off to run-out. The motor and cable shall be capable of continuous submergence underwater without loss of watertight integrity to a depth of 65 feet or greater. I. Motor shall also meet requirements specified in Section 26 05 15, Electric Motors, and the following supplemental data sheet(s). 2.10 PROTECTION 1. Each pump motor stator shall incorporate three thermal switches, one per stator phase winding and be connected in series, to monitor the temperature of the motor. Should the thermal switches open, the motor shall stop and activate an alarm. A float switch shall be installed in the seal leakage chamber and will activate if leakage into the chamber reaches 50% chamber capacity, signaling the need to schedule an inspection. 2. The thermal switches and float switch shall be connected to a Mini CAS control and status monitoring unit. The Mini CAS unit shall be designed to be mounted in the pump control panel. 2.11 ELECTRICAL AND CONTROL SYSTEMS A. General: 1. Conform to Division 26, ELECTRICAL. 2. Provide all necessary electrical components and wiring for a complete, functional system. 3. Where indicated, motor starters for constant-speed, 460-volt motors shall be provided in a separate motor control center specified in Division 26, ELECTRICAL. Provide all necessary control functions to properly interface with this motor starter. B. Wiring: The Drawings and Specifications indicate the anticipated wiring for the equipment provided under this section. If additional wiring is required, or if required wiring does not match what is indicated, the Contractor shall make the necessary modifications to the electrical wiring and documentation as part of the lump sum price. Wiring shall meet the requirements of Division Project No. 18088080 7 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps 26, ELECTRICAL, and NFPA 70. Insulation shall be rated 600 volts, minimum. Low-voltage (24V) signals shall be run in twisted, shielded pair cable. C. Electrical Raceways: Electrical wiring shall be installed in conduit meeting the requirements of Division 26, ELECTRICAL. Raceways shall be installed in accordance with Division 26, ELECTRICAL, and NFPA 70. 2.12 INSTRUMENTATION AND CONTROLS A. All instrumentation and control components shall be provided in accordance with the requirements of Division 26, ELECTRICAL. 2.13 PUMP CONTROL PANEL A. The pump supplier shall furnish and install a complete pump control panel to control, operate, and display information as indicated in the plans and specifications. The control system shall include all equipment, devices, wiring, and incidental materials to operate the system and display or relay information in accordance with these specifications. The intention of this section is to secure a complete control system that will operate equipment in accordance with narratives and requirements indicated in the plans, specifications, and manufacturer's literature for the equipment installed. B. All components provided shall be in accordance with the requirements of Division 26. C. Duplex Pump Control Panel, General: 1. Enclosure shall be NEMA 4X, suitable for installation outdoors. 2. Control panel shall be designed with a minimum SCCR rating of 22kA. 3. Panel shall be constructed in accordance with UL508A. 4. Incoming voltage is 480V, 3 phase. 5. Main circuit breaker disconnect interlocked with door handle. 6. Control power transformer for low voltage controls. 7. Surge protective device. 8. Phase monitor 9. Swing-out panel for operator devices. 10. Full voltage non-reversing starters. 11. H-O-A switch, run light, seal leak light, and elapsed time meter. 12. Flashing red high level alarm beacon. 13. Intrinsically safe relays for float switch inputs. D. Pump Controller 1. Provide a microprocessor-based pump controller specifically designed for use in duplex lift station control applications. The pump controller shall include a human-machine interface screen for operator interaction and monitoring. 2. Control – The pump station shall be configured to control the pumps utilizing five float switches. The float switches shall be configured as low level shutoff, pump off, duty pump on, standby pump on, and high level alarm. E. Control Panel Operator Interfaces: At a minimum, provide the following functions for each pump on the swing-out panel: 1. Hand Switches and Other Controls: a. Pump HAND-OFF-AUTO three position selector switch Project No. 18088080 8 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps b. Reset Momentary Pushbutton 2. Alarms: a. Pump Fault Light - Red b. Seal Leak Light – Yellow c. High Level Alarm Light - Red 3. Status: a. Pump Running - Green b. Elapsed Time Meter F. Control Panel External Interfaces: Provide the following interfaces between the control panel and items outside the system package: 1. Digital Inputs a. One for each float switch. 2. Dry Contact Outputs a. Pump 1 running b. Pump 2 running c. Pump 1 seal leak d. Pump 2 seal leak e. Pump 1 fault f. Pump 2 fault g. Wet well high level PART 3 - EXECUTION 3.1 SHIPPING, STORAGE, HANDLING, AND PROTECTION A. As specified in Section 01 60 00, PRODUCT REQUIREMENTS. 3.2 INSTALLATION A. Work shall be as specified in Section 01 60 00, PRODUCT REQUIREMENTS. 3.3 FACTORY TESTS A. Motor Tests and Test Reports: As specified in Division 26, ELECTRICAL. B. Balance of Vibration: The rotating parts of each pump and its driving unit shall be dynamically balanced before final assembly. The driving unit alone shall operate without vibration in excess of the limits stated in the latest revision of NEMA MG 1. 3.4 FIELD TESTS A. Functional Test: Prior to plant startup, all equipment described herein and in the Submersible Pump Data Sheet(s) following shall be inspected for proper alignment, quiet operation, proper connection, and satisfactory performance by means of a functional test. Provide certification of test results. Tests and certification shall be as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1. Testing performed upon each pump shall include the following inspections: a. Impeller, motor rating and electrical connections shall be checked for compliance with this specification. b. Prior to submergence, each pump shall be run dry to establish correct rotation. c. Each pump shall be run submerged in water. d. Motor and cable insulation shall be tested for moisture content or insulation defects. Project No. 18088080 9 Section 44 42 56.29 Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps 2. Upon request, a written quality assurance record confirming the above testing/inspections shall be supplied with each pump at the time of shipment. 3. Each pump (when specified) shall be tested in accordance with the latest test code of the Hydraulic Institute (H.I.) at the manufacturer to determine head vs. capacity and kilowatt draw required. Witness tests shall be available at the factory upon request. 4. The pump(s) shall be rejected if the above requirements are not satisfied. B. Vibration Test: The complete assembly, consisting of the driving unit and pump, connected and in normal operation, shall not develop amplitudes of vibration exceeding limits recommended by the current edition of Hydraulic Institute Standards. If directed by Engineer, vibration tests shall be conducted at Contractor’s sole expense to determine amplitude of vibration, and Contractor shall make any corrections necessary to meet these requirements. If corrections are made, a second vibration test shall be done following corrections. 3.5 MANUFACTURER’S SERVICES A. Provide representative for three (3) days on-site to verify correct installation, equipment testing, equipment certification, and personnel training. B. The equipment manufacturer shall furnish the services of a qualified factory trained field service engineer for 8-hour working day(s) at the site to inspect the installation and instruct the owner's personnel on the operation and maintenance of the pumping units. After the pumps have been completely installed and wired, the contractor shall have the manufacturer do the following: 1. Megger stator and power cables. 2. Check seal lubrication. 3. Check for proper rotation. 4. Check power supply voltage. 5. Measure motor operating load and no load current. 6. Check level control operation and sequence. 3.6 MANUFACTURER’S CERTIFICATE(S) A. Provide Manufacturer’s certificate(s). In accordance with Section 01 79 00, DEMONSTRATION AND TRAINING. 3.7 SUPPLEMENTS A. The supplements listed below, following “END OF SECTION,” are part of this Specification. 1. Section 44 42 56.29.1 DS – Wet-Pit Submersible Pumps Supplement END OF SECTION Project No. 18088080 1 44 42 56.29.1 Data Sheet Lake Lewisville WTP Dewatering Improvements Wet-Pit Submersible Pumps Section 44 42 56.29.1 –Wet-Pit Submersible Pumps Data Sheet PROJECT: Lake Lewisville WTP Dewatering Improvements OWNER: City of Denton EQUIPMENT NAME(S): Washwater Equalization Pumps EQUIPMENT TAG NUMBER(S): 68EQP03, 68EQP04 CONTROL PANEL(S): 68EQCP02 TOTAL PUMPS REQUIRED: (1) Duty + (1) Standby MANUFACTURERS SUGGESTED MODEL Flygt NP 3202 LT 3~616 KSB SERVICE CONDITIONS PERFORMANCE REQUIREMENTS Liquid Pumped: Backwash Waste Duty Point #1: 3185 gpm @ 40’ TDH Specific Gravity at 60 deg F: 0.99 – 1.10 Duty Point #2: 3431 gpm @ 39’ TDH Largest dia. Solid pump shall be capable of passing: 14 inch Duty Point #3: 3921 gpm @ 35.24’ TDH Min. NPSH available: 34.5 ft -: Explosion Proof (Y/N) N -: Pumping Temperature (°F) 40 – 100 °F Min. rated pump hydraulic efficiency at rated capacity (%): 70 Max pump speed at rated capacity 1800 rpm Min. hydraulic efficiency for operational range (%): 77 EQUIPMENT DESCRIPTION Casing Material: Ductile Iron Casing Wear Ring Material: Ductile Iron Guide Rail Material: Double, SST Impeller Type: Balanced, semi-open or closed, multi vane, Non-Clogging Lifting Chain Material: 316 SST Impeller Material: Cast Iron, A48 Class 35B Pump Removal Hoist (Y/N): N Impeller Wear Ring (Y/N): N Shaft Material: 420 or 431 Stainless Steel Material: N/A Double Mechanical Seal (Y/N): Y MOTOR DATA Type: Squirrel-cage induction meeting requirements of NEMA MG1. Manufacturer: For multiple units of the same type of equipment, furnish motors and accessories of a single manufacturer. Hazardous Location: Furnish motors for hazardous (classified) locations that conform to UL 674 and have an applied UL listing marking Motor Horsepower: 45 Maximum Mounting Type: Horizontal Vertical Voltage: 460 Enclosure Type: Submersible Phase: 3 Material: Cast Iron, A48 Class 35B Frequency: 60 Hz Load Class: Synchronous Speed: 1200 rpm max Multispeed, Two speed: rpm Service Factor: 1.0 1.15 See Division 26, ELECTRIC. Provide Inverter Duty Rated Motors. Windings: One Two Thermal protection embedded in windings. Motor nameplate horsepower shall not be exceeded at any operational point. Provide Space Heater Oversize main terminal (conduit) box for motors Moisture detection switches. SPECIAL FEATURES / NOTES See Division 26 for general instrumentation and control requirements. See Section 26 24 19 MOTOR CONTROL CENTERS for additional requirements. See Section 26 90 40 PROCESS CONTROL DESCRIPTIONS for control descriptions. Provide one set of mechanical seals, bearings, and O-rings required to replace each pump and special tools needed to dismantle pumps. Project No. 18088080 1 Section 44 42 56.53 Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps SECTION 44 42 56.53 - PROGRESSIVE CAVITY PUMPS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: the Work necessary to furnish and install, complete the progressive cavity pumps including all related equipment, material and appurtenances. B. Related Sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 60 00 – Product Requirements. 3. Section 01 78 23 – Operation and Maintenance Data. 4. Section 01 79 00 – Demonstration and Training. 5. Section 03 60 00 – Grout. 6. Section 05 50 00 – Metal Fabrications. 7. Section 09 90 00 – Painting and Protective Coatings. 8. Division 26 – Electrical. 1.2 GENERAL A. Equipment Numbers: See supplemental data sheet(s) at end of section. B. Like items of equipment provided hereinafter shall be the end products of one manufacturer to achieve standardization of appearance, operation, maintenance, spare parts, and manufacturer’s services. C. Unit Responsibility: The Work requires that the thickened residuals transfer pumps, complete with all accessories and appurtenances (including, but not necessarily limited to, electric motors, be the end product of one responsible system manufacturer or responsible system supplier. Unless otherwise indicated, the Contractor shall obtain each system from the responsible supplier of the equipment, which supplier shall furnish all components and accessories of the system to enhance compatibility, ease of operation and maintenance, and as necessary to place the equipment in operation in conformance with the specified performance, features, and functions without altering or modifying the Contractor's responsibilities under the Contract Documents. The Contractor is responsible to the Owner for providing the equipment systems as specified herein. D. General Requirements: See Division 01, GENERAL REQUIREMENTS, which contains information and requirements that apply to the work specified herein and are mandatory for this project. 1.3 DEFINITIONS A. Terminology pertaining to pumping unit performance and construction shall conform to the ratings and nomenclature of the Hydraulic Institute Standards. 1.4 SUBMITTALS A. General: Administrative, shop drawings, samples, quality control, and contract closeout submittals shall conform to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES. B. In addition to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES, submit the following additional specific information: 1. Shop Drawings: Project No. 18088080 2 Section 44 42 56.53 Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps a. Make, model, weight, and horsepower of each equipment assembly. b. Complete catalog information, descriptive literature, specifications, and identification of materials of construction. c. Performance data curves showing head, capacity, horsepower demand, and pump efficiency over the entire operating range of the pump, from shutoff to maximum capacity. Indicate separately the head, capacity, horsepower demand, overall efficiency, and minimum submergence required at the guarantee point. d. Detailed structural, mechanical, and electrical drawings showing the equipment dimensions, size, and locations of connections and weights of associated equipment. e. Power and control wiring diagrams, including terminals and numbers. f. Complete motor nameplate data, as defined by NEMA, motor manufacturer, and including any motor modifications. g. Factory finish system. 2. Quality Control Submittals: Manufacturer's Certificate of Compliance: Commercial products, including painting/ coating systems. a. Special shipping, storage and protection, and handling instructions. b. Test procedures. c. Test results, reports, and certifications. d. Manufacturer's Certificate of Proper Installation e. Operation and maintenance manual. f. Suggested spare parts list to maintain the equipment in service for a period of 1 year and 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. 1.5 QUALITY CONTROL A. Balancing: Rotating elements of equipment, except small, commercially packaged equipment, shall be statically and dynamically balanced at the factory prior to final assembly.' The Contractor shall furnish certified copies of all test results. B. Factory or shop inspections and tests. C. Test one pump identical to that furnished. D. Factory Test Report: Include curve test results, certified correct by a registered professional engineer. E. Functional Test: Perform manufacturer's standard test on equipment. 1.6 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, form, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.7 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the Project No. 18088080 3 Section 44 42 56.53 Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps warranty. In the event the equipment fails to perform as specified, the Manufacturer shall promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Where a manufacturer's standard equipment name and/or model number is listed, the equipment system shall be provided and modified as required to conform to the performance, functions, features, and materials of construction as specified herein. B. Materials, equipment, components and accessories specified in this Section shall be products of: 1. Seepex 2. Moyno 3. Netzch 2.2 GENERAL REQUIREMENTS A. Noise Level: When in operation, no piece of equipment shall exceed the OSHA noise level requirements for an 8 hour exposure, 90 dBA. B. Service Factors: Service factors shall be applied in the selection and design of components where so indicated in individual sections. When not indicated there, minimum service factors shall be 1.25, except for gears and gear drives as specified herein. C. Safety Devices: The completed work shall include all necessary permanent safety devices, such as machinery guards, emergency stops and similar items required by OSHA, and other federal, state, and local health and safety regulations. D. Flanges and Pipe Threads: Comply with ANSI B 16.1. Class 125; or B 16.5, Class 150, unless otherwise indicated. Threaded flanges and fittings shall have standard taper pipe threads complying with ANSI/ASME B 1.20.1. E. Bearings: 1. Conform to the standards of the Anti-Friction Bearing Manufacturers Association, Inc. (AFBMA). 2. Except where otherwise indicated, bearings of process equipment shall have a minimum L-10 life expectancy of 100,000 hours under maximum operating conditions and will not require periodic lubrication. 3. The bearings shall be of the oil lubricated, tapered roller type with diverging pressure angles for maximum shaft stability. Close-coupled pumps, which do not utilize bearings integral to the pump, will not be accepted. 4. Where applicable the bearings shall be protected from contaminants by means of a bearing cover plate bolted to the bearing housing. The bearings shall be enclosed in a separate housing, incorporating a bearing spacer and bolted bearing cover, which eliminates the need to shim the bearings. Inferior methods of positioning the bearings, i.e., snap rings, will not be accepted. F. Rotor: 1. Rotor shall be of one-piece construction with integrally machined rotor head. Rotors made in long lengths and cut to size, with welded rotor heads, will not be accepted. Project No. 18088080 4 Section 44 42 56.53 Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps 2. Rotor shall be machined from alloy steel (or 316 Stainless Steel). The alloy steel shall be ASTM A331-90, grade 4150 cold finish with a yield strength greater than 55,000 psi. 3. The rotor shall be of the single helix design with a high velocity thermal deposition applied coating for maximum abrasion resistance. G. Stator: 1. The stator shall be of the double helix design The Shore A durometer of the stator shall be 71 ± 4. 2. The stator shall be fastened to the suction housing and discharge flange with removable clamp rings or tie rods to facilitate stator removal. 3. The replaceable stator gaskets shall be designed to prevent the material being pumped from contacting the stator bonding and tube. 4. Stators shall be manufactured to size. Stators made in long lengths and cut to size will not be accepted. 5. Stators shall be replaceable without dismantling the pump suction or discharge flanges or any associated piping. Pumps that require additional space for axial/horizontal removal of the stator shall not be allowed. Stator designs shall additionally incorporate a retensioning feature to compensate for wear in lieu of increasing pump speed.. H. Gears and Gear Drives: 1. Except, as otherwise indicated, gears shall be of the helical or spiral-bevel type, designed and manufactured in accordance with AGMA Standards, with a minimum service factor of 1.7, a minimum L-10 bearing life of 60,000 hours and a minimum' efficiency of 94 percent. Worm gears shall not be used. 2. Gear speed reducers or increasers shall be of the enclosed' type, oil- or grease- lubricated and fully sealed, with a breather to allow air to escape but keep dust and dirt out. The casing shall be of cast iron or heavy-duty steel construction with lifting lugs and an inspection cover for each gear train. An oil level sight glass and an oil flow indicator shall be provided and installed for easy reading. 3. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation. 4. Material selections shall comply with AGMA values and the manufacturer's recommendations. Input and output shafts shall be properly designed for the service and load requirements. Gears shall be computer-matched for minimum tolerance variation. The output shall have two positive seals to prevent oil leakage. 5. Oil level and drain location shall be readily accessible. Oil coolers or heat exchangers with all required appurtenances shall be included where indicated. 6. Where gear drive input to output shafts connect to couplings or sprockets, manufacturer shall supply matching key. 7. Rotors shall be replaceable without dismantling the pump suction or discharge flanges or associated piping. Pumps that require additional space for axial/horizontal removal of the rotor shall not be allowed. The rotor design shall include provisions so that rotor replacement does not require the disassembly of either universal joint. I. Run Dry Protection: The stator shall be fitted with a special sensor sleeve and thermistor sensor. A set-point controller shall also be provided and shall be installed by the contractor in the local control panel. The controller shall monitor the stator temperature and activate a shutdown and alarm sequence if the stator temperature reaches the adjustable limit on the controller. The controller shall include a manual local and remote reset function. J. Pressure Protection: Each pump unit shall be supplied with a silicone-filled isolation ring with a dual mounted gauge and single point pressure switch on both the discharge and suction side of the pump. The pressure ranges for the switch and gauge shall be selected specifically for each specified service. The isolation ring shall be mounted between ANSI flanges, be sized according to the discharge pipe as shown on the plans, and be constructed with a carbon steel body and fittings with a Buna sleeve. Project No. 18088080 5 Section 44 42 56.53 Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps K. Anchor bolts shall be specified in Section 05 50 00, METALS. Number and size as recommended by manufacturer. L. Nameplates: Equipment nameplates of stainless steel shall be engraved or stamped and fastened to the equipment in accessible locations with stainless steel screws or drive pins. Nameplates shall contain the manufacturer's name, model, serial number, size, characteristics, and appropriate data describing the machine performance ratings. 2.3 MOTORS A. Provide squirrel-cage AC induction motors meeting the requirements of Division 26, ELECTRICAL, and as specified herein. B. For additional specific requirements on motors, refer to the Motor Data Sheets at the end of this Section. C. The operating characteristics of the motors shall be coordinated with the adjustable frequency drive systems supplied under Division 26, ELECTRICAL, to assure compatibility and system operation. 2.4 SUPPLEMENTS A. See supplements to this section for additional equipment system product, component or accessory information. 2.5 PERFORMANCE REQUIREMENTS A. As specified on the pump data sheets. 2.6 ELECTRICAL COMPONENTS AND ACCESSORIES A. General: Provide all necessary electrical components and wiring for a complete, functional system. Electrical components shall be provided in accordance with requirements of Division 26, ELECTRICAL. B. Motors: Provide as indicated on supplemental data sheets at the end of this Section. 2.7 TOOLS AND SPARE PARTS A. Tools: The work includes one complete set of special tools recommended by the manufacturer for maintenance and repair of each separate type of equipment tools shall be stored in tool boxes, and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box. B. Spare Parts: 1. All equipment shall be furnished with the specified manufacturers spare parts, as indicated in the individual equipment sections. 2. Spare parts shall be tagged by project equipment number and identified as to part number, equipment manufacturer, and subassembly component (if appropriate). Spare parts subject to deterioration such as ferrous metal items and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts with individual weights less than 50 pounds and dimensions less than 2 feet wide,' or 18 inches high, or 3 feet in length shall be stored in a wooden box with hinged wooden cover and locking hasp. Hinges shall be strap type. The box shall be painted and identified with stenciled lettering stating the name of the equipment, Project No. 18088080 6 Section 44 42 56.53 Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps equipment numbers, and the words "spare parts." A neatly typed inventory of spare parts shall be taped to the underside of the cover. 3. Provide at a minimum the following spare parts for each set of pumps: a. 2 mechanical seals. b. Complete set of bearings. c. Complete set gaskets and O-ring seals. d. Complete set rod washers. e. Complete set keys, dowels, pins, etc. f. 3 stators. g. 2 rotors. h. 2 connecting rods with 2 pair of universal joint(s), as required by pump type i. One complete set of any special tools required to dismantle pump. 2.8 FABRICATION A. Shop/Factory Finishing: Shop prime coatings shall conform to the requirements of Section 09 90 00, PAINTING AND PROTECTIVE COATINGS, System No. 5. PART 3 - EXECUTION 3.1 ASSEMBLY AND PREPARATION FOR SHIPMENT A. Each drive unit, including motor, shall be completely factory assembled, aligned, and securely crated for shipment. Accessory equipment which cannot be shipped assembled to the unit, such as shafts, baseplates, impellers, spare parts, and anchorage materials, shall' be separately crated, clearly marked as to the contents, and shipped on the same shipment as the drives. B. For shipment, exposed surfaces subject to rust, such as mounting flange faces, etc., shall be covered with a rust-preventive compound such as Kendall No. 5, or equal. 3.2 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Comply with Section 01 60 00, PRODUCT REQUIREMENTS. B. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. C. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. D. Protection of Equipment: Equipment shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage. Equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Pumps, motors, drives, electrical equipment, and other equipment with anti-friction or sleeve bearings shall be stored in weather tight and heated storage facilities prior to installation. For extended storage periods, plastic equipment wrappers shall not be used to prevent accumulation of condensate in gears and bearings. 3.3 INSTALLATION A. Install in accordance with manufacturer's printed instructions. B. Level base by means of steel, wedges (steelplates and steel shims). Wedge taper not greater than 1/4 inch per foot. Use double wedges to provide a level bearing surface for the pump and Project No. 18088080 7 Section 44 42 56.53 Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps driver base. Accomplish wedging so that there is no change of level or springing of the baseplate when the anchor bolts are tightened. C. Adjust pump assemblies; such that the driving units are properly aligned, plumb, and level with the driven units and all interconnecting shafts and couplings. Do not compensate for misalignment by use of flexible couplings. D. After the pump and driver have been set in position, aligned, and shimmed to the proper elevation, grout the space between the bottom of the baseplate and the concrete foundation with a poured, nonshrinking grout of the proper category, as specified in Section 03 60 00, GROUT. Remove wedges after grout is set and pack void with grout. E. Connect suction and discharge piping without imposing strain to pump flanges. F. Anchor Bolts: Accurately place using equipment templates and as specified in Section 05 50 00, METAL FABRICATIONS. G. Pipe pump drain(s) to hub drain. H. Lubricants: The installation includes oil and grease for initial operation. 3.4 APPLICATION A. Interface with Other Products: (Include discussions of other equipment or material interfaces, such as, conveyors, hoppers, I&C instruments or level elements, odor control ducting materials and equipment specified elsewhere, etc.) B. Pumping of gravity thickened ferric sulfate residuals from a gravity thickener to belt filter press dewatering. 3.5 FIELD QUALITY CONTROL A. Testing: Products shall be field-tested for compliance with the indicated requirements. 1. Functional Tests: a. Alignment: Test complete assemblies for correct rotation, proper alignment and connection, and quiet operation. b. Flow Output: Measured by plant instrumentation and storage volumes. c. Operating Temperatures: Monitor bearing areas on pump and motor for abnormally high temperatures. 2. Performance Tests: In accordance with Hydraulic Institute Standards. B. Witnesses: The Owner and the Engineer (at the option of either) reserve the right to witness field tests. 3.6 MANUFACTURERS' SERVICES A. A manufacturer’s representative for the equipment specified herein shall be present at the job site for the minimum person-days listed for the services hereinunder, travel time excluded: 1. Installation, Startup, and Testing Services: a. 1 person day for installation assistance, inspection, and Certificate of Proper Installation. b. 1/2 person-day for functional and performance testing. c. Provide Qualifications of Manufacturer's Representative. 2. Training Services: a. 1 person-day of prestart classroom or jobsite training of Owner’s personnel. Project No. 18088080 8 Section 44 42 56.53 Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps b. Training of Owner’s personnel shall be at such times and at such location as required and approved by the Owner. B. See Section 01 79 00, DEMONSTRATION AND TRAINING. 3.7 MANUFACTURER’S CERTIFICATES A. Provide Manufacturer’s certificate(s) in accordance with Section 01 79 00, DEMONSTRATION AND TRAINING. 3.8 SUPPLEMENTS A. The supplements listed below, following "END OF SECTION," are a part of this Specification: 1. Thickened Residuals Transfer Pumps Data Sheet END OF SECTION Project No. 18088080 1 44 42 56.53.1 Data Sheet Lake Lewisville WTP Dewatering Improvements Progressive Cavity Pumps Section 44 42 56.53.1: THICKENED RESIDUALS TRANSFER PUMPS DATA SHEET PROJECT: Lake Lewisville WTP Dewatering Improvements OWNER: City of Denton EQUIPMENT NAME(S): THICKENED RESIDUALS TRANSFER PUMPS EQUIPMENT TAG NUMBER(S): 75P03, 75P02, 75P01 SPEED TYPE Continuous, Low and High CONTOL PANEL(S): 75PCP01, 75PCP02, 75PCP03 TOTAL PUMPS REQUIRED 3 MANUFACTURERS MODEL Seepex BN Range with SCT Moyno Z38KS81RMB (EZstrip) Netzsch NEMO BY SERVICE CONDITIONS PERFORMANCE REQUIREMENTS Liquid Pumped: Thickened Ferric Sulfate Water Treatment Residuals Maximum Flow Rate: 250 gpm Largest Solid: 2” Minimum Flow Rate: 50 gpm Pumping Temperature (PT) 7.5-33° C Total Dynamic Head: 50 ft Specific Gravity at PT 0.99 – 1.10 Maximum Speed:: 350 rpm Solids content: 2-5% Minimum Speed: 60 rpm Minimum NPSHA at PT: 15 ft Suction Static Head: Flooded EQUIPMENT DESCRIPTION Bearing Housing: Cast Iron ASTM A48 Class 30 Suction Housing: Cast Iron ASTM A48 Class 30 Rotor: See Specification Packing Gland: Cast Iron ASTM A48 Class 30 Stator: Buna N Connecting Rod: Alloy Steel ASTM 331-90, Grade A862C Joints: Pin or gear type, grease lubricated Shaft: Carbon Steel ASTM A519-90, Grade 3 MT1020 Drive Type / Arrangement: Close Coupled Bearings: Sealed, 100,000 hour minimum Stuffing Box / Mechanical Seal: Mechanical Seal Baseplate:: Fabricated Steel Bearing Lubrication: Oil MOTOR DATA Manufacturer: For multiple units of the same type of equipment, furnish motors and accessories of a single manufacturer. Motor Type Squirrel- cage Voltage 460 Motor Horsepower: 20 (MAX) hp Phase 3 Synchronous Speed 1800 (max) rpm Enclosure Type TEFC Variable Speed Drive: See Division 26, ELECTRIC. Provide Inverter Duty Rated Motors. Winding: One Two Shaft: Split Hollow Upthrust: High (,30%) Extra High (,175%) Mounting Type: Horizontal Vertical SPECIAL FEATURES / NOTES 1. Provide run dry protection accessory. 2. Provide overpressure protection accessory. 3. Pumps will be installed outdoors 4. Pump Control Panels will be installed indoors Project No. 18088080 1 Section 44 44 63 Lake Lewisville WTP Dewatering Improvements Liquid Polymer Feed System SECTION 44 44 63 - LIQUID POLYMER FEED SYSTEM PART 1 - GENERAL 1.1 SUMMARY A. Section includes: The Work necessary to furnish and install a complete, operable liquid polymer feed system. The automatic polymer dilution/feed system shall consist of an integrated equipment package capable of automatically metering, diluting, activating, and feeding liquid polymer and water. B. Principle items to be furnished and installed include the following: 1. Polymer feeder 2. Control panel C. Related Sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 60 00 – Product Requirements. 1.2 GENERAL A. Equipment shall be fabricated, assembled, erected and placed in proper operating condition in full conformity with the drawings, specifications, engineering data instructions, and recommendations of the equipment manufacturer. B. Unless otherwise specified, power supply shall be 120 volts, 60 Hz, single phase. Where control voltage lower than power supply is required, suitable power transformer shall be provided. C. The polymer feeder shall be mounted on a fabricated 304 stainless-steel base to be attached to concrete equipment pad. D. A nameplate shall be provided and mounted on the feeder to identify its function. Nameplates shall be made from black on white phenolic material, or other suitable material approved by the Engineer. E. The manufacturer/supplier shall prepare system drawings, piping layouts/schematics, interconnecting diagrams, panel layout, and other data required for complete system description. The supplier shall verify that each system component is compatible with all other components of the system, that all pipe materials and sizes are appropriate, and that all the devices necessary for a properly operating system have been provided. Review of drawing submitted prior to the final determinations and coordination of related equipment to be provided will not relieve the Contractor from responsibility for supplying systems in full compliance with the specific requirements of related equipment. F. Calibration Graphs: The supplier shall prepare a calibration graph for the feeder. The graph shall show the rate setter graduation conversion to gallons per hour throughout the range of the feeder unit. Each graph shall be furnished on hard paper sealed in clear plastic. 1.3 SUBMITTALS: A. Complete fabrication, assembly, installation drawings, schematics, and wiring diagrams, together with detailed specifications and material data, part lists and other accessories shall be submitted in accordance with the Section 01 33 00, SUBMITTAL PROCEDURES. 1. Complete list of all system components Project No. 18088080 2 Section 44 44 63 Lake Lewisville WTP Dewatering Improvements Liquid Polymer Feed System 2. Make, model, weight, and horsepower of each equipment assembly 3. Complete catalog information, descriptive literature, specifications, and identification of materials of construction 4. Performance data that shows compliance with specification requirements stated herein to each type of equipment 5. Identification of outside utility requirements for each component such as water, air, and power 6. Dimensions, size, and locations of connections to other work 7. System layout installation and placing drawings for all equipment 8. Power control wiring diagrams, including terminals and numbers, panel construction and layout 9. Detailed structural, mechanical, and electrical drawings showing equipment fabrications and interface with other items 1.4 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer will promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. PART 2 - PRODUCTS 2.1 GENERAL A. The polymer system shall be capable of pumping and metering liquid polymer, metering dilution water, activating polymer with dilution water and delivering activated polymer with dilution water. B. The polymer system shall be factory assembled and tested. The unit shall be pre-wired, including 120-V power supply cord (to be hardwired to the junction box), and pre-piped requiring only field connection of dilution water inlet, solution outlet, and polymer inlet. 2.2 MANUFACTURERS A. Where a manufacturer’s standard equipment name and/or model number is listed, the equipment system shall be provided as modified to conform to the performance, functions, features, and materials of construction as specified herein. B. Materials, equipment, components, and accessories specified in this section shall be products of: 1. USGI Chemical Feed, Inc. – (Model M2400-P24AB) 2. Velodyne 3. Or Equal 2.3 SERVICE CONDITIONS A. Service conditions for polymer feed systems: 1. Liquid Pumped: Liquid, dispersed, and/or emulsion polymer (up to 75% active) 2. Pumping Temperature: 50-100 Degrees Fahrenheit 3. Viscosity: Up to 3,000 cps 4. Dilution Water: Potable or non-potable water at 50 psi 5. Polymer Quantity (Neat): 1.20 - 24 gallons polymer per hour Project No. 18088080 3 Section 44 44 63 Lake Lewisville WTP Dewatering Improvements Liquid Polymer Feed System 6. Polymer Concentration after Dilution: 0.05 to 20 percent 7. Pressure at Polymer Solution Injection: up to 9.5 psi 2.4 EQUIPMENT AND MATERIALS A. Polymer Activation: 1. Liquid polymer and water shall be blended in a mixing chamber to produce a complete uniform blend without "fisheyes" and be fully activated to maximize process performance. 2. A Hydrodynamic blending device shall be provided and specifically designed to dilute and activate emulsion, dispersion and solution type polymer with viscosity's up to 3,000 cps and active contents up to 75 percent. Systems without a proven track record with all types of polymers described above will not be considered. 3. The liquid polymer activation chamber's mixing energy shall be staged such that it provides for high, non-damaging mixing energy over the full operating range of the system. The system shall be designed for use with either potable or non-potable dilution water. The type of dilution water used shall not affect the specified warranty in any way. The mixing chamber shall have a maximum rated pressure of 100 psi. 4. At no time shall polymer be exposed to excessive shear. System's which are "retention time dependent - a system which is prone to induce insufficient or excessive mixing energy depending on flow rate and the subsequent retention time in the mixing chamber, or which utilize conventional static mixers, mixing blocks, eductors or flash mixers, shall not be considered. All components which require periodic maintenance shall be readily accessible. B. Polymer Metering Pumps: Minimum emulsion-type; polymer metering pump shall be a progressive cavity type. Pump(s) shall be provided as part of the polymer feed system package and integrally mounted on the systems skid. C. Neat Polymer Check Valve: The valve shall be designed with an open, unobstructed path to the valve seat. The valve body shall be constructed of Teflon or 316 stainless steel. The ball shall be stainless steel. The spring shall be covered such that polymer shall not pass through the spring or the spring shall be compatible with the polymer in use. The valve shall be readily accessible for cleaning and shall be easily disassembled. Check valves which are installed inside the mixing chamber or which require mixing chamber disassembly for servicing will not be accepted. D. Piping Connections: As required for proper operation. E. Dilution Water Control: 1. Each system shall have a nickel- or brass- plated solenoid valve for on/off control of dilution water supply, and rotameter-type flow indicators equipped with integral rate- adjusting valve. 2. The primary flow indicator shall be machined acrylic and will have a valve stop and guided float or be a paddlewheel type flowmeter with pulse output to controller. Water flow rate shall be adjustable to makeup solution over full range of neat pump operation. 3. The secondary flow indicator, if required, shall be machined acrylic and will have a valve stop and guided float or be a paddlewheel type flowmeter with pulse output to controller. Water flow rate shall be adjustable to dilute solution to minimum concentration over full range of pump operation. 4. Incoming dilution water shall provide the motive force to move polymer and water through the mixing regime. The same motive force shall deliver the final polymer solution to the point of application. F. Equipment Skid 1. System’s frame should be of rugged 304 stainless steel construction. No mild steel shall be used. All piping shall be rigidly supported. Project No. 18088080 4 Section 44 44 63 Lake Lewisville WTP Dewatering Improvements Liquid Polymer Feed System 2. The overall system dimensions shall not exceed 34 inches wide, 24 inches deep, and 64 inches tall. G. All metal in contact with polymer or polymer solution shall be Type 304 or 316 stainless steel. This shall include miscellaneous hardware including sheet metal screws, hose clamps, etc. All other materials in contact with polymer or polymer solution shall be constructed of plastics or elastomers suitable for service application. The feed system frame and housing shall be constructed of Type 304 stainless steel. H. Provide one calibration assembly for the feed system to enable calibration of polymer metering pump. Assembly shall generally include a calibration column, tubing, valves, and required fittings. 2.5 ELECTRICAL COMPONENTS AND ACCESSORIES A. General: 1. Furnish in accordance with requirements of Division 26. 2. Provide all necessary electrical components and wiring for a complete, functional system. B. Wiring: Wiring shall meet the requirements of NFPA 70. Insulation shall be rated 600 volts, minimum. Low-voltage (24V) signals shall be run in twisted, shielded pair cable. C. Electrical Raceways: Electrical wiring shall be installed in conduits. D. Motors: Provide squirrel-cage ac induction motors. E. Electrical: The liquid polymer feed system shall be suitable for operation from a 120V ac, 60-Hz, single-phase power supply. 2.6 CONTROLS A. General: Microprocessor-based; LCD display; NEMA4X enclosure B. Operator Controls and Indicators: At a minimum, provide the following functions. 1. Handswitches: ON/OFF/REMOTE (to control both the polymer feed pump and open solenoid valve for dilution water feed). 2. Indicator Light: ON/OFF indicating lights. 3. The controller shall provide speed control of the neat polymer pump; shall have a continuous LCD readout of polymer flow in gallons per minute (or hour). A potentiometer shall be provided for pump control. 4. Each unit shall have a dilution water loss of flow sensor which, sensing that water flow has been interrupted for any reason, will place the polymer pump on standby and will restart it automatically when flow is restored. An integral timer shall monitor loss of flow and energize contacts indicating alarm after 15 seconds of continuous loss. 5. The system shall be installed and wired complete, ready for connection to a 120-volt, single phase supply. System wiring shall be in PVC conduits. A NEMA 4X control panel shall be factory-mounted and wired as an integral part of the system. The following automatic interlocks shall be provided: a. The feeder system shall not operate while the water supply valve is closed, or the water pressure is not adequate. b. Locally, indicator lights shall be provided for power on and alarm conditions. The alarm circuitry shall include low differential pressure and activation chamber overload. 6. Unit shall be operated with a programmable microcontroller. Project No. 18088080 5 Section 44 44 63 Lake Lewisville WTP Dewatering Improvements Liquid Polymer Feed System a. Controller shall have polycarbonate touchpad membrane with four digit LED readout. b. Enclosure shall be non-metallic and of waterproof design. 7. Microcontroller shall pace polymer metering pump based on operator programmed data or based on a 4-20 mA analog input signal. a. Operator shall be able to determine mode of operation at touchpad, internal or external. b. Internal mode shall allow for automatic polymer pump pacing based on programmed setpoint. c. Operator shall be able to enter a makeup concentration setpoint. d. Controller will compute a ratio of polymer to water from primary dilution water flow rate signal generated by flow element. e. Controller will generate signal to pace pump accordingly. f. As primary dilution water flow changes, setpoint concentration will be automatically maintained by controller. g. External mode shall allow for automatic polymer pump pacing based on a 4-20 mA analog input signal. h. 8. Unit shall be controlled through an on-off-remote circuit. a. In the remote mode, the unit shall accept a run signal. b. Unit is manually controlled in the on mode. c. Controller shall indicate mode of operation with LED. 9. 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. 10. An integral timer shall monitor loss of flow and energize contacts indicating alarm after 15 seconds of continuous loss. a. a. Controller shall indicate loss of water alarm with LED. 11. Controller LED display shall indicate: a. Primary water flow b. Secondary water flow c. Polymer flow d. Make up solution concentration in mixing chamber e. Discharge solution concentration including post dilution 1. Controller shall have pre-programmed auto-flush cycle which will disable polymer pump yet allow dilution water to flow through system for a pre-set time at each shutdown. 2. Controller shall have 4-20 mA output signal which is proportional to polymer pump speed. 3. Controller shall have dry contacts for these outputs: a) General alarm b) Run status 4. Controller shall have additional LED indication of these: 1) Loss of water flow alarm 2) One (1) additional configurable alarm 3) Run status Project No. 18088080 6 Section 44 44 63 Lake Lewisville WTP Dewatering Improvements Liquid Polymer Feed System PART 3 - EXECUTION 3.1 GENERAL A. The Contractor shall assume full responsibility for coordination of the entire project, including verification all structures, piping, coating systems and equipment components are compatible. The Contractor and Manufacturer shall initially operate each equipment system and shall make all necessary adjustments so that each system is placed in proper operating condition. B. Installation of equipment shall be in full conformance with the manufacturer’s shop drawings and requirements as approved by the Engineer. 3.2 SHIPPING, STORAGE, HANDLING AND PROTECTION A. As specified in Section 01 60 00, PRODUCT REQUIREMENTS. 3.3 WORKMANSHIP A. Handle carefully and protect the equipment and appurtenances to avoid damage. B. The equipment shall be safely secured to the wall and/or floor in accordance with the Engineer’s design drawings. All plumbing and electrical shall be in accordance with state and federal codes. C. Any evidence of improper installation shall be corrected by the Contractor. Care during storage, installation and startup shall be in strict accordance with manufacturer’s recommendations. 3.4 MANUFACTURER’S SERVICES A. The Contractor shall require the manufacturer to furnish the services of a qualified field representative to include 1 visit for a total of 1 day. Service calls shall be made as required to insure proper operation throughout the correction period. 1. Verification of proper installation, start-up of equipment and initial operator instruction. This service shall take place after all mechanical equipment associated with the polymer feed system is installed and mechanically operable. 2. After equipment is fully operational, and before Owner will assume responsibility for the operation of the equipment, the equipment manufacturer’s operation specialists shall instruct the Owner’s operating personnel in the care, maintenance and proper operation of the equipment. B. Field Test 1. During plant start-up all equipment described herein shall be inspected for proper connections and satisfactory performance by means of a function test. 2. The equipment system and associated accessories shall be field tested to verify adequate performance. The units shall be set at the Engineer’s desired feed rate in preparation of plant operation. 3. Units apparently failing to meet the Specifications must be corrected to provide proper service. Should the problem persist due to a flaw in material and/or in the design of the equipment, new equipment must be provided by the Contractor to meet the specifications. C. Instructions for installation of the equipment system and related appurtenance shall be written and furnished by the manufacturer. Project No. 18088080 7 Section 44 44 63 Lake Lewisville WTP Dewatering Improvements Liquid Polymer Feed System 3.5 OPERATION AND MAINTENANCE MANUALS A. Three (3) copies of operation and maintenance manuals shall be furnished. B. The equipment system manufacturer shall be responsible for supplying written instruction, which shall be sufficiently comprehensive to enable the operator to operate and maintain all equipment supplied by the manufacturer. C. The instruction shall be prepared as a system manual application solely to the equipment supplied by the manufacturer and shall include those devices and equipment supplied by him. END OF SECTION Project No. 18088080 1 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms SECTION 44 46 26.13 – GRAVITY THICKENER MECHANISMS PART 1 - GENERAL 1.1 SUMMARY A. This section includes the Work necessary to completely furnish and install the gravity thickener mechanisms, all related equipment, material and appurtenances. 1.2 GENERAL A. Equipment Numbers: See Supplemental Data Sheet(s) at end of section. B. Like items of equipment provided hereinafter shall be the end products of one manufacturer to achieve standardization of appearance, operation, maintenance, spare parts and manufacturer’s services. C. Unit Responsibility: The Work requires that the gravity thickener mechanisms, including but not limited to drives, collector arms with pickets, walkways, weirs, local control panels, instruments, and components, complete with all accessories and appurtenances be the end product of one responsible system manufacturer or responsible system supplier. Unless otherwise indicated, the Contractor shall obtain each system from the responsible supplier of the equipment, which supplier shall furnish all components and accessories of the system to enhance compatibility, ease of operation and maintenance, and as necessary to place the equipment in operation in conformance with the specified performance, features, and functions without altering or modifying the Contractor's responsibilities under the Contract Documents. The Contractor is responsible to the Owner for providing the equipment systems as specified herein. D. General Requirements: See Division 01, GENERAL REQUIREMENTS, which contains information and requirements that apply to the work specified herein and are mandatory for this project. 1.3 REFERENCES A. The following is a list of standards which may be referenced in this Section: 1. American Gear Manufacturers Association (AGMA): 908-B89, Geometry Factor for Determining the Pitting Resistance and Bending Strength of Spur, Helical, and Herringbone Gear Teeth. 2. American Institute of Steel Construction (AISC): Specifications for the Design, Fabrication, and Execution of Structural Steel for Buildings. 3. American National Standards Institute/American Bearing Manufacturers Association (ANSI/ABMA): 9 & 11, Load Ratings and Fatigue Life for Ball Bearings and Roller Bearings. 4. American National Standards Institute/American Gear Manufacturers Association (ANSI/AGMA): a. 2000-A88, Gear Classification and Inspection Handbook Tolerances and Measuring Methods for Unassembled Spur and Helical Gears. b. 2001-C95, Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth. c. 2002-B88, Tooth Thickness Specification and Measurement. d. 2003-B97, Rating the Pitting Resistance and Bending Strength of Generated Straight Bevel, Zerol Bevel, and Spiral Bevel Gear Teeth. e. 2004-B89, Gear Materials and Heat Treatment Manual. f. 2009-A98, Bevel Gear Classification, Tolerances and Measuring Methods. g. 6001-D97, Design and Selection of Components for Enclosed Gear Drives. h. 6010-F97, Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives. Project No. 18088080 2 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms i. 6022-C93, Design Manual for Cylindrical Worm gearing. j. 6034-B92, Practice for Enclosed Cylindrical Worm gear Speed Reducers and Gear motors. k. 9005-D94, Industrial Gear Lubrication. 5. American Society of Mechanical Engineers (ASME): B29.1M, Precision Power Transmission Roller Chains, Attachments, and Sprockets. 6. American Welding Society (AWS): B2.1, Standard for Welding Procedure and Performance Qualification. a. D1.1, Structural Welding Code – Steel. b. QC 1, Standard for AWS Certification of Welding Inspectors. 7. ASTM International (ASTM): a. A36/A36M, Standard Specification for Carbon Structural Steel. b. A48, Standard Specification for Gray Iron Castings. c. A123/A123M, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products. d. A148/A148M, Standard Specification for Steel Castings, High Strength, for Structural Purposes. e. 6A167, Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip. f. A193/A193M, Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service. g. A276, Standard Specification for Stainless Steel Bars and Shapes. h. A283/A283M, Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates. i. A285/A285M, Standard Specification for Pressure Vessel Plates, Carbon Steel, Low- and Intermediate-Tensile Strength. j. A325, Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength. k. A384, Standard Practice for Safeguarding Against Warpage and Distortion during Hot-Dip Galvanizing of Steel Assemblies. l. A385, Standard Practice for Providing High-Quality Zinc Coatings (Hot-Dip). m. A536, Standard Specification for Ductile Iron Castings. n. A666, Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar. o. D3034, Standard Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings. 8. National Electrical Manufacturers Association (NEMA): 250, Enclosures for Electrical Equipment (1,000 Volts Maximum). a. NEMA MG-1. 1.4 DEFINITIONS A. Alarm Torque: 90 percent of design running torque. B. Cutout Torque: 120 percent of design running torque. C. Design Running Torque: 1. Torque used to select size, strength, and type of materials and components for mechanism and drive system. 2. At which or below will provide continuous 24 hour per day mechanism operation for period of not less than 20 years at design torque condition and rotational speed without damage, permanent deformation or overload. 3. Equal to 50 percent on overload device scale. D. Slenderness Ratio: Ratio of unbraced length to least radius of gyration. Project No. 18088080 3 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms E. Submerged Metal: Metal below gear head drive and a plane 18 inches above weir elevation indicated. F. Ultimate Torque: 200 percent of design running torque and below which no portion of mechanism will be damaged if operated for only a short period of time (a few seconds) and equal to 100 percent on overload device scale. G. Certified Welding Inspector (CWI): As defined in AWS QC 1. 1.5 SUBMITTALS A. General: Administrative, shop drawings, samples, quality control and contract close-out submittals shall conform to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES. B. In addition to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES, submit the following additional specific information: 1. Shop Drawings: a. Equipment Assembly: Make, model, weight, and horsepower of each. b. Manufacturer’s Catalog: Product information, descriptive literature, dimensional layouts, specifications, standard and specialized equipment assembly cuts, and identification of materials of construction. c. Detailed Drawings: 1). Structural, Mechanical and Electrical: Show equipment fabrications and interface with other items including dimensions, size, and locations of con- nections to other work, and weights of associated equipment. 2). Structural and Mechanical: Details of walkway bridge, rotating rake arms. d. Design Details: 1). Running, Alarm, Cutout, and Ultimate Torque ratings of drive unit assem- bly. 2). Ultimate Torque load capabilities of drive unit assembly, torque cage, ro- tating rake arms. e. Hydraulic calculations and performance verification data. f. Certification of Structural Calculations: Letter of certification for structural design of mechanism, shall be signed and sealed by registered professional engineer (Designer). Copies of detailed structural design calculations shall not be submitted for review. If submitted, calculations will be returned without review. g. Structural Loads: Static, dynamic, and torque reaction loads to be transferred into structure at center column and Access Bridge support locations. h. Details of torque sensing and load indication device. i. Identification of outside utility requirements for each component such as air, water, and power. j. Power and control wiring diagrams, including terminals and numbers. k. Functional description of internal and external instrumentation and controls to be supplied including list of parameters monitored, controlled, or alarmed. l. Painting/Coating System(s): Include manufacturer’s descriptive technical catalogue literature and specifications. m. Diameter of ball race. n. Motor nameplate data per NEMA MG-1, motor manufacturer and any appurtenances. o. Functional and Performance test description and results. 2. Quality Control Submittals: Project No. 18088080 4 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms a. Designer qualifications: 1). Designer: Professional engineer registered in the State of Texas. 2). Must show 10 years’ experience with gravity thickener mechanism design. b. Manufacturer’s Certificate of Compliance, in accordance with Division 01, GENERAL REQUIREMENTS. c. Special shipping, storage and protection, and handling instructions. d. Test procedures. e. Test results, reports, and certifications. f. List 10 installations of equipment in successful operation similar to equipment specified. g. Operation and Maintenance Data: As specified in Division 01, GENERAL REQUIREMENTS. h. Manufacturer’s Certificate of Proper Installation. 3. Contract Closeout Submittals: Service records for maintenance performed during construction. 1.6 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, form, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.7 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer shall promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Where a manufacturer’s standard equipment name and/or model number is listed, the equipment system shall be provided as modified to conform to the performance, functions, features, and materials of construction as specified herein. B. Materials, equipment, and accessories specified in this Section shall be products of: 1. Westech Engineering. 2. Ovivo, LLC 3. Evoqua 2.2 GENERAL REQUIREMENTS A. Furnish units meeting performance and design requirements as specified and as shown on the Drawings. B. Performance Requirements: Project No. 18088080 5 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms 1. Provide gravity thickening of residuals. 2. Collect and convey thickened residuals to center hopper. 3. Capable of normal operation with residuals stored in the unit. 4. Operates in conjunction with odor control covers, the covers’ associated support systems and the cover’s associated facilities. C. Design Requirements: 1. Design Running Torque: Drive unit shall be sized such that all gearing meets Design Running Torque in accordance with AGMA 2001 and 6034. Design Running Torque shall be selected by Manufacturer for service conditions specified. 2. Rotational Speed: Constant speed between 0.04 rpm and 0.1 rpm. 3. Capable of withstanding, without failure or permanent deformation of any part, torque load of at least twice Design Running Torque and loads generated while sweeping in gravity thickener floor bottom grout. 4. Gears, Bearings, Chains, and Sprockets: Above water surface of gravity thickener. 5. Drive Mechanism: Design to allow removal of internal gears, balls, and strip liners without walkway bridge removal. 6. Base design upon all-welded construction except at locations requiring periodic field adjustment and as specifically approved. 7. At Ultimate Torque load, stresses in members shall not exceed 90 percent of material yield strength. 8. Slenderness Ratio: Maximum of 200 for any compression member and maximum of 300 for any tension member. 9. Mechanism mounted on walkway and supported by structural steel bearing on walls of each end of gravity thickener structure. 2.3 SUPPLEMENTS A. See supplemental data sheets to this Section for additional equipment system product, component, and accessory information and requirements. 2.4 CENTER DRIVE UNIT ASSEMBLY A. Ultimate Torque Rating: Not less than 200 percent of Design Running Torque. B. Motor, Primary and Final Speed Reducers: Separately and independently mounted at center gear head drive platform. C. Electric Drive Motor: In accordance with Division 26, ELECTRICAL and Scraper Drive Data Sheet located in Supplements following “END OF SECTION.” D. Speed Reducer Unit (Option A): 1. Cycloidal, helical, or planetary speed reducers directly connected to a motor and keyed to the pinion. 2. Cycloidal drives shall be made of high carbon chromium bearing steel and be fixed to the drive casing. 3. An eccentric bearing on the high speed shaft shall roll cycloidal discs of the same material around the internal circumference of this main ring gear. 4. The lobes of the cycloid disc shall engage successively with the pins in the fixed ring gear. 5. The movement of the cycloid discs shall be transmitted then by the pins to the low speed shaft. 6. Speed reducer efficiency shall be a minimum of 90% per reduction stage. 7. The reducers shall be fitted with radial and thrust bearings of proper size for all mechanism loads and be grease lubricated. Project No. 18088080 6 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms E. Low Speed Final Reduction Unit (Option A): 1. The drive unit shall consist of a solid internal main spur gear, bearing turntable, pinion, secondary speed reducer, support base, and drive unit bearing. a. The drive bearing shall include a forged steel precision gear/bearing set, with fully contoured raceways hardened to a minimum 58-60 RC and protected by a neoprene seal. 2. Low Speed Gearset: a. The design running torque rating of the drive gearing shall be based on the smaller of the strength and durability values determined from the above AGMA standard. b. The drive main gear shall be designed to a minimum AGMA 6 rating when rated in accordance with the latest AGMA standard. c. All spur gearing shall be designed to the latest AGMA spur gear standard for strength and surface durability, based on a life of 175,000 hours. d. Main internal gear shall be forged of alloy hardened steel. e. The pinion shall be heat treated alloy steel. f. Support base shall be welded steel. 3. Main Bearing: a. Ball raceway diameter: Minimum 20.53” b. The drive main bearing shall be designed for the total rotating mechanism loads with a minimum L-10 life of 100 years or 876,000 hours. F. Primary Speed Reducer (Option B): 1. Horizontally mounted cylindrical-worm or helical-worm gear motor type with gears supported by anti-friction bearings. Connected to secondary speed reducer via a chain. 2. AGMA 6034-B92 and AGMA Service Classification II. 3. The gear motor primary speed reducer shall drive the final worm gear reducer through a #60 roller chain and steel sprockets enclosed in a galvanized 22 gauge steel guard. 4. Oil Fill, Drain and Level Indicator Devices, and Lubricant: ANSI/AGMA 9005-D94. G. Chain Drive (Option B): 1. Roller Chain: Standard, ANSI B29.1. 2. Connect drive sprocket on primary speed reducer to driven sprocket on secondary speed reducer input shaft. 3. Sprockets and chain shall be designed for the connected horsepower of the drive with a minimum service factor of 4.0. Provision shall be made for adjustment of chain tension. H. Secondary Speed Reducer (Option B): 1. Cylindrical-Worm and Worm-Gear Type: a. Shafts supported by antifriction bearings and output shaft directly driving pinion gear of low-speed main bearing assembly. 2. Load Capacity and Torque Rating: AGMA 6034-B92. 3. Design: ANSI/AGMA 6022-C93. 4. Output Shaft: One-piece output extending through worm-gear and low speed main gear drive pinion without intermediate couplings. 5. Worm: Steel, heat treated, ANSI/AGMA 2004-B89, ground and polished. 6. Worm-Gear: Centrifugally cast, high silicon bronze copper alloy, or ductile iron. 7. Bearings: ABMA L-10, life of 180,000 hours minimum. 8. Oil fill, drain and level indicator devices, and lubricant conforming to ANSI/AGMA 9005-D94. 9. Enclosure: Cast iron ASTM A48, Class 40 minimum housing, and registered fit mounted to gear head drive platform. I. Low Speed Final Reduction Unit (Option B): 1. Enclosed turntable, continuous multipoint contact contoured raceway type with hardened surfaces and balls (Precision bearings). a. Ring Gear: Internal or external toothed, spur pinion gear driven, attached to secondary speed reducer output shaft. Project No. 18088080 7 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms 2. Low Speed Gearset: a. Design and Rated: ANSI/AGMA 2001-C95. b. Service Factor: Minimum 1.5 based upon Design running Torque. Power Rating: 1). Lower of pitting resistance and bending strength ratings for pinion and gears. 2). Based upon continuous 24 hours per day service at Design Running Torque for 180,000 hours minimum. c. Spur Pinion Gear: 1). Steel: Heat treated; integral with or keyed to its shaft. 2). Wall Thickness (Above Keyway): Minimum depth of one tooth. d. Ring Gear: 1). Solid one-piece construction of cast alloy bronze (AISI 4140/42H). 2). Split Gear 3). Bolt to center torque cage that support and rotate collection mechanism. e. Teeth: Full depth, ANSI/AGMA 2001-C95. 3. Main Bearing: a. Ball Raceway Diameter: The main bearing shall have a minimum pitch diameter of 16.25 inches to assure stability without the necessity of underwater guide shoes and shall include chrome alloy steel balls, minimum 0.75 inch diameter, which shall bear vertically and horizontally upon a four point contact precision bearing assembly fitted into the turntable base and the worm gear. The bearing assembly shall be such that the B10 life of the liner is a minimum of 50 years based on the mechanism speed and a uniformly distributed load due to the rotating mechanism. 4. Ring Gear, Pinion Gear, and Main Bearing Ball Races: a. Oil bathed, steel dust shield, and felt seal protected. Neoprene seals accepted with approval from ENGINEER. b. Oil fill, drain and level indicator devices, and lubricant conforming to ANSI/AGMA 9005-D94. c. Casing with manual condensate drain. 5. Oil filling and level pipe, drain plug, and sight gauge. Attach pipe to turntable bottom within base center for easy access. J. Mechanism Overload Device: 1. Mechanical or Hydraulic a. Mechanical or Hydraulic: Actuate integral contacts to indicate impending overload and shutoff drive motor at predetermined load. b. Impending Overload Contact (Alarm Torque): Actuate at 90 percent of Design Running Torque. c. Motor Shutdown Contact (Cutout Torque): Actuate at 120 percent of Design Running Torque. d. Contacts: Single-pole, double-throw rated 5 amps, 120V ac. e. Enclosure: NEMA Type 4X cast epoxy coated aluminum. f. Indicating Pointer: Indicate relative load on graduated scale up to Ultimate Torque. g. The pointer shall provide a visual reading of the relative worm gear output torque on a 0 to 100 percent graduated scale. The 100 percent reading shall equal the 100 percent drive rating as specified. 2. Sheer Pin a. A safety shear pin shall also be included in the design to prevent overload. Manufacturer shall include their standard shear pin appropriate for the design of their manufactured equipment and process application. 2.5 INFLUENT STILLING WELL AND PIPE A. Steel, ASTM A36, minimum 3/16-inch thick plates and minimum 1/4-inch thick shapes. B. Stilling Well Configuration: Project No. 18088080 8 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms 1. The stilling well shall efficiently and evenly disperse the influent liquid into the tank without disturbance and provide a flocculation zone. 2. Extend minimum 6 inches above clarifier static liquid level. 3. Influent stilling well depth below clarifier static liquid level: As indicated on data sheets. 4. Stilling well diameter: As indicated on data sheets. C. Inlet Pipe: 1. Provide inlet pipe for delivering influent into stilling well. 2. Provide flange connections as required to connect pipe to existing gravity thickener piping. 3. Provide all necessary pipe supports, brackets, and accessories to properly support pipe. 2.6 ACCESS WALKWAY A. Access Walkway Support System: 1. All-welded rolled wide flange beam type bridge or truss construction supported rigidly at one end on gravity thickener wall with thermal expansion compensating anchorage. a. Contractor shall be responsible for field verifying and coordinating dimensions and other pertinent information with Manufacturer, as necessary for proper installation. b. See Drawings for additional information regarding walkway attachment methods and coordination. 2. Diagonally cross brace and space beams as necessary to carry loads and produce required clear walkway width. B. Bridge Design: 1. Maximum Vertical Deflection: 1/360 of span under uniform 50-pound per square foot of walkway surface live load, plus dead load. Camber for 1/3 live load plus dead load. 2. Maximum Horizontal Deflection: 1/360 of span under uniform horizontal loading of 50 pounds per linear foot. 3. Walkway Surface Elements: Do not utilize to reduce calculated bridge deflections. 4. Designed to support mechanism. C. Walkway Surface: 1-1/2-inch minimum thickness aluminum grating and extend in width to at least guardrail/handrail supports. D. Walkway Width: 36 inches minimum clear between guardrails/handrails. E. Guardrails/Handrails: 1. Extend all along both sides of bridge and all around center platform. 2. Anodized Aluminum: In accordance with Division 05, METALS. 3. Truss type bridge members shall not be used as guardrail/handrail. Attach top and intermediate rails specified to bridge elements using standard premanufactured wall bracket units. F. Kickplates: 1. Anodized Aluminum: In accordance with Division 05, METALS. 2. Four-inch minimum high by 3/16-inch minimum thickness anodized aluminum, attached with Type 316 stainless steel fasteners. 3. Located around center platform perimeter and full length of both sides of access walkway. 2.7 CENTER SHAFT AND RAKE ARMS A. Center shaft to be minimum 6” Schedule 40 provided with connection point for two residuals removal arms Project No. 18088080 9 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms B. Quantity: Two Rake Arms per mechanism (minimum). Rake arms to be stainless steel truss construction or stainless steel channel with steel raking blades and adjustable stainless steel squeegees. Rake arms to be supported from center shaft. C. Pickets: The gravity thickener mechanism shall be provided with pickets, which rotate with the rake arms. The pickets shall be constructed of stainless steel angle. Pickets shall be spaced evenly along the rake arm to insure complete raking of the basin floor twice per revolution, as recommended by the Manufacturer. D. Sufficient strength and rigidity such that at Ultimate Torque load and while sweeping in floor grout no member will be stressed to level beyond maximums allowed by current AISC Specifications. E. Steel (non-submerged): ASTM A36, angular and tubular elements. Designed to meet or exceed current AISC Specifications when continuous torque of the drive unit is applied. F. Steel (Submerged or partially submerged): ASTM A276 316 Stainless Steel angular and tubular elements. Designed to meet or exceed current AISC Specifications when continuous torque of the drive unit is applied. G. Scraper blades shall be designed for sufficient residuals transport capacity to handle the design solids loading rate with the depth of the blade varying from a minimum at the tank periphery to a maximum at the tank center. H. Squeegees: Materials: 20-gauge Type 316 stainless steel. 1. Bolts, Nuts, and Washers: Type 316 stainless steel. 2. Vertical Alignment: Between 1/2-inch minimum and 1-1/2-inch maximum clearance above grouted gravity thickener bottom. Designed for a 2-inch minimum adjustment in the vertical plane. 3. Attached to stainless steel residuals scraper blades. I. Residuals Removal: 1. The center shaft shall extend down to a residuals cone in the center of the tank floor. The shaft shall have a steel cone scraper attached to its lower end to prevent deposit of solids in the residuals cone. 2.8 ENERGY DISSIPATING INLET A. Provide inlet baffles to promote effective mixing and tapered flocculation B. Flow shall impinge three (3) overlapping vertical target baffles in secession with a series of 4 (4) impingement zones. Maximum baffle exit velocity shall be less than 0.15 fps at peak influent flow. C. Design to provide a “Gt” (t = time in seconds) value in the well not exceeding 6,000 with a velocity gradient “G” within the well of at least 35 fps/ft and not exceeding 60 fps/ft at a minimum water temperature of 10 degrees-C at peak influent flow. D. Baffles shall bolt to center cage and well support beams. E. Baffles shall be fabricated from minimum 3/16” thick A36 carbon/HDG steel plate. F. Hydraulic calculations shall be provided showing dimensional characteristics, port area, velocity, headloss, and mixing intensity. Project No. 18088080 10 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms 2.9 WEIR PLATES A. Provide weirs where required as indicated on gravity thickener data sheets following end of this section. B. Weirs shall be constructed of fiberglass reinforced plastic (FRP) as specified in Section 06 80 17, Weirs. 2.10 ELECTRICAL COMPONENTS AND ACCESSORIES A. General: 1. Conform to Division 26, ELECTRICAL. 2. Provide all necessary electrical components and wiring for a complete, functional system. 3. Where indicated, motor starters for constant-speed, 460-volt motors shall be provided in a separate motor control center specified in Division 26, ELECTRICAL. Provide all necessary control functions to properly interface with this motor starter. B. Wiring: The Drawings and Specifications indicate the anticipated wiring for the equipment provided under this section. If additional wiring is required, or if required wiring does not match what is indicated, the Contractor shall make the necessary modifications to the electrical wiring and documentation as part of the lump sum price. Wiring shall meet the requirements of Division 26, ELECTRICAL, and NFPA 70. Insulation shall be rated 600 volts, minimum. Low-voltage (24V) signals shall be run in twisted, shielded pair cable. C. Electrical Raceways: Electrical wiring shall be installed in conduit meeting the requirements of Division 26, ELECTRICAL. Raceways shall be installed in accordance with Division 26, ELECTRICAL, and NFPA 70. 2.11 INSTRUMENTATION AND CONTROLS A. All instrumentation and control components shall be provided in accordance with the requirements of Division 26. B. General: The Drawings and these Specifications depict the minimum functional requirements of the control system to be provided. Provide all items not specifically called out which are required to implement the functions described herein. The supplier shall provide all instrumentation and controls necessary to provide a safe and operable system. The specific control system proposed shall be subject to the approval of the Engineer. C. Instrumentation: Provide and install an electromechanical torque sensing-device that is actuated by thrust from the worm gear. The device shall provide indication of torque sensed and shall provide two independently adjustable SPDT torque alarm contacts (HIGH and HIGH-HIGH). The device shall be mounted in a NEMA 4X enclosure with an integral conduit box and terminals. Contacts shall be rated for a minimum of 5A at 120V ac. D. Control Panel, General: 1. Enclosure: Corrosion resistant, NEMA 4X stainless steel, suitable for installation outdoors. 2. Power- 480 volts, 3-phase, 60-Hz. 3. Main Disconnect: Circuit breaker interlocked with door handle. 4. In general, the control panel shall include the following components: a. Panel space heater with thermostat. b. Motor starters for each motor associated with the panel. c. Surge Arrestor d. Phase monitor e. Control power transformer Project No. 18088080 11 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms f. Control relays g. Solid State Overload Relay h. Terminal points for interconnection with ancillary equipment. 5. The control panel shall meet U.L. requirements and shall be U.L. 508A listed as a complete assembly. The control panel shall be completely pre-wired and factory tested prior to shipment. E. Control Panel Operator Interfaces: The control panel shall at a minimum be provided with the following functions on the face of the panel. 1. Hand switches and other controls: a. Gravity Thickener HAND/OFF/REMOTE switch b. Reset c. HIGH TORQUE alarm horn silence 2. Alarms: a. Gravity Thickener Fault Light b. 90% HIGH TORQUE Light c. 120% Cutoff Torque Light 3. Status: a. Gravity Thickener Running Light b. Elapsed Time Meter F. External Interfaces: Provide the following interfaces between the control panel and items outside the system package. 1. Dry Contact Inputs: a. Gravity Thickener Enable 2. Dry Contact Outputs: a. Run status b. Hand/Off/Auto switch in REMOTE status c. Motor high temperature d. Phase loss e. Motor overload f. 90% TORQUE alarm g. 120% TORQUE alarm 2.12 DISSIMILAR METALS A. Isolate dissimilar metals or connectors to prevent direct contact and electrical conductivity. 1. Use 1/8-inch thick continuous neoprene gasket to insulate aluminum gratings, checker plate and handrail post bases from access walkway support bridge and other components. 2. Use insulating washers and Teflon sleeves at bolted connections. 2.13 ACCESSORIES A. Lifting Lugs: Provide on equipment assemblies and components weighing over 100 pounds. B. Anchor Bolts: Provide coated Type 316, stainless steel bolts, sized by equipment manufacturer and at least 1/2 inch in diameter. C. Equipment Identification Plates: Provide 16-gauge, Type 316 stainless steel, identification plate securely mounted on each separate equipment component and panel in a readily visible location. Plate shall bear 1/4-inch high engraved block type black enamel filled equipment identification number and letters. Project No. 18088080 12 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms 2.14 TOOLS AND SPARE PARTS A. Tools: The work includes furnishing two complete set of special tools recommended by the manufacturer for maintenance and repair of each separate type of equipment; tools shall be stored in tool boxes, and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box. B. Spare Parts: 1. All equipment shall be furnished with the specified manufacturers spare parts, as indicated in the individual equipment sections. 2. Spare parts shall be tagged by project equipment number and identified as to part number, equipment manufacturer, and subassembly component (if appropriate). Spare parts subject to deterioration such as ferrous metal items and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts with individual weights less than 50 pounds and dimensions less than 2 feet wide, or 18 inches high, or 3 feet in length shall be stored in a wooden box with hinged wooden cover and locking clasp. Hinges shall be strap type. The box shall be painted and identified with stenciled lettering stating the name of the equipment, equipment numbers, and the words "spare parts." A neatly typed inventory of spare parts shall be taped to the underside of the cover. 3. At a minimum furnish, tag, and box for shipment and storage the following spare parts and special tools: Item Quantity Gaskets, O-rings, keys, dowels, and Pins One complete set per unit Gear reducer bearings and seals One complete set per unit Shear pins of each different size Six per unit Drive chain and/or belts One set each type and size per unit Special tools required to maintain or dismantle drive unit except for low speed main bearing, but including that required for removal/insertion of main bearing race balls One complete set Lubricants As required for 1 year of continuous operation. 2.15 FABRICATION A. General: Fabricate bridge beam or stringer sections in continuous unbroken pieces. B. Shop Assembly: 1. Shop fabricate and assemble mechanism components in the largest sections practicable and permitted by transportation carrier regulations. 2. Properly match-mark units for ease of field erection. 3. Completely assemble center drive unit in manufacturer’s shop and test to assure proper operation, and calibration of torque controls. 4. Completely shop assemble and test control panels. 5. Divide large assemblies into flanged sections. Bolt together with Type 316 stainless steel fasteners and provide continuous field seal welds at all connections. Project No. 18088080 13 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms C. Shop/Factory Finishing: 1. Exposed metal surfaces of motors, gear reducers, and assemblies shall be factory prepared and primed and field finish coated in accordance with Section 09 90 00 Painting and Protective Coatings, System No. 3. 2. Surfaces inaccessible subsequent to erection, all submerged surfaces and all surfaces that are located below the installed foul air cover system shall be prepared, primed, and finished in accordance with Section 09 90 00 Painting and Protective Coatings, System No. 2. 3. Seal welding shall be provided for submerged welded joints. Skip welds are not acceptable. PART 3 - EXECUTION 3.1 ASSEMBLY AND PREPARATION FOR SHIPMENT A. Each drive unit, including motor, shall be completely factory assembled, aligned, and securely crated for shipment. Accessory equipment which cannot be shipped assembled to the unit, such as shafts, baseplates, impellers, spare parts, and anchorage materials, shall be separately crated, clearly marked as to the contents, and shipped on the same shipment as the drives. B. For shipment, exposed surfaces subject to rust, such as mounting flange faces, etc., shall be covered with a rust-preventive compound such as Kendall No. 5, or equal. 3.2 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Comply with Section 01 60 00, PRODUCT REQUIREMENTS. B. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. C. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. D. Protection of Equipment: Equipment shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage. Equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Mechanisms, motors, drives, electrical equipment, and other equipment with anti-friction or sleeve bearings shall be stored in weather-tight and heated storage facilities prior to installation. For extended storage periods, plastic equipment wrappers shall not be used to prevent accumulation of condensate in gears and bearings. 3.3 INSTALLATION A. The Contractor shall install the gravity thickener as shown on the drawings. B. Installation shall be by the Contractor with coordination from Manufacturer. C. Anchor Bolts: Provide templates and specify bolts for furnishing by Contractor. D. Manufacturer shall coordinate with Contractor during all phases of installation to ensure that manufacturer’s representative is present during critical installation operations. Project No. 18088080 14 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms 3.4 FIELD QUALITY CONTROL A. Prior to placement of gravity thickeners into service, check weir plate settings by filling gravity thickeners with water to design elevation shown on the Drawings. Readjust as recommended by Engineer. B. Weirs: Level to within plus or minus 1/16 inch of design elevation. C. Functional Tests: Conduct on each mechanism. Test for continuous 3-hour period without malfunction, as witnessed by and approved by Owner or Engineer. D. Performance Test: 1. Conduct on each completed assembly in accordance with accepted test procedures. 2. Perform under actual or approved simulated operating conditions. 3. Perform to confirm mechanical and structural compliance with specified torque requirements. 4. Load each mechanism to 120 percent of Design Running Torque to demonstrate mechanism’s structural capability to withstand resulting loads. a. Apply loads to mechanism’s rake arms through cables or other means anchored to basin floor or wall. Utilize hydraulic cylinder, springs, or other means that allows machine to rotate for peripheral distance of at least 3 feet under load. b. Accomplish testing with machine in operation. c. Conduct static torque test on mechanism. Anchor both collector arms, start collector drive, and load drive to 120 percent of Design Running Torque to demonstrate mechanism’s structural capability to withstand resulting loads. 5. Demonstrate mechanism overload devices; verify actual torques at which Alarm and Cutout (shutdown) contacts are actuated. a. Correlate with scale indications. b. Prepare test report containing results. 6. Replace shear pins after torque testing is completed. Spare parts shall not be used. 3.5 MANUFACTURER’S SERVICES A. A manufacturer’s representative for the equipment specified herein shall be present at the job site for the minimum person-days listed for the services herein under for each unit provided, travel time excluded: 1. Installation, Startup, and Testing Services: a. 1 person-day for installation assistance, inspection, and Certificate of Proper Installation prior to grouting. b. 1 person-day for functional and performance testing. c. Provide Qualifications of Manufacturer's Representative. 2. Training Services: a. 1 person-day of prestart classroom or jobsite training of Owner’s personnel. b. Training of Owner’s personnel shall be at such times and at such locations as required and approved by the Owner. B. See Section 01 79 00, DEMONSTRATION AND TRAINING. 3.6 MANUFACTURER’S CERTIFICATES A. Provide Manufacturer’s certificate(s) in accordance with Section 01 79 00, DEMONSTRATION AND TRAINING. Project No. 18088080 15 Section 44 46 26.13 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms 3.7 SUPPLEMENTS A. Supplements listed below are part of this Specification. 1. 44 46 26.13.1 DS – Gravity Thickener Mechanisms Supplement END OF SECTION Project No. 18088080 1 Section 44 46 23.13.1 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms Data Sheet Section 44 46 26.13.1: GRAVITY THICKENER MECHANISMS PROJECT: Lake Lewisville WTP Dewatering Improvements OWNER: City of Denton EQUIPMENT NAME(S): GRAVITY THICKENER EQUIPMENT TAG NUMBER(S): 70TM01 LOCAL CONTROL PANEL(S) 70TCP01 MANUFACTURERS Westech Engineering, Inc. Ovivo Evoqua SERVICE CONDITIONS PERFORMANCE REQUIREMENTS Liquid Handled: Filter Backwash and Clarifier Blowdown The thickener shall perform as specified at the following flow rates: Influent Flow: 3100 -3700 (Intermittent) gpm Suspended Solids: 0.3%to 4% Solids Loading Rate: 9,713 (peak) lbs/d Liquid Temperature: 60 degrees F Under Flow Rate: 600-1200 gpm Elevation: 640.0 Feet Elevation Under Flow Solids: 1% to 4% EQUIPMENT DESCRIPTION Thickener Diameter: 50’-0” Furnish complete with components as necessary to meet the performance requirements specified herein and as shown on the Drawings: SWD: 14’-0” Design Running Torque (Westech): 27, 500 ft-lb Floor Slope: 2:12 (Evoqua): 25, 000 ft-lb Center Pier. Dia.: By Manufacturer (Ovivo): 30, 500 ft-lb Type: Bridge Support Type, Wall Supported, Center Drive Stilling Well Diameter: 4’-0” Minimum______ Scraper Blades: Straight, Pickets Stilling Well Height: 3’-0” Minimum______ MOTOR DATA Type: Squirrel-cage induction meeting requirements of NEMA MG1. Manufacturer: For multiple units of the same type of equipment, furnish motors and accessories of a single manufacturer. Hazardous Location: Furnish motors for hazardous (classified) locations that conform to UL 674 and have an applied UL listing marking. Motor Horsepower , max: 2.5 Enclosure Type: TEFC Voltage: 230/460 Material: Cast Iron A48 Class 35B or Steel ASTM A36 Phase: 3 Mounting Type: Horizontal Vertical Frequency: 60 Load Class: Constant Torque Synchronous Speed, max: 0.08 Rpm Multispeed, Two Speed: rpm Service Factor: 1.0 1.15 Adjustable Speed Drive: See Division 26, ELECTRIC, Provide Inverter Duty Rated Motors. Windings: One Two Thermal protection embedded in windings Motor nameplate horsepower shall not be exceeded at any operational point. Additional Motor Requirements: See Section 26 05 15, ELECTRIC MOTORS Provide: Space Heater Oversize main terminal (conduit) box for motors Moisture detection switches CONTROL PANEL Provided by manufacturer. SPECIAL FEATURES / NOTES x All dimensions shall be field verified. See drawings. x Peak loading of solids to thickener will persist from 5:00 pm on Friday until 9:00 am on Monday while dewatering operations are down for the weekend. Solids will accumulate in the thickener during that time. x All submerged and partially submerged metal to be 316 Stainless Steel. Project No. 18088080 2 Section 44 46 23.13.1 Lake Lewisville WTP Dewatering Improvements Gravity Thickener Mechanisms Data Sheet DIVISION 46 WATER AND WASTEWATER EQUIPMENT Project No. 18088080 1 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station SECTION 46 07 53 – PACKAGED PLANT WATER BOOSTER PUMP SYSTEM PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work necessary to completely furnish and install the Packaged Plant Water Booster Pump System including the plant water booster pump skid, hydro-pneumatic bladder tank, instrumentation and controls, and all related equipment, material, and appurtenances. B. Related sections: 1. Section 01 33 00 – Submittal Procedures 2. Section 01 60 00 – Product Requirements 3. Section 01 78 23 – Operation and Maintenance Data 4. Section 01 79 00 – Demonstration and Training 5. Section 05 50 00 – Metal Fabrications 6. Section 09 90 00 – Painting and Protective Coatings 7. Division 26 – Electrical Sections 1.2 GENERAL A. Equipment Numbers: 1. Plant Water Booster Pumps: 80P01,80P02 and 80P03 2. Hydro-Pneumatic Bladder Tank: 80TNK01 B. Like items of equipment provided hereinafter shall be the end products of one manufacturer to achieve standardization of appearance, operation, maintenance, spare parts, and manufacturer’s services. C. Unit Responsibility: The Work requires that the plant water booster pump skid with required piping and valves, the plant water booster pumps, the hydro-pneumatic bladder tank, local control panel for booster pump station, variable frequency drives, instruments, and components complete with all accessories and appurtenances be the end product of one responsible system manufacturer or responsible system supplier. D. Unless otherwise indicated, the Contractor shall obtain each system from the responsible supplier of the equipment. The supplier shall furnish all components and accessories of the system to enhance compatibility, ease of operation and maintenance, and as necessary to place the equipment in operation in conformance with the specified performance, features, and functions without altering or modifying the Contractor's responsibilities under the Contract Documents. E. The Contractor is responsible to the Owner for providing the equipment systems as specified herein. F. General Requirements: See Division 01, GENERAL REQUIREMENTS, which contains information and requirements that apply to the work specified herein and are mandatory for this project. G. The equipment specified herein is included in the MANUFACTURER/ SUBCONTRACTOR Form. Refer to the Bid Form and the Instructions to Bidders for additional requirements. 1.3 SUBMITTALS A. General: Administrative, shop drawings, samples, quality control, and contract closeout submittals shall conform to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES. Project No. 18088080 2 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station B. In addition to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES, submit the following additional specific information: 1. Shop Drawings: a. Make, model, weight, and horsepower of each component including the plant water booster pump skid, plant water booster pumps, hydro-pneumatic tank, booster pump variable frequency drives, and plant water booster pump control panel. b. Manufacturer's catalog information, descriptive literature, specifications, and identification of materials of construction. c. Detailed mechanical, and electrical drawings showing the equipment fabrications and interface with other items. Include dimensions, size, and details of anchorage and connections to other work, and weights of associated equipment. d. External utility requirements (quantity and connection details) such as air, water, power, drain, etc., for each component. e. Motor nameplate data, motor manufacturer, and any motor modifications. f. Electrical submittals should also include panel layouts, point-to-point I/O wiring diagrams for motors, including terminals and numbers, control panel network diagrams, instrumentation sheets, and product data sheets for all electrical equipment. g. Suggested spare parts list to maintain the equipment in service for a period of 1 year and 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. h. List of special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance. i. Instrumentation and Control Submittals: In conformance with Division 26. 2. Quality Control Submittals: a. Manufacturer's Certificate of Compliance: Commercial products, including painting/coating systems. b. Special shipping, storage and protection, and handling instructions. c. Test procedures. d. Test results, reports, and certifications. e. Manufacturer's Certificate of Proper Installation. f. Operation and maintenance manual. 3. Contract Closeout Submittals: Service records for maintenance performed during construction. 1.4 QUALITY CONTROL A. Balancing: Rotating elements of equipment, except small, commercially packaged equipment, shall be statically and dynamically balanced at the factory prior to final assembly. The Contractor shall furnish certified copies of all test results. 1.5 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, format, and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. 1.6 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer will promptly repair or replace the defective equipment without additional cost to the Owner. Project No. 18088080 3 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station B. Spare parts identified within this specification shall not be used to address warranty repairs. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Where a manufacturer's standard equipment name and/or model number is listed, the equipment system shall be provided and modified as required to conform to the performance, functions, features, and materials of construction as specified herein. B. Materials, equipment, components, and accessories specified in this section shall be, products of: 1. Plant Water Booster Pump Skid, Plant Water Booster Pumps, Local Control Panel and Variable Frequency Drives: a. Goulds Aqua Force b. Pentair Aurora Intelliboost c. Bell and Gossett d. Motor Controls Inc. 2. Hydro-Pneumatic Bladder Tank a. Roy E. Hanson Jr. MFG (Hanson Tank) b. Wessels c. AA Tanks d. Or Approved Equal 2.2 GENERAL REQUIREMENTS A. Noise Level: When in operation, no piece of equipment shall exceed the OSHA noise level requirements for a 1-hour exposure, 105 dBA. B. Service Factors: Service factors shall be applied in the selection and design of components where so indicated in individual sections. When not indicated there, minimum service factors shall be 1.25, except for gears and gear drives as specified herein. C. Safety Devices: The completed work shall include all necessary permanent safety devices, such as machinery guards, emergency stops and similar items required by OSHA, and other federal, state, and local health and safety regulations. D. Flanges and Pipe Threads: Comply with ANSI B 16.1, Class 125; or B 16.5, Class 150, unless otherwise indicated. Threaded flanges and fittings shall have standard taper pipe threads complying with ANSI/ASME B 1.20.1. E. Bearings: 1. Conform to the standards of the Anti-Friction Bearing Manufacturers Association, Inc. (AFBMA). 2. Except where otherwise indicated, bearings of process equipment shall have a minimum L-10 life expectancy of 100,000 hours. F. Gears and Gear Drives: 1. Except as otherwise indicated, gears shall be of the helical or spiral-bevel type, designed and manufactured in accordance with AGMA Standards, with a minimum service factor of 1.7, a minimum L-10 bearing life of 60,000 hours, and a minimum efficiency of 94 percent. 2. Gear speed reducers or increasers shall be of the enclosed type, oil- or grease-lubricated and fully sealed, with a breather to allow air to escape but keep dust and dirt out. The casing shall be of cast iron or heavy-duty steel construction with lifting lugs and an Project No. 18088080 4 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station inspection cover for each gear train. An oil level sight glass and an oil flow indicator shall be provided and installed for easy reading. 3. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation. 4. Material selections shall comply with AGMA values and the manufacturer's recommendations. Input and output shafts shall be properly designed for the service and load requirements. Gears shall be computer-matched for minimum tolerance variation. The output shall have two positive seals to prevent oil leakage. 5. Oil level and drain location shall be readily accessible. Oil coolers or heat exchangers with all required appurtenances shall be included where indicated. 6. Where gear drive input to output shafts connect to couplings or sprockets, the gear drive manufacturer shall supply matching key. G. Anchor bolts shall be specified in Section 05 50 00, METAL FABRICATIONS. Number and size as recommended by the manufacturer. All anchor bolt assemblies shall be constructed of stainless steel, as specified. H. Stainless Steel: Stainless steel components shall be 304 stainless steel, or higher, as specified. I. Nameplates: Equipment nameplates of stainless steel shall be engraved or stamped and fastened to the equipment in accessible locations with stainless steel screws or drive pins. Nameplates shall contain the manufacturer's name, model, serial number, size, characteristics, and appropriate data describing the machine performance ratings. 2.3 SUPPLEMENTS A. See supplements (if any) to this section for additional equipment system product, component or accessory information. 2.4 SERVICE CONDITIONS A. The plant water booster pump system, complete with local control panels and variable frequency valves shall be installed within the existing belt filter press building. The plant water booster pump skid, plant water booster pumps, hydro-pneumatic tank, booster pump variable frequency drives, plant water booster pump control panel, and other auxiliary equipment shall be installed as shown on the Drawings. Sufficient space for maintenance, repair, and installation of the unit shall be confirmed by the contractor and vendor prior to procurement of the unit. B. The plant water booster pump system shall operate indoors in a ventilated building with a maximum ambient temperature of 105 degrees Fahrenheit. C. Plant water supply feed will be supplied to the system via the 8” plant water line to the west of the Dewatering Facility with a supply pressure ranging from 70 to 100 psi. D. The plant water booster pump system shall boost a flow rate from 100 gpm to a minimum upper flow rate of 300 gallons per minute at a discharge pressure of 120 psig to the belt filter press spray-down system. The 120 psig reading is set at the pipe exiting the skid, any further headloss due to piping is assumed to be minimal; thus this condition is deemed acceptable. E. Contractor shall ensure proper interface coordination between the elements of the plant water booster pump system: 1. The local control panel for the plant water booster skid shall be integrated with the discharge flow meter, which is downstream of the hydro-pneumatic tank. Project No. 18088080 5 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station 2.5 SYSTEM PERFORMANCE AND FUNCTIONAL REQUIREMENTS A. The plant water booster pump system shall be capable of the following: 1. Boosting at a minimum of 300 gallons per minute to a discharge pressure of 120 psig, which shall be measured on the skid discharge pipe. 2. The minimum plant water demand will be 100 gallons per minute. The system manufacturer shall appropriately size the hydro-pneumatic bladder tank so to provide this minimum flow while maintaining a maximum number of start and stop cycles for each booster pump to be two (4) cycles per hour. 2.6 EQUIPMENT AND MATERIALS A. General Description: 1. The Plant Water Booster Pump System shall be comprised of the following components: the plant water booster pumps, plant water booster pump skid with required piping and valves, the hydro-pneumatic bladder tank, local control panel for the booster pump station, variable frequency drives, instruments, and components complete with all accessories and appurtenances. B. Plant Water Booster Pumps: 1. Pump: a. The pump station shall be a triplex pump station with additional pumps activating when the maximum flow of a single pump is exceeded. b. Each pump shall be a vertical, multistage centrifugal pump. c. Pumps shall be of stainless steel construction. d. Three pumps operating at maximum speed shall boost 300 gallons per minute at a discharge pressure of 120 psig. The pumps shall be operating at a minimum efficiency of 70% at these maximum speed conditions. e. A single pump operating at maximum speed shall boost 100 gallons per minute at a discharge pressure of 120 psig. 2. Motor: a. Each pump’s motor is identified as a 15 horsepower motor. Any larger motor requirements by the manufacturer to achieve the specified pumping requirements may require electrical system upgrades which will be the financial responsibility of the Contractor and the manufacturer. b. Conform to Division 26, ELECTRICAL. c. The electric motor will be 60 Hz, 3 PH, 3600 RPM totally enclosed, TEFC, 15HP, "C" flange, high efficiency, service factor 1.15, insulation "F" class, design "B". Motor voltage shall be 460 volts. The electric motor is directly coupled to the speed reducer. 3. Control: a. A Control Panel, integral to the frame of the system shall be provided. The enclosure shall be rated NEMA 4X and constructed of 304 Stainless Steel. The control panel and all components shall be industrial duty. All skid mounted electrical components interconnected to the control panel shall terminate at numbered and labeled terminal blocks. The terminal blocks shall be sized for 14 gauge wire. Wires shall be neatly run through wire race-way and numbered with adhesive type labels. The control panel shall be positioned such that there are no obstructions in front of the control panel per related NFPA requirements. b. The control panel shall have a 5.7-inch touch screen controller interface. c. The control system shall be programmed for lead/lag alteration with automatic standby replacement upon an operating pump failure. d. In AUTO Mode, the control system shall adjust pump speed and number of operating pumps to maintain an operating pressure point. e. The plant water booster control panel shall monitor and control the following signals and equipment: Project No. 18088080 6 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station i) Station pumped output ii) Operator Interfaces with the following features as a minimum: a) MANUAL / AUTO operational mode select. b) MANUAL mode: 1) MANUAL mode run screen features: 2) Pump speed control in MANUAL mode. c) AUTO mode: 1) Discharge pressure set point for control as part of Auto Mode. d) High Pressure Set Point, that shall discontinue pump station operation e) Low Suction Pressure Set Point that shall discontinue pump station operation. iii) Pump station output flow rate (GPM) iv) Variable Speed Drives operating speeds v) Discharge pressure vi) Suction pressure vii) Alarm screen features viii) Indication of alarm ix) Reset x) Set-up screen features xi) Semi-auto pump calibration xii) Discrete selector switch and system indicator C. Plant Water Booster Pump Station Manifold: 1. Pump Station Skid: a. The pump station ski shall be fabricated from Type 304 Stainless Steel. All connectors shall be fabricated from Type 304 Stainless Steel. Any non-stainless elements shall be coated as required in Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. b. The frame and base for the pump station skid shall support the following elements: i) Plant water booster pumps (3 each). ii) Suction and discharge piping including both headers, associated valves, and fittings. iii) Support panel for the pumps’ variable frequency drives, which shall also be constructed of Type 304 Stainless Steel. iv) Plant Water Booster Pump Station Control Panel. c. Threaded connections for service and instrumentation will be located on the inlet and discharge header manifolds. 2. Piping Manifold: a. Piping i) The suction header and discharge header piping plant water booster pump skid will be made of Schedule 10, Type 304 stainless steel. ii) The suction and discharge manifolds and other accessories will be tested in the shop at a minimum of 200 PSI hydrostatic pressure. b. Pipe fittings should be flanged or grooved end type. i) On the lines less than 10 feet long: Style 77 Victaulic joints or equivalent. ii) On the lines more than 10 feet long: Style 07 "Zero Flex" Victaulic joints or equivalent. iii) Flange-to-flange joints: Style 741 "Vic-flange" or equivalent. iv) For butt or field adjust joint coupling, the Victaulic style 99 "Roust-A-Bout" or equivalent. c. Valves and Accessories i) Pump isolation valves (suction and discharge) shall be ball type valves with manual valve operators. ii) Check valves shall be non-slam silent type and constructed of 316 stainless steel. 3. Control Project No. 18088080 7 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station a. A control panel integral to the frame of the system shall be provided. The enclosure shall be rated NEMA 4X and constructed of 304 SSTL. Manufacturer’s standard panel may be required to be placed in a separate NEMA 4X panel. The control panel and all components shall be industrial duty. Power supply to the control panel shall be 115 V/ 60HZ. b. All skid mounted electrical components interconnected to the control panel shall terminate at numbered and labeled terminal blocks. i) The terminal blocks shall be sized for 14 gauge wire. Wires shall be neatly run through wire race-way and numbered with adhesive type labels. ii) The control panel shall be positioned such that there are no obstructions in front of the control panel per related NFPA requirements. c. Operator Interfaces with the following features as a minimum: i) MANUAL / AUTO operational mode select ii) Manual advance iii) Manual Reset d. MANUAL mode: i) Backwash by Timer Selector Switch ( ¼ hour, ½ hour, 1 hour through 2 hours) ii) Flush Period Selector (2 seconds through 30 seconds) iii) DWELL Period Selector (0 seconds through 90 seconds) should a second filter be connected iv) MANUAL Power On and Off Selector Switch e. AUTO mode: i) Initiate backwash based upon differential pressure reading ii) Alarm based upon three (3) consecutive backwashes without resolving high differential pressure reading f. Power: i) 120 VAC, 1Ph, 60/50 Hz, 15A D. Hydro-pneumatic Bladder Tank: 1. The hydro-pneumatic tank shall meet these requirements: a. ASME Construction b. Material: Carbon Steel c. System Connection: Stainless Steel d. Bladder: Heavy-Duty Butyl Rubber (NSF / FDA approved materials) e. Factory Pre-charge: 30 PSI (field adjustable) f. Standard Design Pressure: 125 PSI (200 PSI & 250 PSI models available) g. Standard Design Temperatures: -20F to 240F h. Standard exterior Finish: Red Oxide Prime Painted i. Interior Epoxy Finish j. Seismic and Wind Load Calculations as specified herein. 2. Furnish and install, as shown on plans, a minimum 75 gallons of usable volume from a vessel with minimum dimensions of 24 inches in diameter by 55 inches (high) pre-charged steel hydro-pneumatic tank with replaceable heavy-duty butyl bladder. 3. The tank shall have NPT epoxy lined system connections and a 0.302”-32 charging valve connection (standard tire valve) to facilitate the on-site charging of the tank to meet system requirements. 4. The tank must be constructed in accordance with the most recent addendum of Section VIII Division 1 of the ASME Boiler and Pressure Vessel Code. 5. Tank shall receive field coating as required in Section 09 90 00, PAINTING AND PROTECTIVE COATINGS. 2.7 ELECTRICAL COMPONENTS AND ACCESSORIES A. General: 1. Conform to Division 26, ELECTRICAL. 2. Provide all necessary electrical components and wiring for a complete, functional system. Project No. 18088080 8 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station 3. Where indicated, motor starters shall be provided in a separate motor control center specified in Division 26, ELECTRICAL. Provide all necessary control functions to properly interface with this motor starter. B. Wiring: The Drawings and Specifications indicate the anticipated wiring for the equipment provided under this section. If additional wiring is required, or if required wiring does not match what is indicated, the Contractor shall make the necessary modifications to the electrical wiring and documentation as part of the lump sum price. Wiring shall meet the requirements of Division 26, ELECTRICAL, and NFPA 70. Insulation shall be rated 600 volts, minimum. Low-voltage (24V) signals shall be run in twisted, shielded pair cable. C. Electrical Raceways: Electrical wiring shall be installed in conduit meeting the requirements of Division 26, ELECTRICAL. Raceways shall be installed in accordance with Division 26, ELECTRICAL, and NFPA 70. D. Provide breather drain units in the bottom of all electrical enclosures to allow moisture to exit the enclosure. E. Motors: 1. Provide squirrel-cage ac induction motors meeting the requirements of Division 26, ELECTRICAL, and as specified herein. 2. For additional specific requirements on motors, refer to the Motor Data Sheets at the end of the Section. F. Variable Frequency Drives (VFDs) 1. Provide individual VFDs for the three plant water booster pumps. 2.8 INSTRUMENTATION AND CONTROLS A. All instrumentation and control components shall be provided in accordance with the requirements of Division 26. B. The Packaged Plant Water Booster Pump System will consist of plant water booster pump skid with required piping and valves, the three (3) plant water booster pumps, the hydro-pneumatic bladder tank, local control panel for booster pump station, variable frequency drives, local control panel along with control devices necessary to control and vary pumping to provide pressurized plant water to match the the belt filter presses’ varying demand. C. Control Panel, General: 1. One (1) NEMA 4X control panel shall be furnished for the entire system. The control panel shall contain door mounted lights, switches, and operator interface terminal along with PLC. PLC shall be Modicon M340 series. a. PLC shall have inputs and outputs sufficient to interface with all panel and field mounted devices. b. PLC shall control packaged plant water booster pump system and its elements. 2. Power: 480 volts, three-phase, 60-Hz. 3. Main Disconnect: Circuit breaker interlocked with the door handle. 4. Panel climate control - space heater with thermostat and panel air conditioner D. Control Panel Operator Interfaces: At a minimum, provide the following functions on the face of the panel: 1. Operator Process Control Parameters a. Provide the following process control parameters with operator access i) All pressure setpoints (both pump station discharge and suction) ii) Manual control of each piece of equipment Project No. 18088080 9 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station 2. Alarms: The following alarms shall be provided by the panel: a. Plant water High Pressure b. Plant Water Low Pressure c. Water Supply Low Pressure d. Any motor did not start, stop the plant water booster pump system E. Instrumentation: Provide all items specifically listed herein: 1. Flowmeters: a. Plant water flowmeter: The plant water flowmeter will be installed at the pump station discharge. The instrument will have the following specifications: Type Electromagnetic Linearity error ±0,5% Diameter/measuring range 2" -10-300 gpm Process temperature -4 °F to 176 °F (-20 °C to 80 °C) Electrical connection 1/2"NPT Process connection Flange type Display/operation Two-line display with backlit / push button Output signal 4-20mA CSA/FM approval class Class 1 division 2 Liner material Polyurethane Electrode material 316L SS Protection IP67/Nema 4X, IP68/Nema 6P Company Endress & Hauser Series 10W 2. Discharge Water Pressure Gauge and Transmitter: The inlet pressure gauge and transmitter will be installed at the flocculator inlet. The instrument will have the following specifications: Type Digital pressure transducer, capacitive, ceramic Linearity error ± 0.075 % Process temperature - 4 to 257 °F (- 20 to 125 °C) Operating pressure range 0-200 PSI (0-207 kPa) Proof pressure (Without any damage to the trans- ducer) 270 PSI (1860 kPa) Electrical connection 1/2" NPT Calibration Between 0 and 200 PSI (0-207 kPa) Output 4-20mA, with Hart Communication, 2 lines LCD Process connection 1/2" NPT Protection I, II, III Division 1 Diaphragm material Ceramic Company Endress & Hauser Series PMC71 Project No. 18088080 10 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station 3. Supply Water Pressure Gauge and Transmitter: The inlet pressure gauge and transmitter will be installed at the flocculator inlet. The instrument will have the following specifications: Type Digital pressure transducer, capacitive, ceramic Linearity error ± 0.075 % Process temperature - 4 to 257 °F (- 20 to 125 °C) Operating pressure range 0-30 PSI (0-207 kPa) Proof pressure (Without any damage to the trans- ducer) 270 PSI (1860 kPa) Electrical connection 1/2" NPT Calibration Between 0 and 30 PSI (0-207 kPa) Output 4-20mA, with Hart Communication, 2 lines LCD Process connection 1/2" NPT Protection I, II, III Division 1 Diaphragm material Ceramic Company Endress & Hauser Series PMC71 F. Other Instrumentation and Controls: Provide all items not specifically called out which are required to implement the functions described herein. G. Principle of Operation/Control 1. Provide controls necessary to perform the basic principles of operation as listed below: a. All pressure setpoints shall be operator adjustable. b. The plant water booster pumps shall operate in a lead-lag standby configuration. Upon failure of an operating pump, the standby pump shall replace the failed pump in the operating sequence. c. The operating number of pumps and rotating speed of plant water booster pumps shall be varied to match the set point discharge pressure. A high-pressure setting shall remove the lag pump from operation. A high-high-pressure reading shall stop both pumps from operating. d. A low-pressure reading shall initiate the lag pump to operate, while a low-low- pressure reading shall initiate the lead pump’s operation. e. A low suction pressure shall stop all pumps from operating. 2.9 TOOLS AND SPARE PARTS A. Tools: The work includes one complete set of special tools recommended by the manufacturer for maintenance and repair of each separate type of equipment; tools shall be stored in toolboxes, and identified with the equipment number through stainless steel or solid plastic name tags attached to the box. B. Spare Parts: 1. All equipment shall be furnished with the specified manufacturer's spare parts, as indicated in the individual equipment sections. Project No. 18088080 11 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station 2. Spare parts shall be tagged by project equipment number and identified as to part number, equipment manufacturer, and subassembly component (if appropriate). Spare parts subject to deterioration such as ferrous metal items and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts with individual weights less than 50 pounds and dimensions less than 2 feet wide, or 18 inches high, or 3 feet in length shall be stored in a wooden box with hinged wooden cover and locking clasp. Hinges shall be strap type. The box shall be painted and identified with stenciled lettering stating the name of the equipment, equipment numbers, and the words "spare parts." A neatly typed inventory of spare parts shall be taped to the underside of the cover. 3. Provide, at a minimum, the following spare parts for the equipment: a. Plant Water Booster Pumps: i) Complete set of seals and gaskets – Quantity 1 ii) Pump impeller – Quantity 1 b. Set of special tools as required to maintain and repair system 2.10 FABRICATION A. Shop Assembly: The system shall be factory assembled and tested. B. Shop/Factory Finishing: Shop prime coatings shall conform to the requirements of Section 09 90 00, PAINTING AND PROTECTIVE COATINGS, System No. 2. PART 3 - EXECUTION 3.1 GENERAL A. Coordination shall include space and structural requirements, clearances, utility connections, signals, outputs and features required by the manufacturer including safety interlocks. 3.2 ASSEMBLY AND PREPARATION FOR SHIPMENT A. Each drive unit, including motor, shall be completely factory assembled, aligned, and securely crated for shipment. Accessory equipment which cannot be shipped assembled to the unit, such as shafts, baseplates, impellers, spare parts, and anchorage materials, shall be separately crated, clearly marked as to the contents, and shipped on the same shipment as the drives. B. For shipment, exposed surfaces subject to rust, such as mounting flange faces, etc., shall be covered with a rust-preventive compound such as Kendall No. 5, or equal. 3.3 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Comply with Section 01 60 00, PRODUCT REQUIREMENTS. B. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. C. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. D. Protection of Equipment: Equipment shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage. Equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Pumps, motors, drives, electrical equipment, and other equipment with anti-friction or sleeve bearings shall be stored in weather tight and heated storage facilities prior to installation. For extended storage periods, Project No. 18088080 12 Section 46 07 53 Lake Lewisville WTP Dewatering Improvements Packaged Plant Water Booster Pump Station plastic equipment wrappers shall not be used to prevent accumulation of condensate in gears and bearings. 3.4 FIELD QUALITY CONTROL A. Functional Testing: Prior to plant startup, all equipment described herein shall be inspected for proper alignment, quite operation, proper connection, and satisfactory performance by means of a functional test. Provide certification of test results. Tests and certification shall be as specified in Section 01 79 00, DEMONSTRATION AND TRAINING. 3.5 INSTALLATION A. As shown in the Drawings. All anchors, bolts, and accessories shall be 316 stainless steel. The manufacturer shall provide templates for anchor bolt locations. B. Lubricants: Include oil and grease for initial operation. 3.6 MANUFACTURER’S SERVICES A. A manufacturer’s representative for the equipment specified herein shall be present at the job site for the minimum person-days listed for the services here-in-under, travel time excluded: 1. Installation, Startup, and Testing Services: a. 1 person-day for installation assistance, inspection, and Certificate of Proper Installation. b. 1 person-day for functional and performance testing. c. Provide Qualifications of Manufacturer's Representative. 2. Training Services: a. 1 person-day of prestart classroom or job site training of Owner’s personnel. b. Training of Owner’s personnel shall be at such times and at such locations as required and approved by the Owner. B. See Section 01 79 00, DEMONSTRATION & TRAINING. 3.7 MANUFACTURER’S CERTIFICATES A. Provide Manufacturer’s certificate(s) in accordance with Section 01 79 00, DEMONSTRATION & TRAINING. END OF SECTION Project No. 18088080 1 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors SECTION 46 21 75 –SHAFTLESS SCREW CONVEYORS PART 1 - GENERAL 1.1 SUMMARY A. Section includes: Work necessary to completely furnish and install the shaftless screw conveyor, including the troughs and screw assemblies, all related equipment, material, and appurtenances. B. Related sections: 1. Section 01 33 00 – Submittal Procedures 2. Section 01 60 00 – Product Requirements 3. Section 01 78 23 – Operation and Maintenance Data 4. Section 01 79 00 – Demonstration and Training 5. Section 05 50 00 – Metal Fabrications 6. Section 09 90 00 – Painting and Protective Coatings 7. Section 26 05 15 – Electrical Motors 8. Section 40 23 43 – Process Valves 9. Division 26 – Electrical Sections 1.2 GENERAL A. Like items of equipment provided hereinafter shall be the end products of one manufacturer to achieve standardization of appearance, operation, maintenance, spare parts and manufacturer’s services. B. Unit Responsibility: The Work requires that the shaftless screw conveyors, local control panel, instruments, and components complete with all accessories and appurtenances be the end product of one responsible system manufacturer or responsible system supplier. Unless otherwise indicated, the Contractor shall obtain each system from the responsible supplier of the equipment. The supplier shall furnish all components and accessories of the system to enhance compatibility, ease of operation and maintenance, and as necessary to place the equipment in operation in conformance with the specified performance, features, and functions without altering or modifying the Contractor's responsibilities under the Contract Documents. The Contractor is responsible to the Owner for providing the equipment systems as specified herein. C. General Requirements: See Division 01, GENERAL REQUIREMENTS, which contains information and requirements that apply to the work specified herein and are mandatory for this project. 1.3 SUBMITTALS A. General: Administrative, shop drawings, samples, quality control, and contract closeout submittals shall conform to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES. B. In addition to the requirements of Section 01 33 00, SUBMITTAL PROCEDURES, submit the following additional specific information: 1. Shop Drawings: a. All drawings to be generated using a 3D Computer Aided Drafting program including but not limited to Autodesk Inventor, PTC ProEngineer, Dassault Systèmes SOLIDWORKS, or equal. b. Make, model, weight, and horsepower of each component. Project No. 18088080 2 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors c. Manufacturer's catalog information, descriptive literature, specifications, and identification of materials of construction. d. Detailed mechanical, and electrical drawings showing the equipment fabrications and interface with other items. Include dimensions, size, and details of anchorage and of connections to other work, and weights of associated equipment. e. All material and drawings to be provided in Imperial system. Any metric material sizes, drawing dimensions, or hardware are unacceptable. This ensures replacement parts are easily obtained in North America. f. Flight diameter, thickness, and pitch of each screw. g. Trough diameter for each screw. h. Rotating speed of each screw. i. Percentage of active trough area filled under design capacity for each screw. j. Spiral strength calculations for spring (spiral) compression and elongation showing the supplied spiral meets or exceeds spring effect intent herein k. Conveyor torque requirement calculations. l. Torque calculations for the gear reducer and reducer motor. m. External utility requirements (quantity and connection details) such as air, water, power, drain etc., for each component. n. Motor nameplate data, motor manufacturer, and any motor modifications. o. Wiring diagrams for motors, including terminals and numbers. p. Suggested spare parts list to maintain the equipment in service for a period of 1 year and 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information. q. List of special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance. r. Instrumentation and Control Submittals: In conformance with Division 26. 2. Quality Control Submittals: a. Manufacturer's Certificate of Compliance: Commercial products, including painting/coating systems. b. Special shipping, storage and protection, and handling instructions. c. Test and work procedures. Manufacturer shall carry a current, valid certificate of ISO-Certification or equal as approved by the ENGINEER. d. Test results, reports, and certifications. e. Manufacturer's Certificate of Proper Installation. f. Operation and maintenance manual. 3. Contract Closeout Submittals: Service records for maintenance performed during construction. 4. Support and Anchorage Calculations: Manufacturer must supply calculations for support and anchorage design accounting for wind, seismic, and worst-case product load considerations including 100% fill level. Calculations must be validated and P.E. stamped by a third party engineering firm licensed in the state of Texas. 1.4 QUALITY CONTROL A. Balancing: Rotating elements of equipment, except small, commercially packaged equipment, shall be statically and dynamically balanced at the factory prior to final assembly. The Contractor shall furnish certified copies of all test results. 1.5 OPERATION AND MAINTENANCE DATA A. O&M Manuals: Content, format and schedule for providing as specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. B. Maintenance Summary Forms: As specified in Section 01 78 23, OPERATION AND MAINTENANCE DATA. Project No. 18088080 3 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors 1.6 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer will promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. PART 2 - PRODUCTS 2.1 MANUFACTURERS A. Where a manufacturer's standard equipment name and/or model number is listed, the equipment system shall be provided and modified as required to conform to the performance, functions, features, and materials of construction as specified herein. B. Materials, equipment, components, and accessories specified in this section shall be, products of: 1. KWS 2. JMS 3. JDV Equipment Co. 4. SPIRAC (USA) Inc., Newnan, Georgia. 2.2 GENERAL REQUIREMENTS A. Noise Level: When in operation, no piece of equipment shall exceed the OSHA noise level requirements for a 1-hour exposure, 105 dBA. B. Service Factors: Service factors shall be applied in the selection and design of components where so indicated in individual sections. When not indicated there, minimum service factors shall be 1.25, except for gears and gear drives as specified herein. C. Safety Devices: The completed work shall include all necessary permanent safety devices, such as machinery guards, emergency stops, and similar items required by OSHA, and other federal, state, and local health and safety regulations. D. Flanges and Pipe Threads: Comply with ANSI B 16.1, Class 125; or B 16.5, Class 150, unless otherwise indicated. Threaded flanges and fittings shall have standard taper pipe threads complying with ANSI/ASME B 1.20.1. E. Bearings: 1. Conform to the standards of the Anti-Friction Bearing Manufacturers Association, Inc. (AFBMA). 2. Except where otherwise indicated, bearings of process equipment shall have a minimum L-10 life expectancy of 100,000 hours. F. Gears and Gear Drives: 1. Except as otherwise indicated, gears shall be of the helical or spiral-bevel type, designed and manufactured in accordance with AGMA Standards, with a minimum service factor of 1.4, a minimum L-10 bearing life of 60,000 hours, and a minimum efficiency of 94 percent. 2. Gear speed reducers or increasers shall be of the enclosed type, oil- or grease-lubricated and fully sealed, with a breather to allow air to escape but keep dust and dirt out. The Project No. 18088080 4 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors casing shall be of cast iron or heavy-duty steel construction with lifting lugs and an inspection cover for each gear train. An oil level sight glass and an oil flow indicator shall be provided and installed for easy reading. 3. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation. 4. Material selections shall comply with AGMA values and the manufacturer's recommendations. Input and output shafts shall be properly designed for the service and load requirements. Gears shall be computer-matched for minimum tolerance variation. The output shall have two positive seals to prevent oil leakage. 5. Oil level and drain location shall be readily accessible. Oil coolers or heat exchangers with all required appurtenances shall be included where indicated. 6. Where gear drive input to output shafts connect to couplings or sprockets, the gear drive manufacturer shall supply matching key. G. Anchor bolts shall be specified in Section 05 50 00, METAL FABRICATIONS. Number and size as recommended by manufacturer. H. Stainless Steel: Stainless steel components shall be 316 stainless steel, or higher, or as specified. I. Nameplates: Equipment nameplates of stainless steel shall be engraved or stamped and fastened to the equipment in accessible locations with stainless steel screws or drive pins. Nameplates shall contain the manufacturer's name, model, serial number, size, characteristics, and appropriate data describing the machine performance ratings. 2.3 SUPPLEMENTS A. See supplements to this section for additional product, component or accessory information. 2.4 SERVICE CONDITIONS A. The shaftless screw conveyors shall operate within the existing Dewatering Building and Dryer Building. 2.5 SYSTEM PERFORMANCE AND FUNCTIONAL REQUIREMENTS A. The shaftless screw conveyors shall: 1. Accept dewatered residuals from the Belt Filter Presses. 2. Convey residuals through an opening to the bins outside the building. 3. Convey residuals beyond the hopper of the dryer to the truck loading conveyor 4. The dewatered residuals conveyor shall be designed for both continuous and intermittent operation at a capacity not less than that specified. B. See supplement to this section for additional performance requirements. 2.6 EQUIPMENT AND/OR MATERIALS A. System Definition: The conveyor shall be motorized screw type, designed to receive and convey dewatered residuals. The residual conveyors shall be complete assemblies including, but not limited to, the following items: 1. Inlets and Discharges 2. Troughs 3. Wear Liners 4. Hinged and Removable Covers 5. Inspection Hatches Project No. 18088080 5 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors 6. Spiral Flighting 7. Chutes 8. End Shaft 9. Electric Motor and Gear Reducer 10. Mounting and Support Structure B. Inlets and Discharges 1. Each trough shall be equipped with filling and/or discharge openings as required by the contract drawings. If required, each filling and discharge opening shall be flanged suitable for Interconnection to other devices. Any interconnecting devices such as chutes and hoppers shall be fabricated from the same material as the troughs. 2. Inlet and Discharge Chutes. Inlet and discharge chutes shall be provided by the conveyor supplier as shown on the drawings. All chutes shall be fabricated from the same material as the conveyor trough. 3. Inlets into the conveyors shall be constructed so that material will enter the conveyor without any spillage or obstruction from other equipment. Inlets shall be located as shown to accommodate the materials being conveyed without modification to the existing centrifuge. a. An inlet hopper shall be provided to help direct material from the discharge chute of the equipment into the conveyor. The inlet hopper requirements shall be coordinated with the equipment discharge design. b. The inlet hopper shall be fabricated of not less than 3/16-inch-thick material. Side walls shall be inclined at a minimum angle of 60 degrees from the horizontal axis to prevent residuals accumulation in the hopper and on the three facing sides. The hopper shall either extend approximately 6 inches above the discharge chute of the equipment or be directly connected to the equipment to ensure complete collection of materials. 4. The conveyor shall have discharges at locations indicated on Drawings. C. Trough 1. Troughs shall be U-shaped and to the dimensional standards of CEMA 300 unless noted otherwise and enclosure classification IIE. Each conveyor trough shall be U-shaped, fabricated from a minimum 3/16-inch stainless steel plate. 2. Each trough shall be equipped with inlet and discharge openings as shown on the contract drawings. Each inlet and discharge opening shall be flanged suitable for interconnection to other devices. Flanges shall be 316 stainless steel. Chutes and hoppers shall be fabricated from the same grade of material as the troughs and with a gauge thickness to suit the application requirements. 3. In order to avoid excessive wear and increased maintenance, the conveyor shall be designed without the use of steel hold down bars. Hold-down guide liners mounted in the trough sides above the design load fill level that do not interfere with the flow of conveyed product shall be accepted. Simply lining the underside of the trough covers with plastic liner will not be acceptable as that does not prevent the spiral from moving inside the trough. 4. Trough shall be equipped with a top flange. Flanges shall be for attaching the trough cover, as well as connecting sections of the trough together. Troughs and connections shall be designed with a minimum factor of safety of 3 and shall adequately transmit all structural and dynamic loads without deformation. 5. Each housing shall have a minimum of one 6-inch-diameter flanged drain connection with flushing connection provided at the low point of the trough. The location of the drain shall be coordinated with the drain network. 6. Stiffeners shall be placed across the top of the trough and fastened to both sides of the trough to maintain trough shape and act as a face seal for the covers; apply a continuous gasket, one half inch width, to the entire top face of the trough top flange and stiffeners. D. Drain Project No. 18088080 6 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors 1. A flanged covered drain outlet shall be provided with each conveyor to facilitate cleaning. E. Wear Liners: 1. The inside trough surfaces of shaftless conveyors shall be lined with a layer of UHMWPE. The wear liner shall be Xylethon by Durawear, Polystone M by Rochling, or Duraflo SPX. The liner shall be supplied in no more than 4-foot long sections to provide ease of replacement. The liner shall be held in place with stainless steel clips; no fasteners will be allowed. Liner thickness shall be at a minimum 0.5-inch thick. 2. The liner material shall have the following physical properties, as a minimum: Property Value/Unit Testing Method Density 61.2 lbs/ft3 DIN53479 Molecular Weight 9.2x106 g/mol Margolies Ball Indentation Hardness 5,946 lbs/in2 DIN53456 Shore Hardness D 64 DIN53505 Crystalline Melting Range 278º F Dynamic Coefficient of friction 0.1-0.12 ratio of tension/load Plastic to steel F. Covers: 1. Hinged covers shall be furnished for any portion of each trough that is not covered by the filling chute or passing through a restrictive opening or where clearance will not allow a hinged over to be fully opened. Covers shall be manufactured in maximum five (5) foot length sections to allow for easy access and ease of liner replacement. Covers shall be 316 stainless steel. To prevent unsafe access to the conveyors, hinged covers shall also be bolted near the hinge release to prevent access during operation. Each conveyor hatch panel shall be fixed with the appropriate warning labels to call for lock out – tag out of the electrical system before the covers are removed. 2. Bolted covers shall be furnished for any portion of each trough that passing through a restrictive opening or where clearance will not allow a hinged over to be fully opened. Covers shall be manufactured in maximum five (5) foot length sections to allow for easy access and ease of liner replacement. Each conveyor cover shall be fixed with the appropriate warning labels to call for lock out – tag out of the electrical system before the covers are removed. G. Inspection hatches shall be supplied and installed in each discharge chute location on a side that is most easily accessed from the dewatering building floor. The inspection doors shall allow viewing of the interior of the hopper and cleaning. H. Spiral Flight: 1. Spiral flighting for the shaftless screw conveyors shall be designed to convey material without a center shaft or hanger bearings. 2. Spiral flights shall be cold-formed high strength chrome alloy steel with a minimum hardness of 225 Brinnell. The spiral flights shall be designed with adequate stability to prevent distortion and jumping in the trough. A second, inner spiral, concentric with the outside spiral shall also be provided. The torsional rating of the auger flighting shall exceed the torque rating of the drive motor at 150% of its nameplate horsepower. The “spring effect” of the spiral shall not exceed + 0.16-inch per foot of length at maximum load conditions. The minimum outer spiral thickness shall be 1”. 3. The spiral flighting shall be formed from one continuous flat bar and shall be concentric to within +0.125-inch. Sectional flighting formed from plate shall not be permitted. 4. Spiral flighting shall have full penetration welds at all splice connections. The flights shall be aligned to ensure true alignment when assembled in the field and shall be made in accordance with the supplier’s requirements. The spiral flights shall be coupled to the end shaft by a flanged, bolted connection. Project No. 18088080 7 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors I. Spiral Mounting 1. An adjustable greased gland packing ring consisting of two Teflon fiber packing rings shall seal the drive shaft at its penetration through the end plate, along with a greased labyrinth sealing system. 2. CEMA packing glands are acceptable to prevent premature failure and leakage. 3. The connection of the spiral to the drive system shall be through a flanged connection plate that is welded to the spiral forming a smooth and continuous transformation from the flange plate to the spiral. The drive shaft shall have a mating flange and shall be bolted to the spiral connection plate. Shaft must be integral with the flange assemblies and lathe finished after welding so they are true. Shaft must carry a 10-year warranty against torsional failure. J. Drive Units 1. Each spiral conveyor shall be driven by a constant speed gear reducer motor drive unit mounted to a bellhousing adapter flange mounted to the end plate of the conveyor. 2. The adapter flange shall allow the leakage of any material from the conveyor trough to the atmosphere rather than into the gear reducer/motor drive unit. Direct coupling of the gear reducer/motor drive unit to the end flange of the conveyor will not be acceptable. 3. The drive unit shall be rigidly supported so there is no visible "wobble" movement under any operating condition. In the event of a prolonged power failure or emergency system shutdown the drive system shall be designed, at a minimum, to start the conveyor from a dead stop with the trough filled at 1.5 X the design load. 4. All gears shall be AGMA Class II, single or double reduction, helical gear units with high capacity roller bearings. Bearings shall be designed for the thrust loads from the fully loaded startup condition and shall have an ABMA B-10 life of 30,000 hours. 5. The reducer will be air-cooled unit with no auxiliary cooling requirement. The gear reducer shall be sized with a torque service factor of 1.5 times the absorbed power or 1.1 times the motor nameplate, at the driven shaft speed, whichever is greater. K. Conveyor Supports: 1. Each conveyor shall be furnished complete with supports suitable for mounting as shown on the contract drawings, coordinated with actual field conditions, and as required by the supplier’s design, of 316 stainless steel structural angle, minimum 0.25-inch thick or fabricated Unistrut as approved by the ENGINEER. The supports shall be shop fabricated from structural steel shapes and plates and shall be assembled and fitted to the conveyor prior to its delivery to the jobsite. Supports and conveyor segments should be match marked and shipped to the jobsite for assembly by the Contractor. The manufacturer shall allow for 1-inch of grout beneath each support foot pad for the Contractor to compensate for uneven floor elevation. At a minimum, each conveyor shall be provided with supports at the inlet and discharge ends, with intermediate supports as required. 2. All structural supporting members shall be designed such that the ratio of the unbraced length to least radius of gyration (slenderness ratio) shall not exceed 120 for any compression member and shall not exceed 240 for any tension member (of angles about Z-Z axis). In addition, all structural members and connections shall be designed so that the unit stresses will not exceed the American Institute of Steel Construction allowable stresses by more than 1/3 when subject to loading of twice the maximum design operating torque of the spiral conveyor drive motors. 3. All shop welding shall conform to the latest standards of the American Welding Society (AWS). Manufacturer must be an Affiliate Company Member of the AWS and the equipment must be welded ASME and AWS certified welders. The equipment must be inspected by AWS certified welding inspectors and instructors. 4. The supports shall be designed to avoid interference with other equipment or equipment supports. L. Electric Operated Slide Gates Project No. 18088080 8 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors 1. The conveyor shall be furnished with slide gates installed at each discharge chute, as shown on the Drawings. 2. The slide gates shall be specifically designed to operate as an integral part of the conveyor system and shall be supplied by the conveyor manufacturer. 3. Slide gates shall be designed with a maximum vertical dimension of 4” excluding the electric motor operator. The slide gates shall be designed so that in the full, open position, at least one pitch rotation of the spiral is exposed to the opening in the direction of transport and where layout permits 1.5 x spiral pitch opening. The slide gates shall have an opening at least the full width of the conveyor trough. 4. The slide gates shall be fabricated entirely of AISI 316 stainless steel and/or suitable nonmetallic (UHMW PE) components, all minimum 3/16” thickness. The UHMW PE shall have a machined groove to accept the gate blade and provide a positive seal. 5. The conveyor manufacturer shall provide electric motor operated gate operators by Limitorque Model MX05, Auma SA, or approved equal. 6. The actuator shall be rated for NEMA 4X, have internal adjustable NEMA 4X limit switches, to indicate open and closed status, a worm gear motor, and a manual override hand wheel. The actuator shall be supported underneath the conveyor trough by supports designed and supplied by the conveyor manufacturer. 2.7 ELECTRICAL COMPONENTS AND ACCESSORIES A. Electrical products and execution required to complete the Work under this section shall conform to the applicable sections of Division 26, ELECTRICAL. B. Labeling: All electrical materials, devices, appliances, and equipment used shall be indicated as acceptable by established standards. Indication shall be by a valid label affixed to the item. Panels that consist of multiple components shall be listed and labeled as a unit in addition to any other requirements. C. Motors: 1. Provide squirrel-cage ac induction motors meeting the requirements of 26 05 15, ELECTRIC MOTORS, and as specified herein. 2. For additional specific requirements on motors, refer to the Motor Data Sheets at the end of the Section. 2.8 INSTRUMENTATION AND CONTROLS A. All instrumentation and control components shall be provided in accordance with the requirements of Division 26. B. The manufacturer shall provide a main conveyor control panel (77SCCP01) and a secondary conveyor control panel (77SCCP02) for the conveyors as described herein and as depicted on the contract drawings. . C. Main Conveyor Control Panel (77SCCP01) 1. Enclosure: NEMA 1, located in dewatering facility electrical room. 2. Control panel shall be designed with a SCCR rating of 18KA at 480VAC minimum and labeled as such, unless otherwise specified. 3. All terminals utilized in the main panel shall be 600V rated terminals and 20% spare terminal space shall be provided for any potential future revisions. 4. The control panel shall include the following at a minimum: a. Main disconnect circuit breaker interlocked with door handle. b. Lockable individual disconnects for each conveyor motor and gate actuator motor accessible from the front of the panel. c. Motor starters for each conveyor motor. Project No. 18088080 9 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors d. Circuit breaker branch overcurrent protection for each conveyor motor and gate actuator motor. e. Surge arrestor. f. Control power transformer. g. Control relays. h. Solid state overload relays. i. 120VAC power circuits for conveyor zero speed controllers as required. j. Terminal points for interconnection with ancillary equipment. 5. The control panel shall meet U.L. requirements and shall be U.L. 508A listed as a complete assembly. The control panel shall be completely pre-wired and factory tested prior to shipment. 6. Control Panel Operator Interfaces: At a minimum, provide the following functions on the front of the panel: a. Hand Switches and Other Controls: 1) Conveyor HAND-OFF-AUTO for conveyors 1, 2, and 4 (future), label with equipment numbers as appropriate. 2) Conveyor FORWARD-OFF-REVERSE for conveyors 1, 2 and 4 (future), label with equipment numbers as appropriate. 3) Push/Pull Emergency Stop (common to stop all conveyors). 4) Reset for each conveyor b. Alarms: The following alarms shall be provided on the front of the panel: 1) Fault light for each conveyor 2) Fault light for each gate actuator c. Status: The following status shall be indicated on the front of the panel: 1) Running light for each conveyor 2) Open light for each gate actuator 3) Closed light for each gate actuator 7. Control Panel External Interfaces: Provide the following interfaces between the control panel and items outside the system package: a. Dry Contact Inputs: 1) Run signal for each conveyor 2) Open signal for gate actuator 3) Close signal for gate actuator b. Dry Contact Outputs: 1) Conveyor Running for each conveyor 2) Conveyor Fault for each conveyor 3) Conveyor Auto Indication for each conveyor 4) Gate Actuator Opened 5) Gate Actuator Closed 6) Gate Actuator Alarm 7) Gate Actuator Auto Indication D. Secondary Conveyor #3 Control Panel (77SCCP02) 1. Enclosure: NEMA 4X stainless steel, located outside dewatering facility. 2. 20% spare terminal space shall be provided for any potential future revisions. 3. The control panel shall meet U.L. requirements and shall be U.L. 508A listed as a complete assembly. The control panel shall be completely pre-wired and factory tested prior to shipment. 4. Control Panel Operator Interfaces: At a minimum, provide the following functions on the front of the panel: a. Hand Switches and Other Controls: 1) Conveyor HAND-OFF-AUTO for conveyor 3. 2) Conveyor FORWARD-OFF-REVERSE for conveyor 3. 3) Slide gate actuator HAND-OFF-AUTO for gate actuator. 4) Slide gate actuator OPEN pushbutton for gate actuator. 5) Slide gate actuator CLOSE pushbutton for gate actuator. Project No. 18088080 10 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors 6) Push/Pull Emergency Stop (common to stop all conveyors). 7) Reset for conveyor 3. b. Alarms: The following alarms shall be provided on the front of the panel: 1) Fault light for conveyor 3 2) Fault light for gate actuator c. Status: The following status shall be indicated on the front of the panel: 1) Running light conveyor 3 2) Open light for gate actuator 3) Closed light for gate actuator 5. Control Panel External Interfaces: Provide wiring interfaces between the secondary control panel and main control panel as required. E. Instruments 1. Emergency Shutdown a. Each conveyor shall be furnished with an emergency trip cord and safety switch. The conveyor is to be provided with a cable operated OSHA safety stop switch with continuous cable run on both sides. The trip switch shall immediately stop all conveyors when the switch is actuated. The switch shall be RS2X type by Conveyor Components Corporation or approved equal. 2. Motion Detector a. An external conveyor mounted motion failure alarm, (alternately known as “zero speed” or “under-speed” switch) to detect spiral or drive shaft failure shall be utilized. Each conveyor drive unit shall be equipped with a motion failure alarm unit. The location and mounting details shall be as recommended by the conveyor manufacturer. Motion sensor shall be a non-contacting type probe with a pre- amplifier and main electronic assembly. The main electronic controller unit shall operate on 120 volt single phase 60 Hz power supply provided from the conveyor control panel, and shall be housed in a 316 stainless steel NEMA 4X enclosure. A 0 to 60 second time delay shall be provided for startup of the conveyor. F. Other Instrumentation and Controls: Provide all items not specifically called out which are required to implement the functions described herein. G. Control Description 1. Gate Actuator AUTO Control: In the Auto position, the control panel shall adjust the gate position to either open or closed based on the dumpster selection signal received from SCADA. a. Dumpster 1 signal: Close Gate to send dewatered sludge to dumpster 1. b. Dumpster 2 signal: Open Gate to send dewatered sludge to dumpster 2. 2. Conveyor AUTO Control: With conveyors In the Auto position, the control panel will receive run signals for the conveyors based on which belt presses are in operation. a. Belt Press 1 running: Run conveyors 1, 2, and 3. b. Belt Press 2 running: Run conveyors 1, 2, and 3. c. Belt Press 3 running: Run conveyors 1, 2, 3, and 4. 2.9 TOOLS AND SPARE PARTS A. Tools: The work includes one complete set of special tools recommended by the manufacturer for maintenance and repair of each separate type of equipment; tools shall be stored in tool boxes and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box. B. Spare Parts: 1. All equipment shall be furnished with the specified manufacturers spare parts, as indicated in the individual equipment sections. Project No. 18088080 11 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors 2. Spare parts shall be tagged by project equipment number and identified as to part number, equipment manufacturer, and subassembly component (if appropriate). Spare parts subject to deterioration such as ferrous metal items and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts with individual weights less than 50 pounds and dimensions less than 2 feet wide, or 18 inches high, or 3 feet in length shall be stored in a wooden box with hinged wooden cover and locking clasp. Hinges shall be strap type. The box shall be painted and identified with stenciled lettering stating the name of the equipment, equipment numbers, and the words "spare parts." A neatly typed inventory of spare parts shall be taped to the underside of the cover. 3. Provide, at a minimum, the following spare parts for the equipment: a. One packing glad set for each conveyor supplied b. One motion failure probe c. One emergency stop switch (without enclosure) d. One set of liner material for each conveyor. e. One spare gear drive for each conveyor f. One spare drive motor for each conveyor 2.10 FABRICATION A. Factory Applied Finishes: Prepare surfaces and apply protective finishes as specified in Section 01 60 00, PRODUCT REQUIREMENTS. PART 3 - EXECUTION 3.1 GENERAL A. Coordination shall include space and structural requirements, clearances, utility connections, signals, outputs and features required by the manufacturer including safety interlocks. 3.2 ASSEMBLY AND PREPARATION FOR SHIPMENT A. Each drive unit, including motor, shall be completely factory assembled, aligned, and securely crated for shipment. Accessory equipment which cannot be shipped assembled to the unit, such as shafts, baseplates, impellers, spare parts, and anchorage materials, shall be separately crated, clearly marked as to the contents, and shipped on the same shipment as the drives. B. For shipment, exposed surfaces subject to rust, such as mounting flange faces, etc., shall be covered with a rust-preventive compound such as Kendall No. 5, or equal. 3.3 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Comply with Section 01 60 00, PRODUCT REQUIREMENTS. B. Delivery of Materials: Products shall be delivered in original, unbroken packages, containers, or bundles bearing the name of the manufacturer. C. Storage: Products shall be carefully stored in a manner that will prevent damage and in an area that is protected from the elements. D. Protection of Equipment: Equipment shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage. Equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Pumps, motors, drives, electrical equipment, and other equipment with anti-friction or sleeve bearings shall be Project No. 18088080 12 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors stored in weathertight and heated storage facilities prior to installation. For extended storage periods, plastic equipment wrappers shall not be used to prevent accumulation of condensate in gears and bearings. 3.4 FIELD QUALITY CONTROL A. Functional Testing: Prior to plant startup, all equipment described herein shall be inspected for proper alignment, quiet operation, proper connection, and satisfactory performance by means of a functional test. Provide certification of test results. Tests and certification shall be as specified in Section 01 79 00, DEMONSTRATION AND TRAINING. 3.5 INSTALLATION A. The installation of the incline screw conveyor shall be independent of the horizontal screw conveyor to minimize down time and to allow the existing centrifuge to return to service independent of the progress of installation of the additional centrifuge and horizontal conveyor. B. Maximum allowed time for removal of existing incline conveyor and installation of the new conveyor to run in manual mode shall be 3 days. C. Provisions for temporary, but indefinite, operation of the incline conveyor in the absence of the horizontal conveyor shall be provided. D. Any control coordination necessary for safe and reliable operation of the centrifuge and the new incline conveyor between the removal of the existing conveyor and the complete installation and commission of the complete system including the new centrifuge and horizontal conveyor shall be provided by the Contractor. E. All anchors, bolts, and accessories shall be 316 stainless steel, ½-inch diameter, minimum. The manufacturer shall provide templates for anchor bolt locations. F. The equipment shall be installed using all the supports and support locations provided. Align conveyors and grout support into position. Install loose parts such as chutes, lubricants, motors and control devices. G. Provide the services of a factory-trained manufacturer’s representative during the installation for a minimum of two visits of one day each to advise the contractor during the installation. Submit two copies of the manufacturer’s reports of these trips.to the engineer H. Provide the final top coating system for applicable equipment. I. Lubricants: Include oil and grease for initial operation. 3.6 MANUFACTURER’S SERVICES A. A manufacturer’s representative for the equipment specified herein shall be present at the job site for the minimum person-days listed for the services hereinunder, travel time excluded: 1. Installation, Startup, and Testing Services: a. 1 person-day for installation assistance, inspection, and Certificate of Proper Installation. b. 1 person-day for functional and performance testing. c. Provide Qualifications of Manufacturer's Representative. 2. Training Services: a. 1 person-day of prestart classroom or jobsite training of Owner’s personnel. Project No. 18088080 13 Section 46 21 75 Lake Lewisville WTP Dewatering Improvements Shaftless Screw Conveyors b. Training of Owner’s personnel shall be at such times and at such locations as required and approved by the Owner. B. See Section 01 79 00, DEMONSTRATION & TRAINING of Division 01, GENERAL REQUIREMENTS. 3.7 MANUFACTURER’S CERTIFICATES A. Provide Manufacturer’s certificate(s) in accordance with Section 01 79 00, DEMONSTRATION & TRAINING, of Division 01, GENERAL REQUIREMENTS. 3.8 SUPPLEMENTS A. The supplements listed below and following end of section are part of this Specification: 1. 46 21 75.1-DS Shaftless Screw Conveyors From BFPs 2. 46 21 75.2-DS Shaftless Screw Conveyors Inclined 3. 46 21 75.2-DS Shaftless Screw Conveyors To Bins END OF SECTION Project No. 18088080 1 of 1 46 21 75.1 Data Sheet Lewisville Lake WTP Dewatering Improvements Shaftless Screw Conveyors SECTION 46 21 75.1 SHAFTLESS SCREW CONVEYORS PROJECT LAKE LEWISVILLE WTP DEWATERING IMPROVEMENTS OWNER CITY OF DENTON EQUIPMENT NAME(S) SHAFTLESS SCREW CONVEYORS - BFPs EQUIPMENT TAG NUMBER(S) 77SC01 LOCAL CONTROL PANEL(S) 77SCCP01 MANUFACTURERS KWS JMS JDV Equipment Co. SERVICE CONDITIONS PERFORMANCE REQUIREMENTS Material Handled Dewatered Ferric Residuals Cake flow rate 554 ft3/hr Average Density 65 lb/ft3 Trough Fill at Design Flow 35 % EQUIPMENT DESCRIPTION Degrees incline As necessary Max. Screw Speed 25 rpm Feed From BFPs Min. Screw Speed 22 rpm Discharge to Inclined Conveyor Trough nominal width, ID 15 in. No. Discharges/conveyor 1 Trough thickness, min. 1/4 in. Length 17.5 (approximate)_ ft Liner length, max 4 ft Spiral OD, Nominal 14 in. Liner thickness, min. ½ in. Spiral, outer thickness, min. 1 in. Lid thickness, min. 12 ga. in. Spiral Pitch 14 Lid Length, Max. 60 in. Spiral Insert Yes Chute thickness, min. 3/16 in. MOTOR DATA Type: Squirrel-cage induction meeting requirements of NEMA MG1. Manufacturer For multiple units of the same type of equipment, furnish motors and accessories of a single manufacturer. Hazardous Location Furnish motors for Class II Division 2 hazardous (classified) locations that conform to UL 674 and have an applied UL listing marking. Location of Drives Push Motion failure probes/conveyor 1 Drive HP, Max. 5 NEMA rating at probe 4X Voltage 460 Enclosure Type TEFC Phase 3 Material Frequency 60 Mounting Type Synchronous Speed 1800 rpm Multispeed, Two Speed rpm Service Factor 1.15 Variable Speed Drive: See Division 26, ELECTRICAL, Provide Inverter Duty Rated Motors Winding: One Two Thermal protection embedded in windings. Motor nameplate horsepower shall not be exceeded at any operational point Provide: Space Heater Oversize main terminal (conduit) box for motors Moisture detection switches SPECIAL FEATURES/NOTES Project No. 18088080 1 of 1 46 21 75.1 Data Sheet Lewisville Lake WTP Dewatering Improvements Shaftless Screw Conveyors SECTION 46 21 75.2 SHAFTLESS SCREW CONVEYORS PROJECT LAKE LEWISVILLE WTP DEWATERING IMPROVEMENTS OWNER CITY OF DENTON EQUIPMENT NAME(S) SHAFTLESS SCREW CONVEYORS - Incline EQUIPMENT TAG NUMBER(S) 77SC02 LOCAL CONTROL PANEL(S) 77SCCP01 MANUFACTURERS KWS JMS JDV Equipment Co. SERVICE CONDITIONS PERFORMANCE REQUIREMENTS Material Handled Dewatered Ferric Residuals Cake flow rate 554 ft3/hr Average Density 65 lb/ft3 Trough Fill at Design Flow 35 % EQUIPMENT DESCRIPTION Degrees incline 30, or as necessary Max. Screw Speed 36 rpm Feed From BFP Conveyor Min. Screw Speed 33 rpm Discharge to Bin Conveyor Trough nominal width, ID 17 in. No. Discharges/conveyor 1 Trough thickness, min. 1/4 in. Length 24 (approximate) ft Liner length, max 4 ft Spiral OD, Nominal 16 in. Liner thickness, min. 1/2 in. Spiral, outer thickness, min. 1 in. Lid thickness, min. 12 ga in. Spiral Pitch 10.5 Lid Length, Max. 60 in. Spiral Insert Yes Chute thickness, min. 3/16 in. MOTOR DATA Type: Squirrel-cage induction meeting requirements of NEMA MG1. Manufacturer For multiple units of the same type of equipment, furnish motors and accessories of a single manufacturer. Hazardous Location Furnish motors for Class II Division 2 hazardous (classified) locations that conform to UL 674 and have an applied UL listing marking. Location of Drives Pull Motion failure probes/conveyor 1 Drive HP, Max. 10 NEMA rating at probe 4X Voltage 460 Enclosure Type TEFC Phase 3 Material Frequency 60 Mounting Type Synchronous Speed 1800 rpm Multispeed, Two Speed rpm Service Factor 1.15 Variable Speed Drive: See Division 26, ELECTRICAL, Provide Inverter Duty Rated Motors Winding: One Two Thermal protection embedded in windings. Motor nameplate horsepower shall not be exceeded at any operational point Provide: Space Heater Oversize main terminal (conduit) box for motors Moisture detection switches SPECIAL FEATURES/NOTES Project No. 18088080 1 of 1 46 21 75.2 Data Sheet Lewisville Lake WTP Dewatering Improvements Shaftless Screw Conveyors SECTION 46 21 75.3 SHAFTLESS SCREW CONVEYORS PROJECT LAKE LEWISVILLE WTP DEWATERING IMPROVEMENTS OWNER CITY OF DENTON EQUIPMENT NAME(S) SHAFTLESS SCREW CONVEYORS - Bins EQUIPMENT TAG NUMBER(S) 77SC03 LOCAL CONTROL PANEL(S) 77SCCP01, 77SCCP02 MANUFACTURERS KWS JMS JDV Equipment Co. SERVICE CONDITIONS PERFORMANCE REQUIREMENTS Material Handled Dewatered Ferric Residuals Cake flow rate 554 ft3/hr Average Density 65 lb/ft3 Trough Fill at Design Flow 35 % EQUIPMENT DESCRIPTION Degrees incline 5 Max. Screw Speed 28 rpm Feed From Conveyor Min. Screw Speed 22 rpm Discharge to Outdoor Bins Trough nominal width, ID 15 in. No. Discharges/conveyor 2 Trough thickness, min. 1/4 in. Length 32 (approximate)_ ft Liner length, max 4 ft Spiral OD, Nominal 14 in. Liner thickness, min. 1/2 in. Spiral, outer thickness, min. 1 in. Lid thickness, min. 12 ga in. Spiral Pitch 14 Lid Length, Max. 60 in. Spiral Insert Yes Chute thickness, min. 3/16 in. MOTOR DATA Type: Squirrel-cage induction meeting requirements of NEMA MG1. Manufacturer For multiple units of the same type of equipment, furnish motors and accessories of a single manufacturer. Hazardous Location Furnish motors for Class II Division 2 hazardous (classified) locations that conform to UL 674 and have an applied UL listing marking. Location of Drives Pull Motion failure probes/conveyor 1 Drive HP, Max. 5 NEMA rating at probe 4X Voltage 460 Enclosure Type TEFC Phase 3 Material Frequency 60 Mounting Type Synchronous Speed 1800 rpm Multispeed, Two Speed rpm Service Factor 1.15 Variable Speed Drive: See Division 26, ELECTRICAL, Provide Inverter Duty Rated Motors Winding: One Two Thermal protection embedded in windings. Motor nameplate horsepower shall not be exceeded at any operational point Provide: Space Heater Oversize main terminal (conduit) box for motors Moisture detection switches SPECIAL FEATURES/NOTES Project No. 18088080 1 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System SECTION 46 76 21 – BELT FILTER PRESS SYSTEM PART 1 - GENERAL 1.1 SUMMARY A. The contractor shall furnish and deliver; ready for installation, two (2) complete Model 3DP 1.0- meter belt filter press dewatering systems as specified herein. Each system shall include the press, hydraulic unit, spare parts, and all electrical controls. Water of sufficient pressure will be supplied to the system. The belt press equipment specified in this section shall be provided by a single supplier to ensure coordination and compatibility of equipment. B. The contractor and the belt filter press manufacturer are advised to familiarize themselves with the overall plant process in order to evaluate the compatibility of the manufacturer’s equipment to dewater the particular water treatment solids generated. C. The system shall consist of an independent gravity belt thickener and a continuous belt press. It shall be designed to receive water treatment solids, concentrate it and dewater the solids by means of three belts of synthetic fiber mesh arranged to perform the conveying, pressing, and dewatering functions. The belt press, as described in this section, shall have no less than three distinct dewatering zones. The three zones shall be independent variable speed gravity drainage, wedge, and pressure/shear sections. D. The belt press equipment shall be as manufactured by BDP Industries, Inc. 1.2 DESCRIPTION OF SYSTEM AND PERFORMANCE CRITERIA A. Belt Press Operational Requirements: The belt press shall meet the following operating parameters when processing the solids specified. B. Sludge Specifications: 1. The solids shall be derived from the water treatment process with an expected consistency of 0.3% – 2.0% by weight dry solids. C. Belt Press Performance Specifications: 1. The belt filter press shall be capable of meeting the performance listed in both of the following two scenarios: a. Inlet flow of 80 GPM of solids at 1.0% feed solids concentration while producing a filter cake with a minimum dry solids content of 20%. b. Inlet flow of 270 GPM of solids at 0.3% feed solids concentration while producing a filter cake with a minimum dry solids content of 18%. 2. The overall solids capture shall be no less than 95% at 1% feed solids concentration or greater. 3. The belt filter press will be required to meet the above performance specifications by using polymer as a conditioning agent. Maximum polymer usage shall be 16 lbs active polymer per dry ton of solids processed. D. Process Performance Test and Guarantee:, the manufacturer shall operate the equipment and meet the performance specification listed above for a minimum of 5 days of operation during the normal day shift. Representative samples of feed solids, solids cake, and filtrate shall be drawn to determine compliance. Should the press fail to meet the minimum standards specified, the following shall occur: 1. Plant operating procedures shall be reviewed to determine that the solids concentration is within the design specifications. Project No. 18088080 2 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System a. If it is determined that the solids is representative and within these specifications, the manufacturer shall make any modifications necessary to accomplish the specified performance levels. b. If the solids can be demonstrated as within specified parameters and if the manufacturer cannot meet the performance after 30 days of operation, the Owner may elect to have the manufacturer remove the press for a full refund for the equipment. 1.3 QUALIFICATIONS A. The belt filter press equipment shall be furnished by a single supplier who has a minimum of thirty (30) years’ experience in the manufacture of solids dewatering equipment. The belt press manufacture shall have twenty (20) years’ experience manufacturing same model and size “three- belt design” belt presses. The equipment shall be designed, constructed and installed in accordance with the best practices and methods, and shall be manufactured by BDP Industries, Inc. B. These specifications describe equipment of a specific manufacturer and are not designed to limit competition. They are intended to describe a level of quality and process capability. There are certain areas affecting process functions, operation and maintenance reliability under which no exceptions shall be allowed. These are as follows: 1. High Strength Tubular Steel Construction Per ASTM 500 2. Hot Dipped Galvanized per ASTM 123 specification 3. Up-flow flocculation tank 4. High solids feedbox distributor with variable speed paddle wheel 5. Independent Variable Speed Gravity Drainage Section at Operator Level 6. Curved Wedge Zone 7. Vertical Pressure Section 8. Machined Bearing Pads 9. Dual Pressure Section Drives 10. Double Flange Roll Construction 11. 70 PLI Self-Compensating Hydraulic Tensioning and Tracking System 12. Hot-Dipped Galvanized Corrosion Protection System 13. All catwalks required to easily facilitate the operation and service of the press per section 2.03.C.9. The balance of this specification shall determine the quality level under which equipment shall be reviewed. C. The contract drawings and specifications are based on a BDP model 3DP. Equipment, which differs from the specifications, be offered as an alternate it must be accomplished with 5 copies of complete submittals fourteen days prior to the date of the bid. The submittal shall include a complete equipment submittal including room layout drawings, electrical drawings, equipment design calculation, component catalog cuts, contact list and performance guarantee. All exceptions shall be clearly identified by the manufacturer with a cost to supply the component specified. Any exceptions not identified will lead to immediate rejection of the submittal by the engineer and Owner. The cost of the engineer review shall be paid by the contractor submitting the alternate substitution. The cost of the review shall be billed at $250 per hour. A minimum of 40 hours will be required to review each alternate equipment submittal. The burden of proof of merit for the proposed item is upon the prospective bidder. Any modifications to the contract drawings that are required for the alternate units shall be borne by the installation manufacturer. The engineer and Owner reserve the right to reject any and all alternate requests based upon on their review. D. The room layout is based on the BDP model 3DP. Any alternate layouts proposed will be reviewed by the Owner and engineer. If the gravity zones are evaluated above 4’ the press manufacturer Project No. 18088080 3 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System shall provide catwalks that extend down both sides of the entire gravity zone. If the press needs to be elevated for the discharge chute, the contractor shall provide all piers, room layout drawings and additional foundation supports at no additional cost to the Owner. The Owner and engineer reserve the right to reject any or all offerings based on their review. E. The belt press manufacturer shall supply the original manufacturer part numbers for all buy-out items in the O&M manual and shall list all of the local suppliers to the Owner. All suppliers shall be within a 100-mile radius. F. The Owner reserves the right to waive any informalities and intends to make a qualifications based selection for the BFP, which may not necessarily be the lowest bid. G. The belt press manufacturer shall be a UL control panel shop manufacturer for the last 10 years. H. The belt press shall be manufactured by a US corporation. All manufacturing shall be completed in-house by the belt press manufacturer in the United States. No manufacturing shall be out sourced or purchased from outside companies. 1.4 WARRANTY A. Provide warranty for a period of 24 months after the final acceptance of the equipment by the Owner and Engineer. The warranty shall stipulate that the equipment furnished is suitable for the purpose intended and free from defects of material and workmanship for the duration of the warranty. In the event the equipment fails to perform as specified, the Manufacturer shall promptly repair or replace the defective equipment without additional cost to the Owner. B. Spare parts identified within this specification shall not be used to address warranty repairs. 1.5 SUBMITTALS A. The supplier shall submit a complete list of equipment and materials required for shop drawing or submittal approval. The term “shop drawing” as used herein shall be understood to include detailed arrangement drawings, foundation layout drawings, control drawings, pneumatic or hydraulic controls systems, catalog sheets and similar items. Unless otherwise required, these drawings shall be submitted in sufficient time to be reviewed by the ENGINEER, and to accommodate the construction schedule required under the contract. B. The manufacturer shall furnish five copies of shop drawings in three ring binders to the Engineer. Submitted packages shall include a complete bill of materials for all equipment, recommended spare parts list, list of any deviations from the contract documents and a statement of machine warranties. C. It is considered reasonable that the manufacturer shall make a complete and acceptable submittal by the second submission of drawings. The Owner reserves the right to withhold money due the supplier to cover additional costs of the Engineer’s review beyond the second submission. D. Revisions indicated on shop drawings shall be considered as changes necessary to meet the requirements of the contract drawings and specifications, and shall not be taken as a basis of claims for extra work. E. The review of said drawings by the Engineer will be limited to checking for general agreement with the specifications and drawings, and shall in no way relieve the supplier of responsibility for errors or omissions contained therein, nor shall such review operate to waive or modify any provision contained in the Specifications or Contract Drawings. Project No. 18088080 4 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System F. Submit shop drawings and product data required to establish compliance with this Section. Submittals shall include the following: 1. Certified shop and erection drawings showing all important details of construction, solids feed, wash water, drainage connections, wiring diagrams, itemized motor horsepower, dimensions and anchor bolts. 2. Descriptive literature, bulletins and/or catalogues of the equipment. This material shall include, but not be limited to, the following: a. Functional description of internal and external instrumentation and controls to be supplied, including list of parameters monitored, controlled or alarmed and testing plan. b. Materials of construction and of all coatings of all major components, including bearings. Include sizes of materials and thickness of coatings. c. Details of the drive system for belts. d. Details of the static solids/polymer mixer supplied. e. Information on field erection requirements, including total weight of assembled components, weight of the single largest component that will require removal during the life of the unit and gross operating weight. f. Statement of roller, bearing, frame and belt guarantees for units furnished. Also, describe typical range of belt tension and recommended belt tension for this application. g. Total connected nameplate horsepower and operating horsepower for each belt press dewatering system motor. Itemize this information for each motor. Include motor data as required by Section 01 60 01. h. Statement of water requirements (flow and pressure) and any other utility requirements. i. Description of gravity drainage and low, medium and high pressure stages. j. For the baseplate of the belt filter press, furnish the loads including all horizontal and vertical components as follows: 1) Deadloads due to unit weight empty. 2) Deadloads due to unit weight full of solids, drain pans full and similar circumstances. 3) Dynamic loads. 4) Combination of 2) and 3) above. 5) Loads exerted during belt changing procedures. k. Control panel elevation drawings showing construction and placement of operator interface devices and other elements. Control panel data to include: 1) Dimension and layout details. 2) Materials of construction. 3) Brand names and catalog literature on all control devices such as, but not limited to: a) Fused disconnects b) Thermal Magnetic Circuit Breakers c) Motor starters d) Motor Circuit Protectors e) Terminal blocks f) Fuse blocks g) Variable Frequency Drives h) Audible and Visual Alarm Indicators. i) All switches, pushbuttons and lights j) Timers, relays and related equipment k) Programmable logic controllers (PLC) l) Surge Protection m) Enclosures l. A complete total bill of materials for all equipment. Project No. 18088080 5 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System m. A complete parts list, showing current price and delivery time for each part. Include manufacturer's recommended spare parts and a firm price quotation good for one (1) year after Substantial Completion. n. A maintenance schedule, showing the required maintenance, frequency of maintenance and lubricants and other items needed at each regular preventive maintenance period. o. Provide certified safety factor calculations as described in Paragraph 2.03 below for structural frame, roller bearings and roller shafts, as well as maximum roller and frame deflection based on maximum design belt tension of 70 PLI (lbs per lineal inch of belt width) or total of 280 PLI for both belts at a belt speed of 5 meters per minute. These calculations shall be signed and sealed by a professional Engineer licensed to practice in the state of manufacturing facility. p. Complete data on motors and controls as specified in Paragraph 2.05 below. q. Addresses for alarms/data to SCADA. r. In the event that it is impossible to conform to certain details of this Section due to different manufacturing techniques, describe completely all non-conforming aspects. s. Submit to the Engineer operating and maintenance data as specified. Manuals shall be provided for all BFP related equipment specified in this or other Sections. This data shall be prepared specifically for this installation and shall include all necessary Drawings, equipment lists that are required to instruct operations and maintenance personnel unfamiliar with such equipment. Approved operating and maintenance data shall be available and used during the period of operation and maintenance instructions provided by the equipment manufacturer. PART 2 - BELT PRESS SPECIFICATIONS 2.1 GENERAL A. The equipment covered by these specifications is intended to be belt filter press dewatering equipment of proven ability as manufactured by reputable concerns having long term experience in the production of such equipment. The equipment furnished shall be designed and constructed in accordance with the best practice and methods. B. All components of the solids dewatering equipment shall be Engineered for long continuous and uninterrupted service. Provisions shall be made for easy lubrication, adjustment, or replacement of all parts. Corresponding parts of multiple units shall be interchangeable. Except as otherwise specified, steel plates and shapes shall have a minimum thickness of ¼” and bolts shall have a minimum diameter of ½ “. C. All welding shall be in accordance with the latest acceptable codes of the America Welding Society ANSI/AWS D1-1. D. All material used in the construction of the solids dewatering equipment shall be of the best quality and entirely suitable in every respect for the service required. All structural steel shall conform to the ASTM standard specification for structural steel, designation A500. All iron casting shall conform to the ASTM standard specification for gray iron casting, designation A48-76, and shall be of a class suitable for the purpose intended. Other materials shall conform to ASTM specifications where such specifications exist; the use of such material shall be based on continuous and successful use under the similar conditions of service. E. Unless otherwise specified herein, all metal parts in contact with polyelectrolyte or solids shall be type 304 stainless steel. All fasteners, pins, and anchor bolts shall be type 304 stainless steel. F. All fiberglass-reinforced plastics (FRP) shall be manufactured in conformance with NBS standards PS15-69. Project No. 18088080 6 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System 2.2 SURFACE PROTECTION A. Ferrous metals shall be hot-dipped galvanized per the latest revision of ASTM A123 specification. Flame sprayed coatings shall not be allowed. B. All buyout items such as motors and bearing housings shall be covered with the following paint system: 1. First coat of Tnemec series #66 or equal red primer to a minimum of four (4) dry mills thickness. 2. Apply a second coat of UV resistant urethane top coat, finished color, minimum of two (2) mills thickness. Total thickness of the two (2) coats will be a minimum of six (6 mills dry. C. The control panel enclosure shall be Nema 4X constructed of type 304 stainless steel. The inside back panel of the control panel box shall be white. 2.3 MECHANICAL DETAILS A. Main Structural Frame 1. The frame shall be fabricated from steel structural members designed to adequately support all components and accessories. Steel shall meet the requirements of ASTM A36; all welding shall be performed in accordance with ANSI/AWS D1.1. Where frame components are bolted, stainless steel fasteners shall be used. The frame moment of inertia shall be a minimum of 17 in4 in the xx axis and 5.8 in4 in the yy axis. The load bearing frame member of the pressure section shall have a moment of inertia minimum of 69 in.4 in the xx axis and 9 in.4 in the yy axis. Channel, plate or I-beam construction will not be accepted. 2. The fabricated steel frame shall be designed to withstand the maximum stresses imposes on the individual members with a safety factor of 10. Specifically, the maximum actual stress on any member, connection, plate, etc., shall not exceed 1/10 of the yield strength of the frame material used. The deflection ratio of any structural member shall not exceed L/600 where L is the member span. The tension used for the calculations shall be at least 70 lbs per linear inch of actual belt width. 3. Drip pans shall be fabricated a minimum 14 gauge type 304L stainless steel and shall collect filtrate from all gravity and pressure sections. 4. The framework shall be constructed in such a manner that it will insure absolute plane parallelism of all rolling elements by machined bearing pads. 5. The framework shall be of welded and/or bolted construction. No disassembled component, excluding the belt filter frame, shall weigh more than 3500 lbs. 6. Provide adjustable leakage seals to contain the solids on the belt through the gravity drainage zone. Seals shall be 304 stainless steel with rubber skirts, designed to provide an effective seal without causing wear to the belt. B. Flocculation/Conditioning System: To achieve rapid contact between solids particles and a solution of dilute polyelectrolyte, provide: 1. A static, in-line, adjustable energy non-clogging Venturi mixer shall be provided. The mixer shall be equipped with Vortex polymer injection ring with four (4) tangentially mounted polymer injectors. The mixer shall be located upstream of the belt filter press. The belt filter press manufacturer shall recommend the proper layout of the system. The contractor shall provide spool piece(s) of the size and number shown on the drawings at alternate locations. The in-line Venturi mixer shall be fabricated of 316L stainless steel with an adjustable open throat area. 2. A conditioning tank shall be provided after the Venturi mixer to insure optimum solids conditioning. This conditioner shall be vertically baffled and discharged into a stainless steel distributor. The conditioning tank assembly shall be fabricated of type 304 Stainless Steel. The feed distributor shall consist of an up-flow rectangular cross section conditioning tank that transitions from the feed pipe diameter at floor level to the full width of the filter Project No. 18088080 7 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System belt at the gravity deck level with a minimum volume of 40 gallons. This conditioning tank shall be vertically baffled and discharged into a stainless steel weir trough distributor. Inside the weir trough there will be a variable speed paddle wheel with six (6) 4:” wide rubber paddles driven by a 1/3 HP AC/VFD drive that will push the slurry over the weir trough on to the filter cloth. The feed distributor must form a uniform slurry depth over the full belt width immediately upon leaving the feed distributor of plus or minus 1/16 inch. Tank and trough to be constructed of 304L stainless steel, rubber blades are SBR material. C. Independent Gravity Drainage Area 1. The press shall be furnished with an independent gravity drainage consisting of a variable speed-moving belt designed to contain and drain conditioned solids. The inlet distributor shall be utilized to evenly distribute the conditioned solids over the face of the moving filter belt. The belt system shall be sealed to prevent leakage and shall be easily accessible for operating, viewing, cleaning, and adjusting. 2. All materials in contact with the solids in the distributor area shall be 304 stainless steel with adjustable angle furrowing plows of UHMW plastic. The gravity belt thickener shall have a minimum horizontal area of 31 ft2. The gravity drainage section shall be supported by slide strips. Supports shall be designed to prevent deflections greater than 0.05 inches with a loading of 100 lbs. per square foot. Slide strips shall be easily removable without disassembly of any components. The height of the decks shall be adjustable for extended life of the slide strip and containment seals. 3. The belt support shall be a series of UHMW wear strips within a 304 stainless frame. The strips shall be every 6” and be of a design to not only to provide support but also enhance gravity dewatering. Only systems, which have been demonstrated as effective in the area, shall be considered. 4. Provide adjustable leakage seals to contain the solids on the belt through the gravity drainage zone. Seals shall be neoprene rubber with 304SS deckle supports, designed to provide an effective seal without causing wear to the belt. 5. Six rows of swing up type furrowing plow devices shall be supplied in the gravity drainage section and shall be readily removable. 6. The adjustable plows shall be mounted on a support system that can be raised for cleaning via lifting handles. 7. Plows will be high-density polyethylene with hot-dipped galvanized support holders. Plow position will be adjustable from 0 to 30 degrees with respect to the direction of belt travel. All plows will be adjustable in unison for each plow row. To facilitate cleaning, each row of plows will include a single lifting handle, designed to raise the entire row of plows at least six inches from belt. 8. The independent gravity unit shall be equipped with a variable speed VFD drive, powered and controlled from the main press panel. 9. The gravity section provided shall be constructed at operator level for easy viewing and operation. For equipment with elevated gravity section, catwalks must be supplied on both sides of each machine. The platform height shall be such that the gravity deck of the belt filter press is easily visible accessible. The platform shall be constructed such that its placement will not interfere with routine maintenance of the belt filter presses. All additional costs for foundation and anchor supports shall be at no extra cost to the customer. Handrails and vertical stairs shall be provided for the platform. Kick plates (toe plates) shall be provided which shall project a minimum of 4 inches above the walking surface. The platform and all supports shall be constructed of load 200 pounds per square foot not to exceed the working stresses for materials in 1990 BOCA Code. All walking surfaces shall be non-slip. Minimum platform width shall be 30 inches. 10. The independent gravity section shall be provided with hydraulic tension and tracking system as specified in this specification. Manual tensioning or tracking systems will not be acceptable. D. Curved Wedge Section Project No. 18088080 8 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System 1. The wedge section shall be of a curved belt path design. Straight belt path designs will not be allowed. The initial radius of curvature must be a minimum of 24” and transition to a final radius of curvature of 16.5”. The design will provide gradual increase in cake pressure through the zone to enhance dewatering. 2. The belt filter process shall be furnished with a distribution chute to receive solids from the primary gravity dewatering section for purposes of even distribution of the solids to the wedge section. 3. The wedge section shall be constructed to contain the solids on the belts with adjustable sealed deckles. This area shall be easily accessible for operating, viewing, cleaning, and adjusting. 4. Movement through the wedge section shall be designed to insure a uniform layer of solids across the entire working width of the belt. It further shall be adjustable to allow operator determination of proper relationship between belt speed and cake height, in order to insure optimum dewatering. 5. The materials in contact with the solids shall be fabricated from type 304 stainless steel. All fasteners, along with mounting and adjustment hardware shall be 304 stainless steel. 6. The use of vacuum assisted drainage sections is not acceptable. Vertical or non – curved wedge zones will not be acceptable. 7. The upper and lower press section filter belts, while in the wedge section, shall be supported by construction equal to that of the gravity belt section, shall be minimum of 2” wider than the width of the belt and so designed to reduce belt wear. 8. The wedge section shall have a minimum horizontal area of 20ft2. This calculation is based on only one belt. 9. The wedge zone shall have a 304L stainless steel drip pan to collect filtrate and eliminate filtrate from dropping on the return belt or rewetting the cake. E. Vertical Pressure Zone 1. The vertical belt filter press shall be furnished with a pressure zone following the wedge section drainage area. 2. The wedge shall become uniform at the tangent of the first low pressure, non-rewetting, 304 stainless steel, and perforated drainage roll. It shall be a minimum of 20” in diameter, followed by a 16” diameter reversing turn, completing a full S with each turn exceeding 200 degrees. 3. The next stage of the pressure zone shall consist of an arrangement of a minimum of five (5) rollers developing a continued 2000 S-shaped belt travel. The rolls shall decrease from 12” in diameter to 10” in diameter. 4. The decreasing roll diameter is to provide an increasing pressure profile in the pressure zone, made adjustable by changing the belt tension. 5. The seventh and eighth rollers in the pressure section shall be a 10” diameter drive roll forming the last 2000 turn. 6. The minimum bearing size in the pressure section will be 50mm. 7. The pressure section shall have a minimum area of 60ft2. This calculation is based on one belt in contact with the roll surface. 8. The vertical pressure zone configuration shall include a tray beneath each roll such that the filtrate is removed from the solids cake without rewetting of the downstream cake. Each drip pan shall be directed to a final collection pan and piped to the sump area. The collection pans must eliminate filtrate from landing on the returning belt. F. Dewatering Belts 1. Belts shall be seamed and fabricated of monofilament polyester, wear resistant plastic material or combination monofilament polyester and stainless steel material. The mesh design shall be selected for optimum dewatering of the solids to be processed with a minimum blinding of the filter fabric. 2. Belt selection shall be based on the manufacturer’s experience obtained at other installations dewatering similar solidss with similar polyelectrolyte conditioning chemicals. Project No. 18088080 9 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System 3. The belts shall be warranted for 2,000 hours operation. Any belt that fails before that time, provided that the belt press has been operated per the instructions in the operation and maintenance manual, will be replaced on a pro rate basis. 4. Each belt and connecting splice shall be designed for a minimum tensile strength equal to five times the normal maximum dynamic tension to which the belt shall be subjected. The splice shall be designed to fail before the belt. 5. Belt shall be designed for ease of replacement with a minimum of belt filter downtime. Belt replacement shall be such that disassembly is not required. G. Belt Wash System 1. Each filter belt shall be washed by a belt wash station. The belt wash system shall use high-pressure water spray nozzles equipped with manually operated wire brushes for internal nozzle cleaning. The spray assembly shall be housed in an enclosure in a manner that limits the spray pattern within the housing assembly. The housing and nozzle assembly shall be readily removable. The housing shall be fabricated from type 304 stainless steel. 2. The housing shall be sealed against the belt with rubber seals. The belt shall be protected from excessive wear by the edges of the wash station housing by replaceable guide surfaces. The belt wash station shall extend over the full width of the filter belt by a minimum of 2 inches. 3. Pressuried water for the Belt Wash System will be provided by a Booster Pump Station not provided by belt press manufacturer. The control system for the belt press will monitor for adequate pressure to the belt wash system and notify by alarm if pressure is not adequate. H. Belt Aligning System 1. The belt aligning devices shall be hydraulically operated to align each belt and locate it centrally on the rollers by means of sensing arm, which detects the position of the belt edge. This arm shall operate a pilot valve, which in turn affects the position of the hydraulic actuator. The actuator shall be connected to a pivot belt-aligning roller, causing this roller to skew from its traverse position. 2. The alignment system shall function as a continuous automatic belt guidance system and shall be an integral part of the press. The alignment system shall operate with smooth and slow motions resulting in a minimum of belt travel from side to side. The use of electric servos shall not be accepted. 3. Backup limit switches for the belt aligning system shall be provided on the machine with sufficient contacts to de-energize all drives and sound alarm in case of a belt over travel. 4. A complete simplex hydraulic system shall be provided for each unit. This package shall include adjustable pressure, adjustable flow pump, 2 hp TEFC motor, valves, 20-gallon stainless steel storage reservoir, all controls and piping as necessary to provide a complete and operating system. The unit shall include a low-pressure switch, relief valve, temperature gauge, and tank level gauge. The system shall include the necessary pressure and return filters. The hydraulic unit will be floor mounted away from the press to eliminate wash down spray. 5. The hydraulic unit shall be supplied with a 304 stainless steel support stand to allow for the tank oil to be easily drained. The tank shall also include a 304 stainless steel drain valve to allow for draining the hydraulic oil. 6. All hydraulic lines shall be 316 stainless steel tubing and be rigidly supported on the structural frame and be properly sized for the intended use with adequate factors of safety for the rated pressure. 7. All belt alignment control equipment shall be fabricated from corrosion resistant materials or effectively coated not to rust or stain. All cylinders shall be composite cylinders with 316 stainless rods. Cylinders shall be rated for 1,000 PSI. 8. The installation contractor shall be responsible for supplying and interconnecting the power unit to the belt press hydraulic manifold with 316 stainless steel tubing. I. Belt Tensioning System Project No. 18088080 10 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System 1. Each belt shall be provided with a belt tensioning system. The belt tensioning system shall be hydraulically actuated. The design of the tensioning system shall be such that the dewatering pressure is directly proportional to belt tension and that adjustments in the tension shall result in immediate changes in dewatering pressure. Manual or electric servo tensioning systems are not acceptable. 2. Each belt tensioning shall be furnished with an individual control station such that independent adjustment for each belt is possible. The control stations shall incorporate an on/off selector, calibrated pressure regulating valve and a pressure gauge to indicate actual operating pressure on each system. 3. The design of the belt tensioning system shall insure parallel movement of the tensioning cylinders. The tensioning roller shall be mounted on a rugged yoke assembly, with hydraulic cylinders at each end for the gravity belt section. The pressure section tensioning shall incorporate stainless steel rack and pinion tensioning system with cylinders on each side of the unit. The belt tensioning system shall accommodate a minimum of 2.5% increase in belt length. 4. Sensing device shall be furnished to determine belt travel beyond normal operating limits. The sensing devices shall be electrically connected within the alarm system to cause “an alarm shut down”. Manual reset shall be required. J. Press Drives 1. The gravity section shall be driven by a 1 HP motor. The pressure section shall be driven by two (2) 1.5 HP motors. Each shall be variable speed with a variable frequency AC drive unit. A speed indicator readout for each shall be installed in the main press control panel. 2. The gravity belt drive shall be capable of varying output speed from 8 to 75 feet per minute and the press section drive, 3 to 15 ft. per minute. 3. The feedbox paddle wheel shall be driven by a variable speed 1/3 HP AC drive. 4. The nominal input horsepower rating of each gear or speed reducer shall be at least equal to the nameplate horsepower of the drive motor. Each drive unit shall be designed for 24- hour continuous service. 5. Each gear reducer shall be totally enclosed, water spray proof, oil lubricated with anti- friction bearings throughout. All motors shall be IP65 severe duty TEFC. 6. The drives shall be furnished with provisions for use on 480 volt, 60 hertz, and 3-phase power supply. 7. The belt drive for the pressure section shall be driven by two (2) adjacent rollers. The gearboxes shall be shaft mounted. Spur gears or chain driven rollers shall not be acceptable. K. Safety Guards 1. All equipment having exposed moving parts such as fans, V-belts, gears, couplings, chains, and including the pressure roll section, shall be provided with safety guards as required by OSHA standards. L. Discharge Blades 1. Discharge blades shall be provided to scrape dewatered solids from the belt at the final discharge rollers. The doctor blade shall be made of wear resistant UHMW plastic. The blades shall be readily removable. The blade holders shall be secured in place by means of counterweights. Spring tension type fasteners are not acceptable. 2. The minimum discharge height shall be 6’6” high. If necessary, the belt presses ad catwalks shall be supplied with additional support legs by the press manufacturer. 3. The press manufacturer shall provide a machine mounted 304 stainless steel discharge chute to discharge the cake into the existing hole in the floor. The solids chute shall include hinge mounted viewing point and be designed to be operated by one person. M. Bearings 1. The shafts of all rollers shall be equipped with heavy-duty greasable type, self-aligning ball or roller bearings in sealed, splash proof housings. All bearings in the press section shall Project No. 18088080 11 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System be heavy duty split case spherical roller bearings. The housings shall allow the changing of the bearings without changes in the factory alignment of the roller. The housing shall be sealed to provide adequate sealing from moisture and grime. The outside of the housing on roller bearings shall also incorporate a sealed end cap. 2. All bearings shall have a minimum B-10 bearing life of 1,000,000 hours based on ANSI- B13.6-1972. The B-10 bearing life of 1,000,000 hours shall be based on the maximum summation of all forces applied to the bearing. The forces shall include both belts at a belt tension of 70 PLI each, maximum belt speed of 15 ft/min and torque of the drive motor. 3. Bearings and housings shall be US manufactured and shall be manufactured by FMC Corporation, Link-Belt Division, Indianapolis, Indiana; Reliance Electric Company, Dodge Division, Greenville, South Carolina; or equal. 4. All bearings shall be manufactured and supplied with off the shelf bearings and housings from the above manufacturers with original part numbers. Any manufacturers that supply only their belt press manufacturer part number, provide custom bearing manufacturing, or manufacture the bearing housing will not be considered. N. Rollers 1. All rollers shall be of solid steel or double-separated plate stub and shaft construction. The stub end shaft and roller heads shall be welded in place. Bolted and or through shaft roll construction is unacceptable. All rollers shall be designed to have a maximum deflection of 0.05 inches at their center when under maximum loading of 70 PLI belt tension. 2. All rollers except drive and tracking rollers shall be of carbon steel construction, coated with a minimum of 30 mills of thermoplastic nylon, selected for intended service. Drive and tracking shall incorporate 75mils nylon, 3/8” vulcanized Nitrile rubber surface or approved equal for abrasion resistance and proper belt tracking and drive. Other types of roller coatings shall not be acceptable. 3. All rollers must be US manufactured at the suppliers manufacturing facility. Out sourced roll suppliers will not be accepted. O. Drainage Pans 1. Drainage pans shall be supplied as necessary to contain all filtrate and wash water within the belt filter press and to reduce rewetting of downstream cake. Filtrate and wash water pans shall be constructed of minimum 14-gauge type 304 stainless steel. All drainage piping shall be furnished adequately sized for the intended service and rigidly attached to the press frame. 2.4 ELECTRICAL REQUIREMENTS A. General requirements 1. The belt filter press shall be provided with a local full operating panel complete with all motor control and supervisory device for press-mounted equipment. The panel shall also include such ancillary drives as hereafter specified. The panel shall be designed to interface with main control power and other plant control provided by others. All electrical work shall be performed in accordance with applicable local and national electric codes. The control panel shall include an Modicon M340 PLC capable of Ethernet communication. 2. Three phase, 480 volt, 60-Hertz power shall be supplied to the main control panel. 3. A control transformer will be provided in the control panel to provide a 120-volt, single phase power source for motor starter coils, lights, relays, timers, controllers, local operating panel and other related items. 4. The local control panel shall be provided with terminal blocks for power wiring to and from the panel. The incoming terminal blocks shall be provided with a single magnetic circuit breaker disconnect switch. Fuse protected motor starters with thermal overloads shall be supplied for each motor furnished with the press. 5. All electrical equipment controls located on the belt filter press shall have 304 stainless steel NEMA 4X enclosures and wired, through PVC conduit, to a single common NEMA 4X terminal box. Project No. 18088080 12 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System 6. All devices within the panel shall be permanently identified. Nameplates shall be provided on the face of the panel or on the individual devices as required. Nameplates shall be made of laminated phenolic materials with a white face and a black core. 7. The panel shall be designed for manual starting and stopping of all drives. A master run- jog switch shall be supplied to override the alarm system and allow operation of any drive through a momentary contact push button. 8. All drive stations shall be equipped with a start/stop switch and run light. The main press drive and gravity belt drive drives shall also incorporate a variable speed potentiometer and speed indicator. The solids pump, conveyor, hydraulic unit, and polymer system shall have start/stop and run lights. A motor starter shall be provided for the hydraulic unit. The polymer controls shall include a potentiometer and a 4 to 20 mA signal for remote speed control. 9. Alarm lights, sensors, and related circuitry shall be provided for the following functions: belt misalignment, high and low belt tension, emergency trip cord on each side of the press, and low hydraulic pressure. In the event of any of the above malfunctions, the machine will shut down and an alarm will sound. The alarm system shall include an audible horn rated at 90 DBA at 10’. The system shall include silencing provisions, but the function alarm contacts shall be provided for remote alarm indication and for interruption of ancillary drives such as polymer and feed solids pumping. 10. Arrange the local press panel to include the following controls for each belt press control panels to allow either manual or automatic control of belt press equipment. When “MANUAL” operation is selected, all equipment associated with the belt press shall be controlled by “START/STOP” pushbuttons. When “AUTOMATIC” operation is selected, control of equipment shall be “AUTOMATIC/START” and “AUTOMATIC/STOP” pushbuttons, and programmable controller: a. Local belt press control panels shall include OIT touchscreens with the following: 1) One control mode selector switch marked “AUTOMATIC/ MANUAL.” When “MANUAL” operation is selected, all equipment associated with belt press shall be controlled by “START/STOP” pushbuttons. Provide one “START” and one “STOP” pushbutton for each of the following: a) Feedbox Drive. b) Gravity Belt Thickener Drive. c) Press Drive. d) Hydraulic Unit. e) Wash Water Pump. f) Sludge Pump Drive. g) Polymer Pump Drives. h) Discharge Conveyor System 2) One speed potentiometer for manual adjustment of each drive speed. 3) Digital indicators for solids feed flow rate. Indicators shall accept 4 to 20 mADC field input and shall be calibrated in GPM. 4) Indicating lights for “RUNNING” status for each unit operated from panel, including wash water solenoid valve energized indication. Colors to be coordinated with facility standards 5) Indicating lights for “OFF” status for each unit operated from panel, including wash water solenoid valve de energized indication. Colors to be coordinated with facility standards 6) One each “AUTOMATIC/START” and one “AUTOMATIC/STOP” momentary pushbuttons, for automatically starting and stopping each belt press system. Sludge cake conveyor shall be manually controlled when belt press control mode selector switch is in either the “AUTOMATIC” or “MANUAL” position. 7) One “EMERGENCY STOP” red mushroom pushbutton. 11. Automatic Controls and Sequencing: a. General: 1) Program the PLC for automatic control of belt press, system sequencing, and interlock functions as specified. Project No. 18088080 13 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System 2) Configuration and programming of PLC system shall be responsibility of belt press manufacturer. System documentation including memory loading, I/O configuration and programming shall be provided. 3) Provide and install auxiliary relays and wiring for equipment and devices specified in this Section required for implementing functional requirements specified. b. “AUTOMATIC START/AUTOMATIC STOP” Cycle (typical for all belt presses): 1) Automatic start cycle request to PLC shall be initiated by “AUTOMATIC/START” pushbutton. 2) Control logic for an “AUTOMATIC/START” cycle shall start belt press in the following order after “AUTOMATIC/START” command has been initiated and interlocks are complete. a) Wash water pump. b) Belt Shower “Pre-Wash” c) Belt press drive. d) Gravity Belt Thickener drum drive. e) Press drive. f) Polymer solution pump drive. g) Sludge feed pump. h) Discharge Conveyor System. 3) In “AUTOMATIC” mode the polymer system will automatically be called to dilute the neat emulsion polymer system. 4) Each drive shall not start until previous drive is running and necessary time delay has elapsed. The belt press manufacturer shall determine where time delays are required and shall program settings to provide smooth start-up of equipment. 5) Once all drives are confirmed running by motor run contacts from their respective starters, PLC shall cause the run indicating light to illuminate. Loss of run status contact for a drive once cycle logic is complete shall shut down belt press and associated equipment. 6) Upon “AUTOMATIC /STOP” command, system shall shut down in order that is reverse of specified start-up order with necessary time delays. c. Interlocks: The following interlocks shall be satisfied when control mode selector switch is in either “AUTOMATIC” or “MANUAL” position. Failure of any one signal during start cycle or after cycle is complete shall shut down all associated belt press equipment. 1) Wash water pump must be on and sufficient wash water pressure must be sensed at a specified level. 2) Hydraulic pressure must be sensed at a specified level. 3) Control mode selector switch shall be in “AUTOMATIC” position. 4) “EMERGENCY STOP” pushbutton shall be in operating position. 12. Annunciation and Alarms: a. Provide audible alarm and detailed alarm history in belt press control panel for alarming of the following: 1) Gravity Belt Thickener drive failure. 2) Press drive failure. 3) Feedbox failure. 4) Local emergency stop initiated at either belt filter press control panel or pull cord switch. 5) High discharge pressure at solids feed pump. 6) Low washwater pressure. 7) Low hydraulic pressure. 8) Polymer pump failure. 9) Sludge pump failure. 10) Conveyor zero speed. 11) Low polymer tank level. Project No. 18088080 14 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System b. Wire all alarms to PLC system for relaying to remote location. 13. Additional stations shall be included as hereinafter specified for other ancillary drives or systems. B. Electric Motors furnished with this equipment shall meet the following requirements: 1. Rated for continuous duty at 40ºC ambient and insulated with a minimum of Class F insulation, with Class B temperature rise. All motors shall be totally enclosed, fan cooled or non-ventilated. All motors supplied shall be rated at 150% nameplate horsepower of the required horsepower maximum service condition. PART 3 - INSTALLATION 3.1 INSTALLATION SUPERVISION A. As a minimum, the contractor shall include with his bid, a minimum of one (1) day of on-site services of a qualified factory representative to advise contractor on proper installation of all equipment, piping, and wiring procedures. This shall include one day of on-site services. B. All necessary control wiring, conduit, and terminations shall be provided by the Contractor, per NEC standards, to complete a fully operational system. 3.2 OPERATION & MAINTENANCE MANUALS A. Three (3) copies (in three ring binders) of operation and maintenance manuals for all equipment supplied under this specification shall be furnished. The manuals shall be prepared specifically for this installation and shall include detailed operating and maintenance instructions and specifications relative to the following; assembly, alignment, checking, lubrication, placing in operation, adjustment, maintenance of each unit of equipment, auxiliaries furnished under this contract, together with complete parts lists, and copies of dimension drawings. 3.3 START-UP SERVICES A. Prior to start-up, the manufacturer representative shall make a thorough inspection of the installation to make sure the press was installed properly and that all equipment relating to it was installed according to the needs of the press. 1. As a minimum, the contractor shall include with his bid, a minimum of six (6) days spread over three trips of on-site services by the manufacturer’s representative to place the system into operation. The Owner shall assist the manufacturer’s representative by starting up and operating all support systems such as water, solids pumping, polymer mixing and feed, electrical power and instrumentation, and other ancillary equipment as needed. B. Services provided shall include but are not limited to the following: 1. Adjust all edge seals, discharge scraper blades, drive chains, etc. 2. Adjust spray wash, cloth tension, and belt aligning system. by the manufacturer shall be as detailed in the O&M manuals and shall include at a minimum the following: a. Check equipment alignment and assure that there are no unusual internal stresses. b. Calibrate all instrumentation such as hydraulic systems. c. Check hydraulic systems to insure proper operation. d. Check lubrication in all devices. e. Start the drives and assure they are operating with no binding and with correct rotation. f. Insure that all ancillary systems have been properly adjusted, including polymer and solids feed. Project No. 18088080 15 Section 46 76 21 Lake Lewisville WTP Dewatering Improvements Belt Filter Press System C. Start-up services shall be considered completed when the manufacturer and contractor have demonstrated that the units are operating without mechanical problems. 3.4 TRAINING SUPERVISION A. As part of the start-up services, the equipment manufacturer shall provide (4) days spread over two trips of onsite training to the Owner’s employees for proper operation and maintenance of the solids dewatering equipment. These trips will be scheduled within the first year of operation at the Owners request at no additional cost to the Owner. B. At a minimum, the manufacturer shall make an additional follow up training and inspection trip after the machine has been in operation within 60 days of start-up. PART 4 - MISCELLANEOUS 4.1 SPARE PARTS A. The contractor shall furnish the following spare parts in addition to other spare parts recommended by the equipment manufacturer for the first year of operation of the press: 1. One complete set of filter belts. 2. Two sets of discharge blades. 3. One set of seals of each type and size for the gravity zone and each wash box. 4. Two bearings of each type and size. 5. One cleaning brush for nozzles. 6. Ten bulbs of each type indicating light and alarm light. 7. Three fuses of each size and type. 8. One relay of each size and type. 9. One-limit switches of each size and type. 10. One set of seals for each inlet distributor, belt wash station, and wedge section. 11. Ten spray wash nozzles. 12. Ten standardized grease fittings. B. Spare belts should not be furnished with the unit but shipped after a representative operating period to insure suitability of the fabric for the solids being processed. END OF SECTION