PART 1 - GENERAL 1.1 DESCRIPTION · SECTION 40 05 05 EXPOSED PIPING INSTALLATION PART 1 - GENERAL...

SECTION 40 05 05

EXPOSED PIPING INSTALLATION

PART 1 - GENERAL

1.1 DESCRIPTION

A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment and incidentals

as shown, specified, and required to install and test all exposed piping, fittings, and specials. The Work includes the following: a. All types and sizes of exposed piping, except where exposed piping

installations are specified under other Sections. b. Unless otherwise shown or specified, this Section includes all piping

beginning at the outside face of structures or structure foundations and extending into the structure. Piping embedded in concrete within a structure or foundation shall be considered as exposed and is included herein. Piping that is permanently or intermittently submerged, or installed in sub-aqueous environments, is considered as exposed and is included in this Section.

c. Work on or affecting existing exposed piping. d. Installation of all jointing and gasket materials, specials, flexible

couplings, mechanical couplings, harnessed and flanged adapters, sleeves, tie rods, and all Work required for a complete exposed piping installation.

e. Supports, restraints, and other anchors. f. Field quality control, including testing. g. Cleaning and disinfecting. h. Incorporation of valves, meters, and special items shown or specified into

the piping systems per the Contract Documents and as required

B. Coordination: 1. Review installation procedures under this and other Sections and coordinate

installation of items that must be installed with or before exposed piping Work. 2. Coordinate with appropriate piping Sections of Division 40, Mechanical.

C. Related Sections: 1. Section 09 91 00, Painting. 2. Section 10 14 00, Signage. 3. Section 40 05 08, Wall Pipes, Floor Pipes and Pipe Sleeves.

1.2 REFERENCES

40 05 05 - Exposed Piping Installation.doc

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A. Standards referenced in this Section are: 1. ANSI B16.1, Cast Iron Pipe Flanges and Flanged Fittings 2. ASME Boiler and Pressure Vessel Code. 3. ASME B31.3, Process Piping. 4. American Society for Non-Destructive Testing (ASNT), ASNT-TC-1A,

Recommended Practice, Personnel Qualification, and Certification in Non-destructive Testing.

5. ASTM A380, Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

6. ASTM B32, Specification for Solder Metal. 7. ASTM D4161, Standard Specification for Fiberglass (Glass-Fiber-Reinforced

Thermosetting-Resin) Pipe Joints Using Flexible Elastomeric Seals 8. ASTM D4174, Standard Practice for Cleaning, Flushing, and Purification of

Petroleum Fluid Hydraulic Systems 9. ASTM F2164, Standard Practice for Field Leak Testing of Polyethylene (PE)

Pressure Piping Systems Using Hydrostatic Pressure 10. AWS D1.1/D1.1M, Structural Welding Code-Steel. 11. ANSFAWWA C111, Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and

Fittings. 12. ANSI/AWWA C206, Field Welding of Steel Water Pipe. 13. ANSFAWWA C600, Installation of Ductile Iron Water Mains and Their

Appurtenances. 14. ANSI/AWWA C606, Grooved and Shouldered Joints. 15. ANSFAWWA C651, Disinfecting Water Mains. 16. AWWA M9, Concrete Pressure Pipe. 17. AWWA M11, Steel Pipe - A Guide for Design and Installation. 18. AWWA M23, PVC Piping - Design and Installation. 19. AWWA M41, Ductile-Iron Pipe and Fittings. 20. AWWA M45, Fiberglass Pipe Design. 21. AWWA M55, PE Pipe - Design and Installation. 22. SAE J1227, Method for Assessing the Cleanliness Level of New Hydraulic

Fluid.

1.3 QUALITY ASSURANCE

A. Regulatory Requirements: 1. Comply with requirements and recommendations of authorities having

jurisdiction over the Work, including: a. City of Miamisburg, Ohio. b. Ohio Environmental Protection Agency (0EPA).

1.4 SUBMITTALS


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A. Action Submittals: Submit the following: 1. Shop Drawings:

a. Detailed drawings in plan and, as applicable, section. b. Details of piping, valves, supports, accessories, specials, joints,

harnessing, and main anchor supports, and connections to existing piping, structures, equipment, and appurtenances.

c. Laying schedules for concrete pipe and piping with restrained joints. 2. Testing Plans, Procedures, and Testing Limitations

a. Submit description of proposed testing methods, procedures, and apparatus, and obtain ENGINEER's approval prior to testing.

B. Informational Submittals: Submit the following: 1. Certificates:

a. Submit a certificate, signed by manufacturer of each product, certifying that product complies with applicable referenced standards.

2. Source Quality Control Submittals: a. Submit copies of testing report for each test.

3. Site Quality Control Reports: a. Submit copies of testing report for each test.

C. Closeout Submittals: Submit the following: 1. Record Documentation:

a. Maintain accurate and up-to-date record documents showing field and Shop Drawing modifications. Record documents for exposed piping Work shall show actual location of all piping and appurtenances on a copy of the Drawings, unless otherwise approved by ENGINEER.

b. Record documents shall show piping with elevations referenced to the project datum and dimensions from permanent structures. For straight runs of pipe provide offset dimensions as required to document pipe location.

c. Include section drawings with exposed piping record documents when the Contract Documents include section Drawings.

d. Conform to Section 01 78 39, Project Record Documents.

1.5 DELIVERY, STORAGE AND HANDLING

A. Delivery: 1. Deliver products to Site to ensure uninterrupted progress of the Work. 2. Upon delivery, inspect pipe and appurtenances for cracked, gouged, chipped,

dented, and other damage and immediately remove damaged products from Site.

3. Conform to requirements of Section 01 65 00, Product Delivery Requirements.

B. Storage:


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1. Store products for convenient access for inspection and identification. Store products off the ground using pallets, platforms, or other supports. Protect packaged products from corrosion and deterioration.

2. Pipe and fittings other than thermoplastic materials may be stored outdoors without cover. Thermoplastic pipe and fittings stored outdoors shall be covered.

3. Conform to requirements of Section 01 66 00, Product Storage and Handling Requirements.

C. Handling: 1. Handle pipe, fittings, specials, and accessories carefully with approved

handling devices. Do not drop or roll material of delivery vehicles. Do not otherwise drop, roll, or skid piping.

2. Avoid unnecessary handling of pipe. 3. Keep pipe interiors free of dirt and foreign matter. 4. Protect interior linings and exterior coatings of pipe and fittings from damage.

Replace pipe and fittings with damaged lining regardless of cause of damage. Repair damaged coatings.

5. Conform to requirements of Section 01 65 00, Product Delivery Requirements.

PART 2- PRODUCTS

2.1 MATERIALS

A. Piping materials are specified in the Exposed Piping Schedule at the end of this Section. Piping materials shall conform to Specification for each type of pipe and piping appurtenances in applicable sections of Division 40, Process Integration.

B. Markings and Identification: 1. Pipe Markings:

a. Clearly mark each piece of pipe or fitting with a designation conforming to that shown on the approved Shop Drawings.

b. Manufacturer shall cast or paint on each length of pipe and each fitting the pipe material, diameter, and pressure or thickness class.

2. Pipe Identification Markers and Arrows: Refer to Section 10 14 00, Signage.

C. Appurtenances: Provide products that comply with: 1. Section 40 05 08, Wall Pipes, Floor Pipes and Pipe Sleeves.

PART 3- EXECUTION


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3.1 INSPECTION

A. Examine conditions under which the Work is to be installed and notify ENGINEER in writing of conditions detrimental to the proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. General: 1. Install piping as shown, specified and as recommended by the pipe and fittings

manufacturer. 2. If there is a conflict between manufacturer's recommendations and the Contract

Documents, request in writing instructions from ENGINEER before proceeding.

3. Provide pipe manufacturer's installation specialist at Site as specified on this Section.

B. Temporary Blind Flanges, Plugs, Caps, and Bulkheads: 1. Temporarily plug installed pipe at the end of each day of work or other

interruption of pipe installation to prevent entry of animals, liquids, and persons into pipe, and entrance or insertion of deleterious materials into pipe.

2. Install standard plugs in all bells at dead ends, tees, and crosses. Cap all spigot and plain ends.

3. Fully secure and block blind flanges, plugs, caps, and bulkheads installed for testing, designed to withstand specified test pressure.

4. Where plugging is required for phasing of Work or subsequent connection of piping, install watertight, permanent type blind flanges, plugs, caps, or bulkhead acceptable to ENGINEER.

C. Piping Installation: 1. Conform to manufacturer's instructions and requirements of standards and

manuals listed in this Section, as applicable: a. Ductile Iron Pipe: ANSI/AWWA C600, AWWA M41. b. Thermoplastic Pipe: AWWA M23

2. Install straight runs true to line and elevation. 3. Install vertical pipe truly plumb in all directions. 4. Install piping parallel or perpendicular to walls of structures. Piping at angles

and 45 degree runs across corners of structures will not be accepted unless specifically shown on the Contract Documents or approved by the ENGINEER.

5. Install small diameter piping generally as shown when specific locations and elevations are not indicated. Locate such piping as required to avoid ducts, equipment, beams, and other obstructions.

6. Install piping to leave all corridors, walkways, work areas, and similar spaces unobstructed. Unless otherwise approved by ENGINEER provide a minimum


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headroom clearance under piping and pipe supports of 7.5 feet. Clearances beneath piping shall be measured from the outermost edge ofpiping, flanges or other type of joint that extends beyond the nominal outside diameter of piping.

7. Protect and keep clean interiors, fittings, and valves of pipe that will convey potable water, chemicals, and other pipe designated by ENGINEER.

8. Cutting: Cut pipe from measurements verified at Site. Field cut pipe, where required, with a machine specially designed for cutting type of pipe being installed. Make cuts carefully without damage to pipe, coating, or lining, and with a smooth end at right angles to axis of pipe. Cut ends of push-on joint type pipe shall be tapered and sharp edges filed off smooth. Do not flame-cut

pipe. 9. Place bell and spigot-type pipe so that bells face the direction of laying, unless

otherwise approved by ENGINEER. 10. Deflections at joints shall not exceed 75 percent of amount allowed by pipe

manufacturer, unless otherwise approved by the Engineer. 11. Additional General Requirements for Thermoplastic Piping:

a. Utilize wide band supports as recommended by pipe manufacturer and approved by ENGINEER to minimize localized stresses.

b. Provide piping passing through walls with a sleeve of wearing material to prevent abrasion damage to piping.

c. Provide anchored supports at elbows, valves, bends in piping, and at connections to equipment and tanks.

d. Spacing of supports shall be in accordance with the manufacturer's published recommendations at maximum design operating temperature of

pipe. e. Provide U-clamps with wide band circumferential contact. f. Provide guides on long runs of piping to maintain alignment and reduce

chance of elastic failure of pipe. Space guides as recommended by pipe manufacturer.

g. Provide anchored supports to restrain joints that allow expansion. Minimize use of bellows style joints. Where required and approved by the ENGINEER provide bellows style joints with low axial force to take up pipe expansion. Flexible connectors may be used to absorb thermal movement when approved in writing by ENGINEER.

D. Jointing Pipe: 1. General:

a. Make joints in accordance with pipe manufacturer's recommendations and Contract Documents.

b. Cut piping accurately and squarely and install without forcing or springing.

c. Ream out pipes and tubing to full inside diameter after cutting. Remove all sharp edges on end cuts.


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d. Remove all cuttings and foreign matter from inside of pipe and tubing before installation. Thoroughly clean all pipe, fittings, valves, specials, and accessories before installing.

2. Ductile Iron Mechanical Joint Pipe: a. Wipe clean the socket, plain end and adjacent areas immediately before

making joint. Make certain that cut ends are tapered and sharp edges are filed off smooth.

b. Lubricate plain end and gasket with soapy water or pipe manufacturer's recommended pipe lubricant, per ANSI/AWWA C111, just prior to slipping gasket onto plain end of joint assembly.

c. Place gland on plain end with lip extension toward plain end, followed by gasket with nan-ow edge of gasket toward the plain end.

d. Insert pipe into socket and press gasket firmly and evenly into gasket recess. Keep joint straight during assembly.

e. Push gland toward socket and center it around pipe with the gland lip against the gasket.

f. Insert bolts and hand tighten nuts. g. Deflect joint only after assembled when approved by ENGINEER. h. Make deflection after joint assembly, if approved by ENGINEER, but

prior to tightening bolts. Alternately tighten bolts 180 degrees apart to seat the gasket evenly. Bolt torque shall be:

Pipe Diameter (inches)

Bolt Diameter (inches)

Range of Torque (ft-lbs)

3 5/8 45 to 60 4 to 24 3/4 75 to 90

30 to 36 1 100 to 120 42 to 48 1.25 120 to 150

3. Ductile Iron Push-On Joint Pipe: a. Prior to assembling joints, thoroughly clean with a wire brush the last

eight inches of exterior surface of spigot and interior surface of bell, except where joints are lined or coated with a protective lining or coating.

b. Wipe clean rubber gaskets and flex gaskets until resilient. Conform to manufacturer's instructions for procedures to ensure gasket resiliency when assembling joints in cold temperatures.

c. Insert gasket into joint recess and smooth out entire circumference of gasket to remove bulges and to prevent interference with proper entry of spigot of entering pipe.

d. Immediately prior to joint assembly, apply a thin film of pipe manufacturer's recommended lubricant to surface of gasket that will come in contact with entering spigot end of pipe, or apply a thin film of lubricant to outside of spigot of entering pipe.

e. For assembly, center spigot in pipe bell and push pipe forward until spigot just makes contact with the rubber gasket. After gasket is


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compressed and before pipe is pushed or pulled in the rest of the way, carefully check gasket for proper position around the full circumference of joint. Final assembly shall be made by forcing spigot end of entering pipe past gasket until spigot makes contact with the base of the bell. When more than a reasonable amount of force is required to assemble the joint, remove spigot end of pipe to verify proper positioning of gasket. Do not use gaskets that have been scored or otherwise damaged.

f. Maintain an adequate supply of gaskets and joint lubricant at Site when pipe jointing is in progress.

4. Ductile Iron Proprietary Joints: a. Pipe that utilizes proprietary joints for restraint specified in Section

40 05 19, Ductile Iron Process Pipe, or other such joints, shall be installed in accordance with manufacturer's instructions.

5. Ductile Iron and Steel Flanged Joints: a. Assemble flanged joints using ring-type gaskets, with thickness as

recommended by pipe manufacturer but not less than 1/8-inch thick, for raised-face flanges. Use full-face gaskets for flat-face flanges, unless otherwise approved by ENGINEER or recommended by pipe manufacturer. Gaskets shall be suitable for the service intended in accordance with the manufacturer's ratings and instructions. Gaskets shall be properly centered.

b. Tighten bolts in a sequence that provides equal distribution of bolt loads. c. Length of bolts shall be uniform. Bolts shall not project beyond the nut

more than 1/4-inch or fall short of the nut when fully taken up. Machine-cut ends of bolts to be neatly rounded. Do not use washers.

d. Prior to assembly of flanged joints, lubricate bolt threads and gasket faces.

e. Alternately tighten bolts 180 degrees apart to compress the gasket evenly. f. After assembly, coat all bolts and nuts, except stainless steel bolts and

nuts, with same coating specified in Section 09 91 00, Painting, for material of pipe and fittings being joined.

E. Installing Valves and Accessories: 1. Provide supports for large valves, flow meters, and other heavy items as shown

or required to prevent strain on adjoining piping. 2. Position flow measuring devices in pipe lines so that they have the amount of

straight upstream and downstream runs recommended by the flow measuring device manufacturer, unless specific location dimensions are shown.

3. Position swing check valves and butterfly valves so that they do not conflict with upstream and downstream elements of the piping system.

F. Unions: 1. Install dielectric unions as specified in Section 40 05 06, Couplings, Adapters,

and Specials for Process Piping, where dissimilar metals are connected, except for bronze or brass valves in ferrous piping.


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2. Provide a union downstream of each valve with screwed connections. 3. Provide screwed or flanged unions at each piece of equipment, where shown,

and where necessary to install or dismantle piping.

G. Transitions from One Type of Pipe to Another: 1. Provide all necessary adapters, specials, and connection pieces required when

connecting different types and sizes of pipe or connecting pipe made by different manufacturers.

H. Closures: 1. Provide closure pieces, such as blind flanges and caps, shown or required to

complete the Work.

3.3 THRUST RESTRAINT

A. Provide thrust restraint on all pressure piping systems and where otherwise shown or specified.

B. Thrust restraints shall be designed for axial thrust exerted by test pressure specified in the Exposed Piping Schedule at end of this Section.

C. Restrained Pipe Joints: 1. Pipe joints shall be restrained by means suitable for the type of pipe being

installed. a. Ductile Iron, Push-on Joints and Mechanical Joints: Restrain with a

proprietary restrained joint system as specified in Section 40 05 19. Ductile iron pipe, lugs, and tie rods, or other joint restraint systems approved by ENGINEER. Restrain ductile iron pipe connected by flexible couplings or flanged coupling adapters by harnessing across the coupling or adapter using tie rods or extended bolts connecting between flanges.

b. Thermoplastic Joints: Where bell and spigot-type or other non-restrained joints are utilized, provide tie rods across the joint or other suitable joint restraint system, subject to approval of ENGINEER.

3.4 WORK AFFECTING EXISTING PIPING

A. Location of Existing Piping: 1. Locations of existing piping shown on Drawings is approximate. 2. Determine the true location of existing piping to which connections are to be

made, crossed, and that could be disturbed, and determine location of other facilities that could be affected by the Work.

B. Taking Existing Pipelines Out of Service: 1. Conform to Section 01 14 16, Coordination with Owner's Operations.


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C. Work on Existing Pipelines: 1. Cut or tap pipes as shown or required with machines and tools specifically

designed for cutting or tapping pipelines. 2. Install temporary plugs to prevent entry of mud, dirt, water, and debris into

pipe. 3. Provide necessary adapters, sleeves, fittings, pipe, and appurtenances required

to complete the Work. 4. Conform to applicable requirements of Section 01 14 16, Coordination with

Owner's Operations and Section 01 73 24, Connections to Existing Facilities.

3.5 PAINTING

A. Field painting shall conform to Section 09 91 00, Painting.

36 FIELD QUALITY CONTROL

A. Testing, General: 1. Test all piping, except as exempted in the Exposed Piping Schedule. 2. Notification:

a. Notify ENGINEER at least 48 hours prior to testing. b. When authorities having jurisdiction are to witness tests, notify

ENGINEER and authorities having jurisdiction in writing at least 48 hours in advance of testing.

3. Conduct all tests in presence of ENGINEER. 4. Remove or protect pipeline-mounted devices that could be damaged by testing. 5. Provide all apparatus and services required for testing, including:

a. Test pumps, compressors, hoses, calibrated gages, meters, test containers, valves, fittings, and temporary pumping systems required to maintain OWNER's operations.

b. Temporary bulkheads, bracing, blocking, and thrust restraints. 6. Provide air if an air test is required, power if pumping is required, and gases if

gases are required. 7. Unless otherwise specified, OWNER will provide fluid required for hydrostatic

testing. CONTRACTOR shall provide means to convey fluid for hydrostatic testing into the pipe being tested. CONTRACTOR shall provide fluid for other types of testing required.

8. Repair observed leaks and repair pipe that fails to meet acceptance criteria. Retest after repair.

9. Unless otherwise specified, testing shall include existing piping systems that connect with new piping system. Test existing pipe to nearest valve. Piping not installed by CONTRACTOR and that fails the test shall be repaired upon authorization of ENGINEER or OWNER. Repair of existing piping will be paid as extra work unless otherwise specified.


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B. Test Schedule:

1. Refer to the Exposed Piping Schedule for type of test required and required test pressure.

2. Unless otherwise specified, the required test pressures are at lowest elevation of pipeline segment being tested.

3. For piping not listed in Exposed Piping Schedule: a. Hydrostatically test pipe that will convey liquid at a pressure greater than

five psig. Provide process air pipe test for pipe that will convey air or gas under pressure or vacuum, except chlorine gas, which requires a separate test.

b. Disinfect for bacteriological testing piping that conveys potable water.

4. Test Pressure: a. Use test pressures listed in Exposed Piping Schedule. b. If test pressure is not listed in Exposed Piping Schedule, or if a test is

required for piping not listed in the Exposed Piping Schedule, test pressure will be determined by the ENGINEER based on the maximum anticipated sustained operating pressure and the methods described in the applicable ANSI/AWWA manual or standard that applies to the piping system.

D. Hydrostatic Testing:

1. Preparation for Testing: a. For thermoplastic pipe and FRP pipe, follow procedures described in

Section 7 of ANSFAWWA Standard C605. b. For HDPE pipe, follow procedures described in ASTM F2164. Test

duration, including time to pressurize, time for initial expansion, time at test pressure, and time to depressurize, shall not exceed eight hours. If re-testing of a test section or pipeline is required, at least eight hours shall elapse between tests.

c. For steel pipe, follow procedures described in AWWA Manual M11. Wetting period is not required for pipe that is not cement-lined.

d. For other piping follow procedures described in AWWA Manual M9. A wetting period is not required for pipe that is not cement mortar-lined.

e. Prior to testing, ensure that adequate thrust protection is in place and all joints are properly installed.

f. Piping for Hydraulic Fluid, Lube Oil, and Diesel Fuel: Hydrostatically test system using the fluid with which system will function permanently. Allowable leakage is zero. For fluid power systems, manufacturer shall supervise installation and testing of system components, including field piping.

2. Test Procedure: a. Fill pipeline slowly to minimize air entrapment and surge pressures. Fill

rate shall not exceed one foot of pipe length per second in the pipe being tested.


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b. Expel air from pipe as required. Obtain approval of ENGINEER prior to tapping pipe for expelling air.

c. Examine joints and valves, and make repairs to eliminate visible leakage. d. After specified wetting period, add fluid as required to pressurize line to

required test pressure. Maintain test pressure for a stabilization period of ten minutes before beginning test.

e. HDPE Pipe: After filling pipeline, gradually pressurize pipe to test pressure and maintain required test pressure for three hours for pipe to expand. During expansion, add fluid to maintain required test pressure. Begin timed test period after expansion period and other requirements are met.

f. Timed test period shall not begin until after the pipe has been filled, exposed to the required wetting period, air has been expelled, and pressure stabilized.

g. Timed Test Period: After the stabilization period, maintain test pressure for at least two hours. During timed testing period, add fluid as required to maintain pressure within five psig of required test pressure. For HDPE pipe, after three hour expansion phase, reduce test pressure by ten psig and do not add liquid. The test pressure shall then remain steady for one hour, indicating no leakage.

h. Pump from a test container to maintain test pressure. Measure volume of fluid pumped from test container and record on test report. Record pressure at test pump at fifteen minute intervals for duration of test.

3. Allowable Leakage Rates: Leakage is defined as the quantity of fluid supplied to pipe segment being tested to maintain pressure within five psi of the test pressure during timed test period. Allowable leakage rates for piping are: a. No Leakage: Pipe with flanged, welded, fused, threaded, soldered, or

brazed joints. b. Rates based on formula or table in AWWA Manual M41:

1) Metal and fiberglass pipe joined with rubber gaskets as sealing members, including the following joint types: a) Bell and spigot and push-on joints. b) Mechanical joints. c) Bolted sleeve type couplings. d) Grooved and shouldered couplings.

c. Rates based on make-up allowance in AWWA Manual M9: 1) Prestressed concrete cylinder pipe and other types of concrete pipe

joined with 0-ring rubber gasket sealing members. d. Rates based on formula or table in ANSFAWWA C605:

1) Plastic pipe joined with 0-ring gasket sealing members.

E. Bacteriological Testing: 1. Bacteriological testing for potable water lines, finished water lines, and other

piping per Exposed Piping Schedule, is specified in Article 3.6 of this Section.


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3.7 CLEANING AND DISINFECTION

A. Cleaning, General: Clean pipe systems as follows: 1. Thoroughly clean all piping, including flushing with water, dry air, or inert gas

as required, in a manner approved by ENGINEER, prior to placing in service. Flush chlorine solution and sodium hypochlorite piping with water.

2. Piping 24-inch diameter and larger shall be inspected from inside and debris, dirt and foreign matter removed.

3. For piping that requires disinfection and has not been kept clean during storage or installation, swab each section individually before installation with a five percent hypochlorite solution.

B. Disinfection: 1. Disinfect all potable and finished water piping. 2. A suggested procedure for accomplishing complete and satisfactory

disinfection is specified below. Other procedures may be considered for acceptance by ENGINEER. a. Prior to disinfection, clean piping as specified and flush thoroughly. b. Conform to procedures described in ANSI/AWWA C651. Continuous

feed method of disinfecting shall be used, unless alternative method is acceptable to ENGINEER.

3. Water for initial flushing, testing, and disinfection will be furnished by OWNER. CONTRACTOR shall provide all temporary piping, hose, valves, appurtenances, and services required. Cost of water required for re-disinfection will be paid by CONTRACTOR to OWNER at the water utility's standard rates.

4. Chlorine shall be provided by CONTRACTOR.

3.8 EXPOSED PIPING SCHEDULE

A. The schedules listed below are a part of this Specification section. 1. Table 40 05 05-A, Exposed Piping Schedule.


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TABLE 40 05 05-A, EXPOSED PIPING SCHEDULE

Service Diameter

(inch) Material Interior Lining

Exterior Coating

Pressure Class/

Thickness Joint Test Remarks

FEED 2 PVC -- -- SCH. 80 SW HYD (25) Future chemical

carrier pipe, clear

D ALL PVC -- -- SCH. 80 SW HYD (25)

For each booster pump, field route

drain pipe to nearest floor

drain.

PW SUC 4 to 16 DI CL P Class 56 FLG

or GSEC

HYD (150), DBT

ANSI B16.1 Class 150 Flanges

PW DISC

4 to 16 DI CL P Class 56 FLG

or GSEC

HYD (250), DBT


SNIP 3/4 C -- -- -- SD DBT Type L SPD 2 PVC -- -- SCH. 80 SW HYD (25)

SGR 6 DI CL P Class 56 FLG

or GSEC

HYD (250), DBT


The following abbreviations are used in the Exposed Piping Schedule.


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A. Service Abbreviations

Service Abbrev. Service Abbrev. Sanitary Force Main SFM Overflow OF Raw Water RW Centrate CEN Potable Water PW Filtrate FILT City Water CW Scum SCUM Non-Potable Water NPW Primary Sludge PS Plant Effluent Water PEW Return Activated Sludge RAS Spray Water SPW Waste Activate Sludge WAS Backwash Water BW Thickened Sludge TS Hot Water Supply HWS Mixed Sludge MS Hot Water Return HWR Digested Sludge DS Influent INF Chlorine Solution CLS Effluent EFF Sodium Hydroxide (Caustic) NAOH Drain D Sodium Hypochlorite NAOCL Process Air PA Polymer Solution POLYS Instrument Air IA Alum AL Digester Gas DIG Hydraulic Fluid HF Chlorine Gas CLG Fuel Oil FO Wastewater WW Lube Oil LO Surge Relief SGR Seal Water SW Sump Pump Drain SPD Chemical (Future) CHM

B. Material Abbreviations

Material Abbrev Material Abbrev. Ductile Iron DI Polyvinyl Chloride PVC Cast Iron CI Chlorinated Polyvinyl

Chloride CPVC

Carbon Steel CS Polyethylene PE Stainless Steel SS High Density Polyethylene HDPE Copper C Fiberglass Reinforced

Plastic FRP

Prestressed Concrete Cylinder Pipe

PCCP

Non-Prestressed Concrete Cylinder Pipe

CCP

Steel Cylinder Pipe SCP


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C. Lining/Coating Abbreviations

Lining Abbrev Coating Abbrev. Cement Mortar Lined CL Painted P Glass Lined GL Insulated I Ceramic Epoxy CE Galvanized GALV Fusion Bonded Epoxy Lined

FBEL

Plastic Lined PL

D. Joint Abbreviations

Joint Type Abbrev Joint Type Abbrev. Bell and Spigot BS Flanged FLG Restrained Bell and Spigot RBS Butt Weld BW Push-on Joint POJ Lap Weld LW Restrained Push-on Joint RPOJ Butt Fusion Weld BFW Mechanical Joint MJ Solvent Weld SW Restrained Mech. Joint RMJ Sleeve-type Flexible

Coupling SLFC

Soldered SD Split Flexible Coupling SPFC Brazed BZ Plasticized PVC Coupling PPVC Threaded THD Grooved or Shouldered

End Coupling GSEC

Flanged Adapter FA

E. Test Abbreviations

Test Abbrev Test Abbrev. Hydrostatic Test (test pressure in psig)

HYD ( ) Disinfection and Bacteriological Testing

DBT

Process Air Pipe Test (test pressure in psig)

PA ( ) Examination of Welds EW

Chlorine Pipe Test CL Exfiltration Test EX No Test Required NR

+ + END OF SECTION + +


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SECTION 40 05 06

COUPLINGS, ADAPTERS, AND SPECIALS FOR PROCESS PIPING

PART 1 - GENERAL

1.1 DESCRIPTION

A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment, and incidentals

as shown, specified, and required to furnish and install all couplings, adapters, and specials for process piping.


installation of items that must be installed with or before couplings, adapters, and specials for process piping Work.

C. Related Sections: 1. Section 09 91 00, Painting. 2. Section 33 05 05, Buried Piping Installation 3. Section 40 05 05, Exposed Piping Installation.

1.2 REFERENCES

A. Standards referenced in this Section are: 1 ANSI B16.1, Cast-Iron Pipe Flanges and Flanged Fittings. 2. ANSI B16.39, Malleable Iron Threaded Pipe Unions. 3. ASME B31, Standards of Pressure Piping. 4. ASTM A53/A53M, Specification for Pipe, Steel, Black and Hot-dipped, Zinc-

Coated, Welded and Seamless. 5. ASTM A105/A105M, Specification for Carbon Steel Forgings and Piping

Applications. 6. ASTM B169/B169M Specification for Aluminum Bronze Sheet, Strip, and

Rolled Bar. 7. ASTM B650, Specification for Electro-Deposited Engineering Chromium

Coatings of Ferrous Substrates. 8. ASTM F593, Specification for Stainless Steel Bolts, Hex Cap Screws, and

Studs 9. AWWA C606, Grooved and Shouldered Joints.


A. Qualifications: 1. Manufacturer shall have at least five years experience producing substantial

40 05 06 - Couplings, Adapters, and Specials for Process Piping.doc

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similar products to those specified and shall be able to provide documentation of at least five installations in satisfactory operation for at least five years each.

B. Component Supply and Compatibility: 1. Obtain each type of coupling, adapter, and special for process piping product

included in this Section, regardless of component manufacturer, from a single couplings, adapters, and specials manufacturer.

2. Supplier shall prepare, or review, and approve all submittals for components furnished under this Section.

3. Components shall be suitable for specified service conditions and be integrated into overall assembly by the Supplier.

1.4 SUBMITTALS


a.

Submit piping layout Shop Drawings in accordance with Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.

2. Product Data: a.

Submit product data on each type of coupling, expansion joint, and other piping specialties and accessories, including gaskets, hardware, and appurtenances sufficient to demonstrate compliance with the Contract Documents.


a.

When requested by ENGINEER submit certificate attesting to compliance with standards referenced in this Section, signed by manufacturer.

2. Manufacturer's Instructions: a.

Provide instructions for handling, storing, installing, and adjusting of products.

3. Source Quality Control: a.

When requested by ENGINEER, submit results of source quality control tests.

4. Qualifications Statements: a. Submit qualifications of manufacturer when requested by ENGINEER.


A. Refer to Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.


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PART 2— PRODUCTS

2.1 COUPLINGS

A. Sleeve-type, Flexible Couplings:

1. Pressure and Service: Same as connected piping.

2. Products and Manufacturers: Provide products of one of the following: a. Style 253, as manufactured by Dresser Piping Specialties, part of Dresser,

Inc. b. Style 441, by Smith Blair, Inc. c. Or equal.

3. Material: Ductile Iron.

4. Gaskets: Suitable for specified service, as recommended by manufacturer

5. Bolts and Nuts: Alloy steel, corrosion-resistant, primer-coated. For buried or submerged applications, provide stainless steel bolts complete with washers complying with ASTM F593, AISI Type 316 and with nitrided stainless nuts.

6. Harnessing: a. Harness couplings to restrain pressure piping. For pipelines that will be

under pressure, test pressures are specified in piping schedules in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.

b. Tie adjacent flanges with bolts of corrosion-resistant alloy steel. Provide flange-mounted stretcher bolt plates to be designed by manufacturer, unless otherwise approved. For buried or submerged applications, provide external bolting and other hardware of Type 316 stainless steel, including tie bolts, bolt plates, lugs, nuts, and washers.

c. On plain-end piping, for harnessing couplings, provide anchor restraint system such as Dresser Piping Specialties STAR Anchor Style 443, or equal.

d. Conform to dimensions, size, spacing, and materials for lugs, bolts, washers, and nuts as recommended by manufacturer and approved by ENGINEER for pipe size, wall thickness, and test pressure required. Provide minimum 5/8-inch diameter bolts.

7. Remove pipe stop(s) if used, unless otherwise shown or specified.

B. Flanged Coupling Adapters:

1. Description: One end of adapter shall be flanged and opposite end shall have sleeve-type flexible coupling.

2. Products and Manufacturers: Provide one of the following: a. Style 227, as manufactured by Dresser Piping Specialties, part of Dresser,

Inc. b. Style 912, by Smith Blair, Inc. c. Or equal.

3. Pressure and Service: Same as connected piping.

4. Material: Ductile iron.

5. Gasket: Recommended by the manufacturer.


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6. Bolts and Nuts: Alloy steel, corrosion-resistant, primer-coated. For buried or submerged applications, provide stainless steel bolts complete with washers complying with ASTM F593, AISI Type 316 and nitrided stainless nuts.

7. Harnessing: a. Harness adapters to restrain pressure piping. For pressure pipelines, test

pressures are included in piping schedules in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.

b. For flanged adapters 12-inch diameter and smaller, provide 1/2-inch diameter (minimum) Type 316 stainless steel anchor studs installed in pressure-tight anchor boss. For buried or submerged applications, provide external bolting and other hardware of Type 316 stainless steel, including tie bolts, bolt plates, lugs, nuts, and washers. Provide number of studs required to restrain test pressure and service conditions. Harness shall be as designed and recommended by flanged adapter manufacturer. Provide the following minimum anchor studs unless otherwise approved by ENGINEER. 1) Six-inch Diameter and Smaller: Two 2) Eight-inch Diameter and Smaller: Four 3) Ten-inch Diameter and Smaller: Six 4) Twelve-inch Diameter and Smaller: Eight

c. For adapters larger than 12-inch diameter, provide split-ring harness clamps with minimum of four corrosion-resistant alloy steel bolts. For buried or submerged applications, provide external bolting and other hardware of Type 316 stainless steel, including tie bolts, bolt plates, lugs, nuts, and washers. Harness assembly shall be as designed and recommended by flanged adapter manufacturer. Dimensions, sizes, spacing and materials shall be suitable for service and conditions encountered and shall be approved by ENGINEER.

C. Dismantling Joints:

1. Joints shall be a self-contained flanged restrained joint fitting, including both flanged components and sufficient harness bars to withstand operating conditions of piping system.

2. Joints shall be provided for valves as indicated in the Valve Schedule in Section 40 05 53, Process Valves.

3. Joints shall conform to AWWA C219.

4. Pressure and Service: Same as connected piping. 5. Materials:

a. Spigot piece: ASTM A283 Steel. b. Flange Adapter: Ductile Iron or ASTM A 283 Steel. c. Tie bars: ASTM A 193 Grade B7 threaded rod with rolled ends. d. Gaskets: Suitable for wastewater use. e. Coating: Fusion-bonded epoxy, per Section 09 91 00, Painting.

6. Manufacturer: f. Smith-Blair, Inc., Series 975. g. Or Equal.


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2.2 TAPPING SLEEVE

A. Tapping sleeves: 1. Description: Full circumferential seal, all stainless stell tapping sleeve with

triangular side bar with mechanical joint outlet which meets MSS SP-124 and AWWA C223.

2. Products and Manufacturers: Provide one of the following: a. SST III-MJ Stainless Steel Tapping Sleeve, as manufactured by Romac

Industries Inc. b. Stainless steel tapping sleeve with mechanical joint outlet, as

manufactured by Ford Meter Box Company, Inc. c. Or equal

3. Maximum working pressure: 250 psi 4. Pressure and Service: Same as connected piping. 5. Material:

a. Shell and Lugs: Stainless Steel ASTM A240, Type 304 and type 304L b. Outlet: Ductile Iron ASTM A536

6. Outlet: MJ style in accordance with AWWA standard C111 7. Gasket: gridded virgin SBR per ASTM D2000 8. Side Bars: Triangular 9. Provide mechanical joint gaskets and high strength low alloy T-bolts and nuts

with all tapping sleeves

2.3 HDPE TO DUCTILE IRON ADAPTER

A. HDPE to ductile iron adaptor: 1 Description: AWWA compliant adaptor for connecting DR-9 (DIPS HDPE)to

mechanical joint ductile iron pipe and fittings. 2. Products and Manufacturers: Provide one of the following:

a. Independent Pipe Products, Inc. b. Or equal

3. Provide stainless steel stiffener for insertion into HDPE pipe

2.4 VALVE BOX

A. Valve box:

1. Products and Manufacturers: Provide one of the following: a. Series 6860, as manufactured by Tayler/union b. Or equal

2. Provide 3 piece with lid which states "WATER"

2.5 CURB BOX

A. Curb Box:

1. Products and Manufacturers: Provide one of the following:


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a. Manufactured by Ford Meter Box Company, Inc. b. Or equal

2.6 CORPORATION STOPS

A. Corporation Stops:

1. Products and Manufacturers: Provide one of the following: a. Series F1000-4, as manufactured by Ford Meter Box Company, Inc. b. Or equal

2.7 CURB STOPS

A. Curb Stops:

1. Products and Manufacturers: Provide one of the following: a. Series B44-444, as manufactured by Ford Meter Box Company, Inc. b. Or equal

2.8 TAPPING SADDLE

A. Tapping Saddle:

1. Products and Manufacturers: Provide one of the following: a. Manufactured by Ford Meter Box Company, Inc. b. Or equal

2. Provide for 1.5" and 2" taps

2.9 METER BOX & LID

A. Meter Box & Lid:

1. Products and Manufacturers: Provide one of the following: a. Manufactured by Ford Meter Box Company, Inc. b. Or equal

2. Provide 24" x 30" meter box for 1" meters

3. Provide style W-3 meter box covers (11.5" opening with plastic inner lid with touch read receptacle. a. Cover shall state "WATER METER"

MISCELLANEOUS SPECIALTIES AND ACCESSORIES

A. Dielectric Connections: 1. General: Where copper pipe connects to steel pipe, cast-iron pipe, or ductile

iron pipe, provide either dielectric union or an insulating section of rubber or plastic pipe. When used, insulating section shall have minimum length of 12 pipe diameters.

2. Manufacturers: Provide products of one of the following: a. Epco Sales, Inc.


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b. Watts Regulator Company. c. Capitol Manufacturing Company. d. Or equal.

3. Dielectcric Unions: Rated for 250 psi, ANSI B16.39. 4. Insulating Sections: Rated for same pressure as associated piping test pressure.

Material shall be suitable for the application and service.

2.3 PAINTING

A. Shop Painting: 1. Clean and prime-coat ferrous metal surfaces of products in the manufacturer's

shop in accordance with Section 09 91 00, Painting, unless otherwise specified in this Section

2. Coat machined, polished and non-ferrous surfaces bearing surfaces and similar unpainted surfaces with corrosion prevention compound that shall be maintained during storage and until products are placed into operation.

B. Field painting shall conform to Section 09 91 00, Painting.

PART 3- EXECUTION

3.1 INSPECTION

A. Inspect materials for defects in material and workmanship. Verify compatibility of products with pipe, fittings, valves, and appurtenances.

3.2 INSTALLATION

A. Installation: 1. Install piping specialties in accordance with the Contract Documents and

manufacturer's instructions. 2. For buried installations, refer to Section 33 05 05, Buried Piping Installation. 3. For exposed installations, refer to Section 40 05 05, Exposed Piping

Installation.

B. Adjust expansion joints as required to ensure that expansion joints will be fully extended when ambient temperature is at minimum operating temperature, and fully compressed at maximum operating temperature for the system in which expansion joints are installed.



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SECTION 40 05 07

PIPE HANGERS AND SUPPORTS

PART 1 - GENERAL

1.1 DESCRIPTION

A. Scope: 1. CONTRACTOR shall provide all labor, materials, equipment, and

incidentals as shown, specified and required to design, furnish, and install all hangers, supports and appurtenances necessary to complete the Work.

B. Coordination: 1. Review installation procedures under other Sections and coordinate the

installation of items that must be installed with the pipe hangers and supports Work.

C. Related Sections: 1. Section 03 30 00, Cast-In-Place Concrete. 2. Section 05 50 13, Miscellaneous Metal Fabrications. 3. Section 09 91 00, Painting. 4. Section 40 05 06, Couplings, Adapters, and Specials for Process Piping.

1.2 REFERENCES

A. Standards referenced in this Section are listed below: 1. American Society for Testing and Materials, (ASTM).

a. ASTM A 575, Specification for Steel Bars Carbon, Merchant Quality, M-Grades.

b. ASTM E 84, Test Method for Surface Burning Characteristics of Building Materials.

2. Federal Specification, (FS). a. FS A-A-1192, Hangers, Pipe.

3. Manufacturers Standardization Society of the Valve and Fittings Industry, (MSS). a. MSS SP 58, Pipe Hangers and Supports-Materials, Design and

Manufacture. b. MSS SP 69, Pipe Hangers and Supports - Selection and Application.

4. Underwriters' Laboratories, Inc., (UL). a. UL 203, Pipe Hanger Equipment for Fire Protection Service.

40 05 07 - Pipe Hangers and Supports.doc

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A. Each type of pipe hanger or support shall be the product of one manufacturer.

B. Component Supply and Compatibility: 1. Obtain all equipment included in this Section regardless of the component

manufacturer from a single pipe hangers and supports manufacturer. 2. The pipe hangers and supports equipment manufacturer to review and

approve or to prepare all Shop Drawings and other submittals for all components furnished under this Section.

3. All components shall be specifically constructed for the specified service conditions and shall be integrated into the overall assembly by the pipe hangers and supports equipment manufacturer.

1.4 SUBMITTALS


a. Detailed drawings showing all hangers and supports for each piping system specified. Shop Drawings shall show location, installation, material, loads or forces, and deflection of all hangers and supports.

b. Each pipe system shall be analyzed for all loads and forces on the hangers and supports. Provide calculations of reaction forces to the structure to which they are fastened. Provide confirmation that hanger systems comply with support requirements and codes.

c. Submit and coordinate these with Shop Drawings required for all piping systems.

2. Product Data: a. Submit manufacturers' catalogs, literature, and engineering data on all

hangers and supports. Load ratings, materials and installation shall be consistent with the recommendations of the MSS SP 58, MSS SP 69 and Federal Specification A-A-1192.


A. Packing, Shipping, Handling and Unloading: 1. Deliver materials to the Site to ensure uninterrupted progress of the Work.

Deliver anchor bolts and anchorage devices which are to be embedded in cast-in-place concrete in ample time to prevent delay of that Work.

B. Storage and Protection: 1. Store materials to permit easy access for inspection and identification. Keep

all material off the ground, using pallets, platforms, or other supports. Protect steel members and packaged materials from corrosion and deterioration.


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2. Store materials in covered storage off the ground and prevent condensation.

C. Acceptance at Site: 1. All boxes, crates and packages shall be inspected by CONTRACTOR upon

delivery to the Site. CONTRACTOR shall notify ENGINEER, in writing, if any loss or damage exists to equipment or components. Replace loss and repair damage to new condition in accordance with manufacturer's instructions.

PART 2- PRODUCTS

2.1 GENERAL

A. Hangers and supports shall meet with the following requirements: 1. Standard and fabricated hangers and supports shall be furnished complete

with necessary inserts, bolts, nuts, rods, washers, and other accessories. 2. Generally, run piping in groups where practicable and parallel to building

wall. Provide minimum clearance of 1-inch between pipe and other work. 3. Install hangers or supports at all locations where pipe changes direction. 4. All hangers and supports shall be capable of adjustment after placement of

piping. 5. Different types of hangers or supports shall be kept to a minimum. 6. All suspended or supported ductile iron pipe shall have a hanger or support

adjacent to each hub. 7. Support vertical piping at each floor and between floors by stays or braces to

prevent rattling and vibration. 8. Hanger rods shall be straight and vertical. Chain, wire, strap or perforated

bar hangers shall not be used. Hangers shall not be suspended from piping. 9. Maximum support spacing unless otherwise shown or approved for standard

weight steel pipe shall be as follows:

Pipe Size (inches)

Maximum Pipe Span 1 (feet)

Steel Copper Plastic 2 Cast/Ductile Iron 4

3/8 to 3/4 5 6 Cont. 3 -

1 6 6 5 - 1-1/4 6 6 5 - 1-1/2 6 6 5 -

2 10 10 5 - 2-1/2 10 10 5 -

3 10 10 5 - 4 12 12 5 12 feet for

pressure 6 12 12 5


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40 05 07-3

Pipe Size (inches)

Maximum Pipe Span 1 (feet)

Steel Copper Plastic 2 Cast/Ductile Iron 4

8 12 12 5 Pipe

10 feet for soil pipe

10 12 - 5 12 12 - 10 14 12 - - 16 12 - - 18 12 - - 20 12 - - 24 12 - -

1Pipe shall not have pockets formed in the span due to sagging of the pipe between supports caused by the weight of the pipe, medium in the pipe, insulation, valves and fittings.

2Span shown is for Schedule 80 CPVC pipe at 100°F. Spans for other plastics, other CPVC pipe Schedules and pipes at higher temperatures shall be shortened in accordance with the pipe manufacturer's recommendations.

3Continuous means pipe shall be in unistrut or similar channel. 4 Pipe hanger and support selection shall be as shown and in this Section.

10. Maximum support spacing, unless otherwise shown for plastic pipe at ambient temperature, shall be one-half of the values specified for steel pipe.

11. Plastic pipe at temperature greater than 130°F shall be continuously supported in a metal cradle or tray.

12. Where proper hanger or support spacing does not correspond with joist or rib spacing, structural steel channels may be attached to joists or ribs and pipes suspended there from.

13. Prevent contact between dissimilar metals when supporting copper tubing, by use of copper plated, rubber or vinyl coated, or stainless steel hangers or supports.

14. Isolate thin walled stainless steel piping from carbon steel by use of plastic coated hangers or supports or by taping at points of contact with PVC or vinyl.

15. Supports and hangers shall be of a material that is compatible with the fluid being conveyed in such pipe being supported.

16. Anchors for pipe support systems shall be compatible or protected by a coating system which is compatible with the fluid being conveyed in such pipe being supported.

B. Expansion compensation shall be designed for individual exposed piping systems with the following Design Criteria: 1. AL = L x AT x a

a. Where AL = pipe length change (inches). b. L = pipe length between anchors (inches).


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c. AT = 100 (F). d. a = coefficient of thermal expansion (inches/inches/F).

2. Expansion compensation shall be designed as an integral part of the piping hanger, support and anchorage system.

3. Expansion compensation shall be achieved via expansion joints specified in Section 40 05 06, Couplings, Adapters, and Specials for Process Piping.

2.2 HANGERS AND SUPPORTS

A. Hangers and supports where shown shall be in accordance with detail drawings. Hangers and supports not shown shall be in accordance with MSS SP 58.

B. Products and Manufacturers: Provide one of the following:

Type Description Manufacturers Adjustable wrought clevis

Hangers, 1/2 inch through 30 inch Pipe

Figure 260 by Grinnell Figure B3100 or B3102 by B-Line

Carbon Steel Pipe Clamp

Riser Clamps, 1/2 inch through 30 inch Pipe

Figure 261 by Grinnel. Figure B3373 by B-Line

Cast iron saddle Pipe Saddles, 1-1/2 inch through 36 inch Pipe

Figure 258 by Grinnell Figure B3095 by B-Line

Cast iron saddle with steel yoke and nuts

Pipe Stanchion Saddle, 2-1/2 inch through 36 inch Pipe


Cast iron saddle and reducer with nipple

Adjustable Pipe Saddle Support, 2-1/2 inch through 36 inch Pipe


Fabricated heavy duty steel bracket

Wall Brackets, 1/2 inch through 36 inch Pipe


Channel Type Pipe Support

Hot dip galvanized steel conforming to ASTM A 570, Grade 33, 1-5/8 inches by 1-5/8 inches by 12 gauge

Figure PS200 by Grinnell

O.D. Tubing Clamp

Strut mounted clamp Figure PS1200 by Grinnell Figure B2000 by B-Line

Horizontal pipe support at flange

Flange support. Connecting flange must meet ANSI B16.1 Class 125 and ANSI B16.5 Class 155 standards

Figure B3094 with B3088 base Stand by B-Line


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Copper Pipe: 1/2-inch through 4-inch.

Type Description Manufacturers Adjustable wrought clevis.

Hangers for insulated Pipe. Figure 260 by Grinnell. Figure B3100 by B-Line.

Adjustable copper coated steel clevis.

Hangers for Uninsulated Pipe.

Figure CT65 by Grinnell. Figure B3104CT.

Copper tubing riser clamp.

Riser Clamps. Figure CT-121 by Grinnell. Figure B3373CT by B-Line.

Strut clamps for insulated copper tubing.

Strut Mounted Clamp. Figure B2000 by B-Line with B1999 Vibra Cushion.

Fabricated steel bracket for strut mounting.

Adjustable Strut Bracket. Figure 3064 by B-Line.

360 degrees with galvanized steel jacket.

Calcium Silicate Shield. Figure B3380-B3384 by B-Line.

C. Chemical Piping Systems: 1. All pipe supports and fasteners shall be glass fiber-reinforced plastic with a

flame spread rating of 25, in accordance with ASTM E 84. 2. Materials shall be manufactured by either the pultrusion or extrusion process. 3. All pipe supports shall have a surface veil over 100 percent of the surface

which, along with a filler system, shall protect against degradation from ultra-violet light.

4. All fasteners shall be manufactured from long glass fiber-reinforced polyurethane to ensure strength and corrosion resistance.

5. All-thread rods shall be made from vinylester resin. 6. Manufacturers: Provide products of one of the following:

a. Unistrut Company. b. Or equal.

2.3 ACCESSORIES

A. Hanger rods shall be made from ASTM A 575, with square head nut on top and running thread on bottom end.

B. Concrete Inserts:

1. Concrete inserts shall be as specified in Section 05 05 33, Anchor Systems.

C. Steel Beam Clamps:

1. Steel beam clamps shall be of malleable iron and conform to MSS SP 58 Type 21.


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D. Inserts for Pipe Insulation: 1. Insulated pipe, larger than 1-1/2-inches in diameter, shall be supported by a

rigid insert to protect the insulation. A steel metal saddle of sufficient gauge to carry the weight of the pipe and its fluid without deforming shall extend 2-inches minimum on each side of the rigid insert. The joints between insert and insulation shall be sealed before saddle is installed. Sizes up to 6-inches IPS shall be MSS SP 58, Type 40, and for sizes over 10-inches shall be MSS SP 58, Type 39.

E. Brackets: 1. Brackets for wall mounting shall conform to MSS SP-58 as follows:

a. Medium Duty Welded Steel Brackets: Type 32. b. Heavy Duty Welded Steel Bracket: Type 33. c. Side Beam Support: Type 34.

2. Heavy Duty: Forged steel conforming to Federal Specification WW-H-171C, Type 28, Grinnell Figure 292, Size 2 or equal.

F. Fabricated Pipe Rack: 1. Pipes shall be supported and anchored to the fabricated pipe rack as shown.

Clamps, rollers, and supports for piping shall conform to the general requirements of MSS SP 69.

2.4 PAINTING

A. Clean and prime ferrous metal surfaces in the shop in accordance with the requirements of Section 09 91 00, Painting.

B. Field painting shall conform to the requirements of Section 09 91 00, Painting.

PART 3- EXECUTION

3.1 INSTALLATION

A. Locate hangers, supports, and accessories to support piping, valves, and at all concentrated loads.

B. Locate hangers, supports, and accessories within maximum span lengths specified to support continuous pipeline runs unaffected by concentrated loadings.

C. Locate hanger, supports to prevent vibration or swaying and to provide for expansion and contraction. 1. Temperature differential specified in this Section. 2. Support piping independently so that equipment is not stressed by piping

weight or expansion.


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3. For Uninsulated Copper Pipe or Tubing: Clamps and supports, electroplated copper finish. Instrumentation tubing shall be supported in steel or aluminum troughs with covers. All tubing layout and connections shall be as approved by the manufacturer of the equipment.

4. Uncoated Hangers, Rods and Supports: Dip in zinc chromate primer before installation.

5. Maximum spacing for horizontal piping: a. Steel 1-Inch and Smaller: Seven feet. b. Steel 1-1/2-Inch and Larger: Ten feet. c. Brass or Copper 3-Inch and Smaller: Seven feet. d. Brass or Copper 4-Inch and Larger: Ten feet. e. Additional supports at:

1) Change in direction. 2) Branch piping and runouts over five feet. 3) Concentrated loads due to valves, strainers or other similar items.

f. Maximum support spacing for plastic pipe at ambient temperature shall be one-half the above values.

6. Hanger types for horizontal piping, except as noted and shown: a. Forged steel adjustable clevis type, rod support for all services. b. Slide Bases:

1) Pipe stand, brackets, trapeze or other equivalent structural support. 2) For piping 2-inches or larger.

c. For pipe and covering provide: 1) Saddles for rollers or slide bases. 2) Protective shields or saddles for all other types of supports.

d. Threaded Steel Rods: 1) Two inch vertical adjustment with two nuts each end for positioning

and locking. 2) Size hanger rods according to the schedule below, unless otherwise

noted:

Nominal Pipe Rod Diameter (Inches) (Inches) 2 and less 3/8 2-1/2 to 3-1/2 1/2 4 5/8 6 3/4 8 through 12 7/8 14 through 18 1 20 through 30 1-1/4

3) For Double Rod Hangers: One size smaller than above. 4) Connection to Structure for Piping to 2-Inches: Concrete inserts, or

expansion shields in shear into sides of beams.


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5) Connection to Structure for Piping 2-1/2-Inch or Larger: Concrete inserts, beam clamps or suitable bridging.

7. Vertical Piping: a. Base Support: Base elbow or welded equivalent.

1) Bearing plate on structural support. b. Guides not to exceed:

1) 25 feet for piping to 2-inches. 2) 36 feet for piping 2-1/2-inches or larger.

c. Top Support: 1) Special hanger or saddle in horizontal connection. 2) Provisions for expansion.

d. Intermediate Supports: Steel pipe clamp at floor. 1) Bolted and welded to pipe. 2) Extension ends bearing on structural steel or bearing plates.

e. For Multiple Pipes: Coordinate guides, bearing plates and accessory steel.

8. Insulated Piping: a. Horizontal Pipe Shields at Supports:

1) Minimum 120 degree arc. 2) Length equal to diameter of insulation 12-inch minimum. 3) To 6-Inch Pipe Size: No. 18 USSG galvanized steel.

b. Vertical Pipe Shields at Guides: 1) Full 360 degree arc, securely banded. 2) Length equal to diameter of insulation, 12-inch minimum. 3) To 6-Inch Pipe Size: No. 18 USSG galvanized steel.

D. Install items to be embedded before concrete placement.

E. Fasten embedded items securely to prevent movement during concrete placement.

F. Install hangers and support units on piping systems in accordance with manufacturer's recommendations.

G. Adjust hangers and supports and place gout for concrete supports to bring pipelines to specified elevations.

H. Bring all pipe systems up to operating pressures and temperatures. Cycle systems to duplicate operating conditions. Correct all support malfunctions.



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SECTION 40 05 08

WALL PIPES, FLOOR PIPES, AND PIPE SLEEVES

PART 1 - GENERAL

1.1 DESCRIPTION


as shown, specified and required to furnish and install all floor pipes, pipe sleeves, wall pipes, other wall pieces, and escutcheons to complete the Work.


with the installation of floor pipes, pipe sleeves, wall pipes, other wall pieces and escutcheons that must be installed with or within formwork, walls, partitions, ceilings and panels.

C. Related Sections: 1. Section 03 30 00, Cast-In-Place Concrete. 2. Section 07 92 00, Joint Sealants.

1.2 REFERENCES

A. Standards referenced in this Section are listed below: 1. American National Standards Institute, (ANSI).

a. ANSI B16.1, Cast-Iron Pipe Flanges and Flanged Fittings. b. ANSI B16.4, Gray-Iron Threaded Fittings.

2. American Water Works Association, (AWWA). a. AWWA C104 (ANSI A21.4), Cement-Mortar Lining for Ductile-Iron

Pipe and Fittings for Water. b. AWWA C110 (ANSI A21.10), Ductile-Iron and Gray-Iron Fittings, for

Water. c. AWWA C111 (ANSI A21.11), Rubber-Gasket Joints for Ductile-Iron

Pressure Pipe and Fittings. d. AWWA C115 (ANSI A21.15), Flanged Ductile-Iron Pipe with Ductile-

Iron or Gray-Iron Threaded Flanges. e. AWWA C151 (ANSI A21.51), Ductile-Iron Pipe, Centrifugally Cast, for

Water. f. AWWA C200, Steel Water Pipe 6-Inches and Larger.

40 05 08 - Wall Pipes, Floor Pipes, and Pipe Sleeves.doc

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A. Component Supply and Compatibility: 1. Obtain all equipment included in this Section regardless of the component

manufacturer from a single wall pipes, floor pipes and pipe sleeves manufacturer.

2. The wall pipes, floor pipes and pipe sleeves manufacturer to review and approve or to prepare all Shop Drawings and other submittals for all components furnished under this Section.

3. All components shall be specifically constructed for the specified service conditions and shall be integrated into the overall assembly by the wall pipes, floor pipes and pipe sleeves manufacturer.

1.4 SUBMITTALS


a.

Detailed drawings and data on all wall and floor pipe, and pipe sleeves. Submit and coordinate these with Shop Drawings required for all piping systems.


A. Comply with the requirements of Section 40 05 05, Exposed Piping Installation.

PART 2- PRODUCTS

2.1 MATERIALS

A. Wall and Floor Pipes: 1. Material: Same as specified for the piping connected to wall or floor pipe,

unless otherwise approved by ENGINEER. 2. End Connections: As shown. 3. Thickness: Same as specified for the piping connected to wall or floor pipe. 4. Collars: Provide collars at mid-point of wall for anchorage and

watertightness. 5. Pipes ends shall be flush with wall face, unless otherwise shown. 6. Drill and tap flanged ends and mechanical joint bells for studs. Provide studs

of same material as connected piping, except submerged and buried studs shall be of Type 316 stainless steel.

B. Pipe Sleeves: 1. Ferrous and Plastic Pipe: Use standard weight galvanized steel pipe, unless

otherwise shown. 2. Copper Pipe: Use Type K hard drawn copper pipe, unless otherwise shown.


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C. Cast Wall Sleeves: 1 Material: Ductile iron furnished with integral wall collar. 2. Dimensions: As required for mechanical joint pipe to pass through sleeve.

Length as required.

D. Link Seals: Provide link type mechanical seals suitable for 20 psi working pressure, corrosive service and accessible from one side, with glass-reinforced nylon pressure plate and stainless steel bolts and nuts. 1. Products and Manufacturers: Provide one of the following:

a. Link-Seal, as manufactured by Thunderline Corporation. b. Or equal.

E. Wall and Ceiling Plates: 1. Bare pipes passing through walls and ceilings in finished rooms: Provide

escutcheon plates of cast brass or cast-iron nickel plated, clevis or split ring and hinged with set screws.

2. Provide plated escutcheon plates of 18-gauge steel for insulated pipes passing through walls and ceilings in finished rooms.

PART 3- EXECUTION

3.1 INSTALLATION

A. Wall and Floor Pipes: Install as shown and in accordance with approved Shop Drawings.

B. Pipe Sleeves: 1. Use sleeves wherever pipes pass through walls, partitions, floors, and roofs,

unless otherwise shown. 2. Extend all sleeves through floor slabs a minimum of 2-inches above finished

floor. 3. Anchor sleeves to concrete and masonry walls as shown or otherwise

approved. 4. All sleeves through walls shall be flush with wall face. 5. All pipe joints and annular spaces in exterior walls or walls subjected to

hydrostatic pressure shall be completely watertight. 6. Use link type seals to seal sleeve against hydrostatic pressure. Size sleeves to

provide annular space required to suit the link type mechanical seals that are used.

7. Do not install sleeves and pipes through structural members, unless specifically shown and approved by ENGINEER.

8. Size sleeves to provide annular space as follows:


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Pipe Size

Less than 2-inches 2-inches to 4-inches 6-inches to 12-inches Over 12-inches

Sleeve ID Minus Pipe Or Insulation OD

1/2-inches to 3/4-inches 3/4 inches to 1-1/4-inches. 1-1/4 inches to 2-inches 2-inches to 3-inches

C. Install wall and ceiling plates in accordance with the manufacturer's recommendations and approved Shop Drawings.



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SECTION 40 05 17

COPPER PROCESS PIPE

PART 1— GENERAL

1.1 DESCRIPTION


as shown, specified, and required to furnish copper pipe and fittings. 2. Extent of piping is shown and indicated in the piping schedules in Section

33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.


installation of items to be installed with or before copper pipe Work.

C. Related Sections: 1. Section 33 05 05, Buried Piping Installation. 2. Section 40 05 05, Exposed Piping Installation.

1.2 REFERENCES

A. Standards referenced in this Section are: 1. ANSI/ASME B16.15, Cast Copper Alloy Threaded Fittings: Classes 125 and

150. 2. ANSI/ASME B16.18, Cast Copper Alloy Solder Joint Pressure Fittings. 3. ANSI/ASME B16.22, Wrought Copper and Copper Alloy Solder Joint Pressure

Fittings. 4. ANSI/ASME B16.23, Cast Copper Alloy Solder Joint Drainage Fittings:

DWV. 5. ANSI/ASME B16.24, Cast Copper Alloy Pipe Flanges and Flanged Fittings:

Classes 150, 300, 600, 900, 1500 and 2500. 6. ANSI/ASME B16.26, Cast Copper Alloy Fittings for Flared Copper Tubes. 7. ANSI/ASME B16.29, Wrought Copper and Wrought Copper Alloy Solder

Joint Drainage Fittings: DWV 8. ANSI/ASME B16.39, Malleable Iron Threaded Pipe Unions: Classes 150, 250,

and 300. 9. ANSI/ASME B16.42, Ductile Iron Pipe Flanges and Flanged Fittings: Classes

150 and 300. 10. ANSI/ASME B16.50, Wrought Copper and Copper Alloy Braze-Joint Pressure

Fittings. 11. ANSI/ASME B18.2.1, Square and Hex Bolts and Screws, Inch Series.

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12. ANSI/ASME B18.2.2, Square and Hex Nuts. 13. ASTM A194, Specification for Carbon and Alloy Steel Nuts for Bolts for High

Pressure or High Temperature Service, or Both. 14. ASTM A307, Standard Specification for Carbon Steel Bolts and Studs, 60,000

PSI Tensile Strength. 15. ASTM B32, Specification for Solder Metal. 16. ASTM B68, Specification for Seamless Copper Tube, Bright Annealed. 17. ASTM B88, Specification for Seamless Copper Water Tube. 18. ASTM B251, Specification for General Requirements for Wrought Seamless

Copper and Copper-Alloy Tube. 19. ASTM B302, Specification for Threadless Copper Pipe, Standard Sizes. 20. ASTM B306, Specification for Copper Drainage Tube (DWV). 21. ASTM D1330, Specification for Rubber Sheet Gaskets. 22. FS WW-U-516, Unions — Brass or Bronze. 23. NSF/ANSI 61, Drinking Water System Components - Health Effects.


A. Component Supply and Compatibility: 1. Unless otherwise approved, obtain all pipe, fittings, and appurtenances

included in this Section from a single copper pipe manufacturer. 2. Copper pipe Supplier shall review and approve or prepare all Shop Drawings

and other submittals for pipe, fittings, and appurtenances furnished under this Section.

B. Regulatory Requirements: 1. Pipe and fittings that will convey potable water or water that will be treated to

become potable, shall be certified by an accredited organization in accordance with NSF/ANSI 61 as being suitable for contact with potable water, and shall comply with requirements of authorities having jurisdiction at the Site.

2. Pipe and fittings materials and joint types shall comply with requirements of authorities having jurisdiction at Site.

1.4 SUBMITTALS

A. Action Submittals: Submit the following with Shop Drawings required under Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation: 1. Shop Drawings:

a. Detailed layout drawings for pipe, fittings, and appurtenances. 2. Product Data:

a. Detailed data on pipe, fittings, and appurtenances.



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a. Submit certificate signed by manufacturer of each material that material conforms to applicable referenced standards and the Contract Documents.



B. Maintain ASTM B68 pipe, fittings, and appurtenances free of scale and dirt during transportation, delivery, storage, and handling.

PART 2— PRODUCTS

2.1 MATERIALS

A. Potable Water and Sampling Pipe: 1. Pipe Materials: Comply with ASTM B88. 2. For interior, exposed pipe, provide Type L, hard-drawn tube. 3. For buried pipe and for exterior, exposed pipe, provide Type K, soft-annealed

tube. 4. Fittings shall be soldered except at valves, which may be flared or flanged

joints.

2.2 JOINTS

A. Refer to piping schedules at the end of Sections 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation for the service and joint type specified for each piping system.

B. Provide type of fittings corresponding to the specified joint type in accordance with Table 40 05 17-A.

TABLE 40 05 17-A COPPER PIPE JOINT TYPE AND FITTING SCHEDULE

Joint Type Fitting Type, Applicable Reference Standards Soldered ANSFASME B16.22,

ANSFASME B16.29 (DWV) Threaded ANSFASME B16.15 Brazed ANSFASME B16.50 Flared ANSFASME B16.26

Flanged ANSFASME B16.24 (bronze), ANSFASME B16.42 (ductile iron at dielectric connections)

C. When fully developed, the strength of the joint shall be greater than strength of adjoining pipe.


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D. Unions for Potable Water Service: Shall be bronze, 250-pound class, conforming to FS WW-U-516.

E. Dielectric Connections for Potable Water Service: 1. Manufacturers: Provide products of one of the following:

a. Watts Regulator Company. b. Wilkins, a Zurn company. c. Or equal.

2. Type: Union or flanged. 3. Ratings:

a. Unions: Rated for 250 psi, complying with ANSI/ASME B16.39. b. Flanges: Rated for 175 psi, complying with ANSFASME B16.42 (Ductile

Iron), or ANSI/ASME B16.24 (Bronze). 4. Bodies and flanges, and bolts and nuts shall be steel with galvanized coating.

Insulator shall be nylon; tailpiece shall be brass. Provide EPDM gaskets for pipe temperature up to 200 degrees F, and Viton gaskets for temperatures over 200 degrees F.

2.3 MARKING

A. Mark or label all materials with the following: 1. Metal or alloy designation. 2. Temper. 3. Size and schedule. 4. ASTM reference standard number. 5. Name and location of Supplier.

PART 3— EXECUTION

3.1 INSTALLATION

A. Refer to Section 33 05 05, Buried Piping Installation, for buried piping installation, disinfection, testing and cleaning.

B. Refer to Section 40 05 05, Exposed Piping Installation, for exposed piping installation, disinfection, testing and cleaning.



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SECTION 40 05 19

DUCTILE IRON PROCESS PIPE

PART 1— GENERAL

1.1 DESCRIPTION


as shown, specified, and required to furnish ductile iron pipe and fittings. 2. Extent of piping is shown on the Drawings. Piping schedules in Section

33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation, specify pipe service, diameter, material, lining, coating, pressure rating, joint type, and testing required.


installation of items to be installed with or before ductile iron pipe Work.

C. Related Sections: 1. Section 31 23 05, Excavation and Fill. 2. Section 09 91 00, Painting. 3. Section 33 05 05, Buried Piping Installation. 4. Section 40 05 05, Exposed Piping Installation. 5. Section 40 05 06, Couplings, Adapters, and Specials for Process Piping.

1.2 REFERENCES

A. Standards referenced in this Section are: 1. ANSI B18.2.1, Square and Hex Bolts and Screws Inch Series. 2. ANSI B18.2.2, Square and Hex Nuts. (Inch Series). 3. ASTM A193, Alloy Steel and Stainless Steel Bolting Materials for High-

Temperature Service. 4. ASTM A194, Specification for Carbon Steel and Alloy Steel Nuts for Bolts for

High-Pressure or High-Temperature Service, or Both. 5. ASTM A307, Specification for Carbon Steel Bolts and Studs, 60,000 psi

Tensile Strength. 6. ASTM A354, Specification for Quenched and Tempered Alloy Steel Bolts,

Studs and Other Externally Threaded Fasteners. 7. ASTM A563, Specification for Carbon and Alloy Steel Nuts. 8. ASTM B117, Practice for Operating Salt Spray (Fog) Apparatus. 9. ASTM C283, Test Methods for Resistance of Porcelain Enameled Utensils to

Boiling Acid. 10. ASTM D714, Test Method for Evaluating Degree of Blistering of Paints.

40 05 19 - Ductile Iron Process Pipe.doc

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11. ASTM D792, Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement.

12. ASTM D5162, Discontinuity (Holiday) Testing of Non-Conductive Protective Coating on Metallic Substrates.

13. ASTM E96, Test Methods for Water Vapor Transmission of Materials. 14. ASTM G14, Test Method for Impact Resistance of Pipeline Coatings (Falling

Weight Test). 15. ASTM G62, Test Methods for Holiday Detection in Pipeline Coatings. 16. ASTM G95, Test Methods for Cathodic Disbondment Test of Pipeline

Coatings (Attached Cell Method). 17. ANSI/AWWA C104, Cement-Mortar Lining for Ductile Iron Pipe and Fittings

for Water. 18. ANSI/AWWA C110, Ductile Iron and Gray Iron Fittings for Water. 19. ANSI/AWWA C111, Rubber-Gasket Joints for Ductile Iron Pressure Pipe and

Fittings. 20. ANSI/AWWA C115, Flanged Ductile Iron Pipe with Ductile Iron or Gray Iron

Threaded Flanges. 21. ANSI/AWWA C116, Protective Fusion-Bonded Epoxy Coatings for the

Interior and Exterior Surfaces of Ductile Iron and Gray Iron Fittings for Water Service.

22. ANSI/AWWA C151, Ductile Iron Pipe, Centrifugally Cast, for Water. 23. ANSI/AWWA C153, Ductile Iron Compact Fittings, 3 inch through 24 inch

and 54 inch through 64 inch for Water Service. 24. ANSI/AWWA C606, Grooved and Shouldered Type Joints. 25. European Standard (EN), EN 598: Ductile Iron Pipe, Fittings, Accessories and

Their Joints for Sewerage Applications. 26. MSS-SP 60, Connecting Flange Joint Between Tapping Sleeves and Tapping

Valves. 27. NACE RP0188, Discontinuity (Holiday) Testing of New Protective Coatings

on Conductive Substrates. 28. NAPF 500-03, Surface Preparation Standard for Ductile Iron Pipe and Fittings

Receiving Special External Coatings and/or Special Internal Linings. 29. NSF/ANSI 61, Drinking Water System Components - Health Effects. 30. SSPC PA 2, Measurement of Dry Coating Thickness with Magnetic Gages. 31. SSPC Painting Manual, Volume 1, Para. XIV.


A. Qualifications: 1. Manufacturer:

a. Manufacturer shall have a minimum of five years successful experience producing ductile iron pipe and fittings and shall be able to show evidence of at least five installations in satisfactory operation in the United States that are similar applications to the specified service.

b. Lining and coating products shall be manufactured by a firm with a minimum of five years successful experience in protecting pipelines


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exposed to the specified service conditions , and shall be able to show evidence of at least five installations in satisfactory operation in the United States that are similar applications to the specified service.

c. When not applied by the manufacturer, lining and coating Subcontractor shall have a minimum of five years successful experience in the application of the specified linings and coatings for similar applications for the specified service, and shall be able to show evidence of at least five installations in satisfactory operation in the United States.

B. Supply and Compatibility: 1. Unless otherwise approved, obtain all pipe, fittings, and appurtenances

included in this Section from a single ductile iron pipe manufacturer. 2. Ductile iron pipe manufacturer shall review and approve or prepare all Shop

Drawings and other submittals for pipe, fittings, and appurtenances furnished under this Section.

3. Pipe, fittings, and appurtenances shall be suitable for the specified service and shall be integrated into overall piping system by ductile iron pipe manufacturer.

4. Ductile iron pipe manufacturer shall be responsible for all products and all factory-applied linings and coatings, whether installed at pipe manufacturer's facility or at manufacturer's Supplier's facility.

C. Regulatory Requirements: 1. Pipe and fittings, including linings and coatings, that will convey potable water

or water that will be treated to become potable, shall be certified by an accredited organization in accordance with NSF/ANSI 61 as being suitable for contact with potable water, and shall comply with requirements of authorities having jurisdiction at Site.

1.4 SUBMITTALS

A. Action Submittals: Submit the following with Shop Drawings required under Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation: 1. Shop Drawings:

a. Detailed drawings and data for pipe, fittings, gaskets, appurtenances, linings, and coatings.

2. Product Data: a. Surface preparation and application reports and procedures as required for

lining and coating of pipe and fittings. Ductile iron pipe and fitting manufacturer and manufacturer and applicator of lining and coating, as specified, shall mutually determine recommended surface preparation and application methods, and provide written verification of mutually selected method in the submittals.

3. Samples: a. Submit Sample of pipe and fitting with each type of lining, for use at the


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Site to verify continuity, surface gloss, and color, as applicable, via visual inspection.

4. Test Procedures: For linings and coatings in pipe and fittings.


a. Submit certificate signed by manufacturer of each product that product conforms to applicable referenced standards and the Contract Documents.

b. Submit certificate signed by applicator of the linings and coatings stating that product to be applied conforms to applicable referenced standards and that the applicator shall conform to the Contract Documents.

2. Source Quality Control Submittals: a. Submit results of specified shop tests for pipe, fittings, linings, and

coatings. b. Lining and coating test coupons.

1.5 DELIVERY, STORAGE, AND HANDLING


PART 2 — PRODUCTS

2.1 MATERIALS

A. General: 1. Piping systems shall be suitable for their intended use. 2. Joints shall be as specified in Section 33 05 05, Buried Piping Installation and

Section 40 05 05, Exposed Piping Installation. If not specified, provide flanged joints for exposed piping and push-on or mechanical joints for buried piping. Provide couplings on pipe with plain or grooved ends where shown or where approved by ENGINEER.

B. Ductile Iron Pipe, Joints, and Fittings: 1. Flanged Pipe: Fabricate in accordance with ANSLAWWA C115.

a. Pressure Rating: As specified in piping schedule in Section 40 05 05, Exposed Piping Installation. If not otherwise specified, use Special Thickness Class 56 for three-inch to 54-inch diameter pipe and Pressure Class 56 for 60-inch and 64-inch diameter pipe.

2. Non-Flanged Pipe: Conform to ANSI/AWWA C151 for material, pressure, dimensions, tolerances, tests, markings, and other requirements. a. Pressure Class: As specified in piping schedules in Section 33 05 05,

Buried Piping Installation and Section 40 05 05, Exposed Piping Installation. If not otherwise specified, use Thickness Class 56.

b. Special Thickness Class: As specified in piping schedules in Section


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33 05 05, Buried Piping Installation and Section 40 05 05, Exposed Piping Installation.

3. Pipe Joints: a. Flanged Joints: Conform to AWWA C153 capable of meeting the

pressure rating or special thickness class, and test pressure specified in piping schedule in Section 40 05 05, Exposed Piping Installation. 1) Gaskets: Unless otherwise specified, gaskets shall be at least 1/8-inch

thick, ring or full-face as required for the pipe, of synthetic rubber compound containing not less than 50 percent by volume nitrile or neoprene, and shall be free from factice, reclaimed rubber, and other deleterious substances. Gaskets shall be suitable for the service conditions specified, specifically designed for use with ductile iron pipe and fittings. Gaskets shall be Flange TYTE Gaskets as manufactured by U.S. Pipe and Foundry Co or Equal.

2) Bolts: Comply with ANSI B18.2.1. a) Exposed: ASTM A307, Grade B. b) Buried or Submerged: ASTM A193, Grade B8M, Class 2, Heavy

hex, Type 316 stainless steel. 3) Nuts: Comply with ANSI B18.2.2.

a) Exposed: ASTM A563, Grade A, Heavy hex. b) Buried or Submerged: ASTM A194, Grade B8M, Heavy hex,

Type 316 stainless steel. b. Mechanical Joints: Comply with ANSLAWWA C111 and ANSFAWWA

C151, capable of meeting pressure rating or special thickness class, and test pressure specified in piping schedules in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation. 1) Glands: Ductile iron. 2) Gaskets: Plain tip. 3) Bolts and Nuts: High strength, low alloy steel. 4) Manufacturers: Provide products of one of the following:

a) Clow Water Systems Company b) Atlantic States Cast Iron Pipe Company c) Canada Pipe Company, Ltd. d) McWane Cast Iron Pipe Company e) Pacific States Cast Iron Pipe Company I) Griffin Pipe Products Co. g) American Cast Iron Pipe Co. h) U.S. Pipe and Foundry Co. i) Or equal.

c. Push-On Joints: Comply with ANSLAWWA C111 and ANSFAWWA C151, capable of meeting pressure class or special thickness class, and test pressure specified in piping schedules in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation. 1) Gaskets: Vulcanized SBR, unless otherwise specified. 2) Stripes: Each plain end shall be painted with a circular stripe to

provide a guide for visual check that joint is properly assembled.


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3) Products and Manufacturers: Provide one of the following: a) Tyton or Fastite Joint by Clow Water Systems, Atlantic States

Cast Iron Pipe Company, Canada Pipe Company, Ltd., McWane Cast Iron Pipe Company, Pacific States Cast Iron Pipe Company, and Griffin Pipe Products Company.

b) Fastite Joint by American Cast Iron Pipe Company. c) Tyton Joint by U.S. Pipe and Foundry Company. d) Or equal.

d. Grooved End Joints: Comply with ANSFAWWA C606. 1) Gaskets: Flush seal type designed for ductile iron that complies with or

exceeds requirements of ASTM D2000 2) Bolts and nuts: As specified for flanged joints. 3) Unless otherwise specified, grooved end couplings shall be rigid joint

for exposed service and flexible joint for buried service. 4) Products and Manufacturers: Provide one of the following:

a) Victaulic, Style 31. b) Or equal.

e. Restrained Joints: Restrained push-on joints shall be capable of being deflected after full assembly. Field cuts of restrained pipe are not allowed without approval of ENGINEER. 1) Products and Manufacturers: Provide restrained joints for mechanical

joint piping by one of the following: a) Megalug, Series 1100, by EBBA Iron Sales, Inc. b) MJ Coupled Joint, by American Cast Iron Pipe Co. c) MJ Field Lok, by U.S. Pipe and Foundry Co. d) Or equal.

2) Products and Manufacturers: Provide restrained joints for push-on joint piping by one of the following: a) Super-Lock Joint Pipe, by Clow Water Systems, a division of

Mc Wane, Inc. b) Lok-Ring Joint, or Flex-Ring Joint, by American Cast-Iron Pipe

Company. c) TR Flex Joint, by U.S. Pipe and Foundry Company. d) Snap-Lok, by Griffin Pipe Products Company. e) Or equal.

4. Flanged and Push-On Joint Fittings: Comply with AWWA C153. a. Material: Ductile iron. b. Pressure rating, gaskets, bolts, and nuts shall be as specified for flanged

joints. Pressure rating of fittings shall meet, but not exceed, specified pressure rating or special thickness class of the connected pipe.

5. Mechanical Joint Fittings: Comply with AWWA C153. a. Material: Ductile iron. b. Glands: Ductile iron. c. Pressure rating, gaskets, bolts, and nuts shall be as specified for

mechanical joints. Pressure rating of fittings shall meet, but not exceed, specified pressure rating or special thickness class of connected pipe.


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C. Cement-mortar Lining: 1. Where specified in piping schedules included with Section 33 05 05, Buried

Piping Installation and Section 40 05 05, Exposed Piping Installation, pipe and fittings shall be lined with bituminous seal coated cement-mortar lining in accordance with ANSI/AWWA C104.

D. Couplings: 1. Refer to Section 40 05 06, Couplings, Adapters, and Specials for Process

Piping.

E. Specials: 1. Transition Pieces:

a. Provide suitable transition pieces (adapters) for connecting to existing piping.

b. Unless otherwise shown or indicated, expose existing piping to determine 2. Taps:

a. Provide taps where shown or required for small-diameter piping, service laterals or instrumentation connections.

b. Provide corporation stops where shown or required. c. Where pipe wall thickness or tap diameter will not allow engagement of

2 full threads, provide tapping saddle with outlet joints conforming to requirements of Paragraph 2.1.B.3.a of this Section for four-inch through 12-inch diameter pipe, and Paragraph 2.1.B.3.b. for 14-inch through 54-inch diameter pipe.

d. For flanged connections on tapping saddle outlet branch, counterbore flange in accordance with MSS SP-60 dimensions. Inside diameter of outlet shall be 1/4-inch greater than nominal diameter.

3. Tangential Outlets: a. Provide tangential outlet fittings where shown or indicated. b. Flanged and grooved end joints are not allowed.

2.2 MARKING FOR IDENTIFICATION

A. In addition to identification markings specified in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation, also stamp, mark, and identify push-on joint and mechanical joint pipe with: 1. Name or trademark of manufacturer. 2. Weight, class or nominal thickness, and casting period. 3. Country where cast. 4. Year the pipe was produced. 5. Letters "DI" or "Ductile" shall be cast or metal stamped

B. In addition to identification markings specified in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation, also stamp, mark, and identify flanged pipe with:


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1. Flange manufacturer's mark, size, and letters "DI" cast or stamped on the flanges.

2. Fabricator's mark if other than flange manufacturer. 3. Length and weight.

C. In addition to identification markings specified in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation, also stamp, mark, and identify fittings with: 1. Manufacturer's identification. 2. Pressure rating. 3. Nominal diameters of openings. 4. Country where cast. 5. Number of degrees or fraction of the circle on bends. 6. Letters "DI" or "Ductile" cast on them.

2.3 EXTERIOR SURFACE PREPARATION AND COATINGS

A. General Coating Requirements: 1. Coating types are specified in piping schedules in Section 33 05 05, Buried

Piping Installation, and Section 40 05 05, Exposed Piping Installation.

B. Exposed Pipe and Fittings: 1. Surface Preparation:

a. Initial Surface Inspection: Pipe and fitting manufacturer and coating applicator shall inspect surface to be coated and mutually determine recommended NAPF 500-03 surface preparation method.

b. Surface Preparation: Prepare surface in accordance with recommended NAPF 500-03 method.

c. Finished Surface Inspection: Prepared surfaces shall be inspected by coating applicator prior to application to determine acceptability of finished surface. If surface is unacceptable, repeat surface preparation and re-application as necessary.

2. After recommended surface preparation, prime coat exterior ferrous metal surfaces of pipe and fittings in the shop in accordance with Section 09 91 00, Painting.

3. Field painting shall comply with Section 09 91 00, Painting.

C. Buried Pipe and Fittings: 1. Asphaltic Coating: Where specified in piping schedule in Section 33 05 05,

Buried Piping Installation, coat pipe and fittings with an asphaltic coating approximately one-mil thick, in accordance with ANSLAWWA C151, ANSFAWWA C115, ANSLAWWA C110, and ANSLAWWA C153, as applicable.

2. Fusion Bonded Epoxy Coating for Fittings: a. When specified in piping schedule in Section 33 05 05, Buried Piping

Installation, fittings shall be factory coated with 100 percent solids,


02270037.D001 7/31/15 10:10:32 AM 40 05 19-8

thermosetting, dry powder epoxy, in conformance with ANSI/AWWA C116.

b. Apply coating utilizing a method, recommended by manufacturer that meets requirements of this Section, with finished dry film thickness of at least six mils, with exception of joint areas, which shall receive at least a four-mil dry film thickness coating. Heat and cure fittings in accordance with coating manufacturer's recommendations.

c. Source Quality Control: Cut a test coupon from coated fitting no less than six inches in diameter, and approximately four inches long, and split coupon lengthwise into two equal sections. Surface preparation, application procedure, thickness, and curing parameters shall be the same for test coupon as for Project fittings. Perform the following tests on test coupon: 1) Scribe coating material through to bare surface of fitting with an "X"

across full length of test coupon. Immerse coupon for 500 hours in 150-degree F bath of distilled water. Coating shall show no signs of disbondment or blistering.

2) Test coupon shall be impact tested using AS TM G14 test method with 20 in.-lbf impact applied near center of convex section of test coupon. Coating shall show no signs of cracking or disbondment without

magnification. d. Manufacturer's Inspection and Certification:

1) All coated fittings shall be visually inspected by manufacturer and show no sign of blisters, cracks, or lack of coverage.

2) Check all coated fittings for coating thickness using magnetic film thickness gage utilizing method outlined in SSPC PA 2 Film Thickness Rating.

3) Holiday-test all coated fittings in accordance with ASTM D5162, NACE RP0188, and SSPC Painting Manual Volume 1, Paragraph XIV, with low-voltage, wet sponge holiday detector. Repair methods and materials for holidays shall be as recommended by coating manufacturer and made prior to shipment to the Site.

e. Products and Manufacturers: Provide one of the following: 1) PipeClad 1500, by Valspar Corporation. 2) Or equal.

PART 3— EXECUTION

3.1 INSPECTION

A. Inspect piping to assure that piping is free from defects in material and workmanship. Verify compatibility of pipe, fittings, gaskets, linings, and coatings.

B. Visually inspect at the Site coated or lined pipe and fittings with ENGINEER and compare to approved Samples to verify lining continuity, surface gloss, and color, as applicable. Notify pipe manufacturer of damaged or unacceptable products. Pipe


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manufacturer shall visit the Site and perform testing to verify conformance with the Contract Documents to determine if products require replacement or repair. Repair or replace unacceptable products at no cost to OWNER.

3.2 INSTALLATION AND FIELD QUALITY CONTROL

A. For buried piping installation and testing, refer to Section 33 05 05, Buried Piping Installation.

B. For exposed piping installation and testing, refer to Section 40 05 05, Exposed Piping Installation.



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SECTION 40 05 31

THERMOPLASTIC PROCESS PIPE

PART 1— GENERAL

1.1 DESCRIPTION


as shown, specified, and required to furnish and install thermoplastic piping and fittings.

2. Extent of piping is shown and shall be in accordance with piping schedules in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.


installation of items to be installed with or before thermoplastic piping Work.

C. Related Sections: 1. Section 33 05 05, Buried Piping Installation. 2. Section 40 05 05, Exposed Piping Installation.

1.2 REFERENCES

A. Standards referenced in this Section are: 1. AASHTO, Standard Specifications for Highway Bridges. 2. ASTM D1784, Specification for Rigid Poly (Vinyl Chloride) (PVC)

Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds. 3. ASTM D1785, Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe,

Schedules 40, 80 and 120. 4. ASTM D2464, Specification for Threaded Poly (Vinyl Chlorinated) (PVC)

Plastic Pipe Fittings, Schedule 80. 5. ASTM D2466, Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe

Fittings, Schedule 40. 6. ASTM D2467, Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe

Fittings, Schedule 80. 7. ASTM D2513, Specification for Thermoplastic Gas Pressure Pipe, Tubing, and

Fittings. 8. ASTM D2564, Specification for Solvent Cements for Poly (Vinyl Chloride)

(PVC) Plastic Piping Systems. 9. ASTM D2665, Specification for Poly (Vinyl Chloride) (PVC) Plastic Drain,

Waste, and Vent Pipe and Fittings.

40 05 31 - Thermoplastic Process Pipe.doc

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10. ASTM D683, Specification for Socket-Type Polyethylene Fittings for Outside Diameter-Controlled Polyethylene Pipe and Tubing.

11. ASTM D3034, Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings.

12. ASTM D3035, Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on Controlled Outside Diameter.

13. ASTM D3139, Specification for Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals.

14. ASTM D3212, Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals.

15. ASTM D3222, Unmodified Poly (Vinylidene Fluoride) (PVDF) Molding Extrusion and Coating Materials.

16. ASTM D3261, Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing.

17. ASTM D3311, Specification for Drain, Waste and Vent (DWV) Plastic Fittings Patterns.

18. ASTM D3350, Specification for Polyethylene Plastic Pipe and Fittings Materials.

19. ASTM D4101, Specification for Polypropylene Injection and Extrusion Materials.

20. ASTM F437, Specification for Threaded Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80.

21. ASTM F438, Specification for Socket-Type Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 40.

22. ASTM F439, Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80.

23. ASTM F441/F441M, Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80.

24. ASTM F442/F442M, Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe (SDR-PR).

25. ASTM F477, Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe.

26. ASTM F656, Specification for Primers for Use in Solvent Cement Joints of Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings.

27. ASTM F679, Specification for Poly (Vinyl Chloride) (PVC) Large-Diameter Plastic Gravity Sewer Pipe and Fittings.

28. ASTM F714, Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on Outside Diameter.

29. ASTM F1055, Specification for Electrofusion Type Polyethylene Fittings for Outside Diameter Controlled Polyethylene Pipe and Tubing.

30. ASTM F1336, Specification for Poly (Vinyl Chloride) (PVC) Gasketed Sewer Fittings.

31. ASTM F1674, Standard Test Method for Joint Restraint Products for Use with PVC Pipe.

32. ASTM F1760, Specification for Coextruded Poly (Vinyl Chloride) (PVC) Non-Pressure Plastic Pipe Having Reprocessed-Recycled Content.


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33. AWWA C900, Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4 In.-12 In. (100 mm-300 mm), for Water Transmission and Distribution

34. AWWA C901, Polyethylene (PE) Pressure Pipe and Tubing, 1/2 In. (13 mm) Through 3 In. (76 mm), for Water Service.

35. AWWA C905, Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 14 In.-48 In. (350 mm-1,200 mm).

36. AWWA C906, Polyethylene (PE) Pressure Pipe and Fittings, 4 In. (100 mm) Through 63 In. (1,600 mm), for Water Distribution and Transmission.

37. AWWA C907, Injection-Molded Polyvinyl Chloride (PVC) Pressure Fittings, 4 In. Through 12 In. (100 mm Through 300 mm).

38. NSF 14, Plastic Piping Systems Components and Related Material. 39. ANSI/NSF 61, Drinking Water System Components - Health Effects. 40. Standards of U.S. Food and Drug Administration.


A. Qualifications: 1. Manufacturer: Shall have a minimum of five years experience producing

thermoplastic pipe and fittings substantively similar to the materials specified, and shall be able to submit documentation of satisfactory service in at least five completed installations in operation for at least five years each.

2. Installer: a. Engage a single pipe installer who shall be responsible for all

thermoplastic pipe Work, and who shall employ only tradesmen with specific skills and experience in the type of Work required.

b. Installer shall have a minimum of five years experience installing thermoplastic pipe and fittings substantively similar to the materials specified and substantively similar to or larger than the scope of thermoplastic piping Work on the Project, and shall be able to submit documentation of satisfactory experience in at least five completed installations in operation for at least five years each.

B. Component Supply and Compatibility: 1. Obtain all materials included in this Section, regardless of component Supplier,

from a single thermoplastic pipe Supplier. All pipe of each material type shall be furnished by the same manufacturer.

2. Thermoplastic pipe Supplier shall review and approve to prepare all Shop Drawings and other submittals for all materials furnished under this Section.

3. Materials shall be suitable for specified service conditions and shall be integrated into overall assembly by thermoplastic pipe Supplier.

1.4 SUBMITTALS



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a. Submit piping layout Shop Drawings in accordance with Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.

2. Product Data: a. Submit product data on pipe, fittings, gaskets, hardware, and appurtenances

sufficient to demonstrate compliance with the Contract Documents.


a. Submit manufacturer's certificate of compliance standards referenced in this Section.

2. Source Quality Control Submittals: a. When requested by ENGINEER, submit results of source quality control

tests. 3. Qualifications Statements:

a. Submit qualifications of manufacturer when requested by ENGINEER. b. Submit qualifications of installer when requested by ENGINEER.



PART 2 — PRODUCTS

2.1 SERVICE CONDITIONS

A. General: 1. Pipe materials shall be suitable for services intended. Refer to piping schedules

in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.

2. Pipe shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions, and other defects. Unless otherwise shown or indicated, pipe shall be uniform in color, opacity, density, and other physical properties.

3. Comply with NSF 14. 4. Buried pipe shall be capable of withstanding external live load, including

impact, equal to AASHTO H-20 loading, with cover shown or indicated on the Drawings.

5. Pipe, fittings, and appurtenances in contact with potable water or water that will be treated to become potable shall be listed in ANSI/NSF 61 as being suitable for contact with potable water, and shall comply with requirements of the authorities having jurisdiction at the Site.

2.2 POLYVINYL CHLORIDE (PVC) PIPING


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A. PVC Pipe — General Applications: Unless otherwise shown or indicated, PVC pipe shall comply with the following: 1. Manufacturers: Provide products of one of the following:

a. Ipex, Inc. b. Spears Manufacturing Company. c. Or equal.

2. Material: Unless otherwise specified, comply with the following: a. Type and Grade: Type 1, Grade 1. b. Wall Thickness: Schedule 80 complying with ASTM D1784 and ASTM

D1785, and US Product Service PS 21-70 as having same outside diameter dimension as cast-iron pipe.

c. Temperature Rating: Rated for temperature to 140 degrees F. d. Color: Gray.

3. Fittings: Type, grade, schedule, and color of fitting shall match the associated

pipe. a. Solvent Weld: Comply with ASTM D2467. b. Threaded: Threaded fittings shall comply with ASTM D2464. c. Flanged: Provide flanged fittings with gaskets as recommended by the

manufacturer for intended service condition. 4. Joints:

a. Solvent Weld: Use primer and solvent cement recommended by PVC pipe manufacturer for the application. Primer shall be in accordance with ASTM F656, and solvent cement shall be in accordance with ASTM D2564.

b. Threaded: Use 100 percent virgin polytetrafluoroethylene (Teflon or PTFE) tape for threaded fittings. Pipe shall not be threaded.

c. Flanged: Provide with backup flange minimum 1/8-inch thick. Backup flanges and connecting bolts shall be Type 304 stainless steel.

2.3 IDENTIFICATION

A. Pipe material identification requirements are in Section 33 05 05, Buried Piping Installation, and Section 40 05 05, Exposed Piping Installation.

2.4 SOURCE QUALITY CONTROL

A. Shop Tests: 1. Pipe manufacturer shall maintain continuous quality control program. 2. Where applicable and when requested by ENGINEER, submit results of

source quality control tests specified in reference standards. 3. CPVC plastic molding materials used for manufacturing pipe and fittings

under this Section shall be tested for compliance with ASTM D1784.


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PART 3- EXECUTION

3.1 INSPECTION

A. Inspect pipe materials for defects in material and workmanship. Verify compatibility of pipe and fittings.

3.2 INSTALLATION

A. For buried piping installation, refer to Section 33 05 05, Buried Piping Installation.

B. For exposed piping installation, refer to Section 40 05 05, Exposed Piping Installation.



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SECTION 40 05 33

HIGH DENSITY POLYETHYLENE PROCESS PIPE

PART 1 - GENERAL

1.1 DESCRIPTION


as shown, specified and required to furnish, test, and place in satisfactory service the High Density Polyethylene (HDPE) process pipe and fittings as shown.

2. The extent of HDPE pipe and fittings to be furnished is shown and in the piping schedules included in Section 33 05 05, Buried Piping Installation.

B. Coordination:

1. Review installation procedures under other Sections and coordinate the installation of items that must be installed with, or before, the HDPE process pipe Work.

C. Related Sections:

1. Section 03 30 00, Cast-In-Place Concrete. 2. Section 09 91 00, Painting. 3. Section 33 05 05, Buried Piping Installation. 4. Section 33 05 23.13, Utility Horizontal Directional Drilling. 5. Section 40 05 19, Ductile Iron Process Pipe 6. Section 40 05 53, Process Valves, Four-inch Diameter and Larger.

1.2 REFERENCES

A. Standards referenced in this Section are listed below: 1. American Society for Testing and Materials, Inc., (ASTM).

a. ASTM D 638, Test Method for Tensile Properties of Plastics. b. ASTM D 696, Standard Test Method for Coefficient of Linear Thermal

Expansion of Plastics between - 30°C and 30°C with a Vitreous Silica Dilatometer.

c. ASTM D 746, Test Method for Brittleness Temperature of Plastics and Elastomers by Impact.

d. ASTM D 790, Test Methods for Flexural Properties of LTnreinforced and Reinforced Plastics and Electrical Insulating Materials.

e. ASTM D 1238, Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer.

40 05 33 - High Density Polyethylene Process Pipe.docx

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f. ASTM D 1505, Test Method for Density of Plastics by the Density-Gradient Technique.

g. ASTM D 1525, Test Method for Vicat Softening Temperature of Plastics.

h. ASTM D 1598, Test Method for Time-to-Failure of Plastic Pipe under Constant Internal Pressure.

i. ASTM D 1599, Test Method for Resistance to Short-Time Hydraulic Failure Pressure of Plastic Pipe, Tubing, and Fittings.

j. ASTM D 1603, Test Method for Carbon Black in Olefin Plastics. k. ASTM D 1693, Test Method for Environmental Stress-Cracking of

Ethylene Plastics. 1. ASTM D 2122, Test Method for Determining Dimensions of

Thermoplastic Pipe and Fittings. m. ASTM D 2240, Test Method for Rubber Property-Durometer Hardness. n. ASTM D 2290, Test Method for Apparent Hoop Tensile Strength of

Plasticor Reinforced Plastic Pipe by Split Disk Method. o. ASTM D 2412, Test Method for Determination of External Loading

Characteristics of Plastic Pipe by Parallel-Plate Loading. p. ASTM D 2657, Practice for Heat Fusion Joining of Polyolefin Pipe and

Fittings. q. ASTM D 2774, Practice for Underground Installation of Thermoplastic

Pressure Piping. r. ASTM D 2837, Test Method for Obtaining Hydrostatic Design Basis for

Thermoplastic Pipe Materials or Pressure Design Basis for Thermoplastic Pipe Products.

s. ASTM D 3035, Specification for Polyethylene (PE) Plastic Pipe (DR-PR), Based on Controlled Outside Diameter.

t. ASTM D 3261, Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing.

u. ASTM D 3350, Specification for Polyethylene Plastics Pipe and Fittings Materials.

v. ASTM F 412, Terminology Relating to Plastic Piping Systems. w. ASTM F 714, Specification for Polyethylene (PE) Plastic Pipe (SDR-

PR) Based on Outside Diameter. x. ASTM F 1248, Test Method for Determination of Environmental Stress

Crack Resistance (ESCR) of Polyethylene Pipe. 2. American Water Works Association, (AWWA).

a. AWWA C901, Polyethylene (PE) Pressure Pipe and Tubing, 1/2-inch through 3-inch, for Water Service.

b. AWWA C906, Polyethylene (PE) Pressure Pipe and Fittings, 4-inch through 63-inch, for Water Distribution.

3. National Science Foundation, (NSF). a. NSF 14, Plastics Piping Components and Related Materials.



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A. Manufacturer's Qualifications: 1. Manufacturer shall have a minimum of five years experience producing

substantial similar type materials and shall be able to show evidence of at least five installations in satisfactory operation for at least five years.

2. HDPE process pipe and fittings shall be the product of a single manufacturer. 3. The HDPE process pipe and fittings manufacturer shall have an established

Quality Assurance Program responsible for inspecting incoming and outgoing materials.

4. The HDPE process pipe and fittings manufacturer shall have an established Quality Assurance program responsible for assuring the long-term performance of materials and products.

5. The HDPE process pipe and fitting manufacturer shall maintain permanent Quality Assurance/Quality Control (QA/QC) records.

B. Installer's Qualifications: 1. Engage a single installer regularly engaged in HDPE process piping

installation and with experience in the installation of the types of materials required; and who agrees to employ only tradesmen with specific skill and experience in this type of Work. Submit name and qualifications to ENGINEER.

2. Engage a single installer for the entire HDPE process piping system with undivided responsibility for performance and other requirements.

C. Component Supply and Compatibility: 1. The HDPE process pipe and fittings manufacturer shall review and approve

or prepare all Shop Drawings and other submittals for all components furnished under this Section.

2. All components shall be specifically constructed for the specified service conditions and shall be integrated into the overall assembly by the HDPE process pipe and fittings manufacturer.

1.4 SUBMITTALS

A. Submit these with Shop Drawings required under Section 33 05 05, Buried Piping Installation and 33 05 23.13, Utility Horizontal Directional Drilling.

B. Action Submittals: Submit the following: 1. Shop Drawings:

a. Details of piping system including location of supports, restraints, fittings, anchors, vents, low-point drains, termination assemblies and all accessories necessary for piping system.

b. Pipe laying schedules. 2. Product Data:

a. Details of construction, fabrication, and pipe materials. b. Detailed procedures to be used in joining and installing piping system,

including manufacturer's recommendations.


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3. Testing Plans, Procedures, and Testing Limitations: a. Pipe testing procedures.

C. Informational Submittals: 1. Certificates:

a. Materials Certificates of Conformance: Submit certificates of conformance with Referenced Standards as required in Article 2.4, below.

b. Upon shipment, CONTRACTOR shall furnish the HDPE pipe manufacturer's Quality Assurance/Quality Control (QA/QC) certifications to verify that the materials supplied for the Project are in accordance with the requirements of this Section and a manufacturer's warranty covering materials and workmanship of the HDPE piping.

2. Suppliers Instructions: a. Detailed procedures to be used in joining and installing piping system,

including manufacturer's recommendations. 3. Qualifications Statements:

a. Installer's qualifications.


A. Refer to Sections 33 05 05, Buried Piping Installation.

PART 2- PRODUCTS

2.1 SYSTEM PERFOMANCE

A. HDPE piping system shall be specifically designed, constructed, and installed for the service intended and shall comply with the following service conditions.

2.2 PHYSICAL PROPERTIES

A. Materials used for the manufacture of polyethylene pipe and fittings shall meet the following physical property requirements:

Property Unit Test Procedure Value

1. Material Designation PPI/ASTM - 2. PPI Material Listing PPI TR-4 PE 4710 4. Cell Classification ASTM D 3350 445574C 5. Density g/cm3 ASTM D 1505 >0.947 6. Melt Index (E) g/10 min ASTM D 1238 <0.15 7. Flexural Modulus psi ASTM D 790 >110,000 8. Tensile Strength psi ASTM D 638 >3,500 9. SCG (PENT) hours ASTM D 1693 >500


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10. HDB psi ASTM D 2837 1,600 @ 23°C 11. UV Stabilizer (C) °A) carbon black ASTM D 1603 2 to 3

B. There shall be no evidence of splitting, cracking or breaking when the pipe is tested in accordance with Article 2.4, below.

C. Ring Stiffness Constant (RSC) values for the pipe can be directly related to the pipe's class designation. (Nominal RSC of Class 40 pipe = 40, etc.). The minimum RSC is 90 percent of the nominal.

D. The HDPE pipe and fittings shall be homogeneous throughout and free from visible cracks, holes, foreign inclusions or other injurious defects. The pipe shall be as uniform as commercially practical in color, opacity, density and other physical properties.

E. Clean rework or recycled material generated by the manufacturer's own production may be used as long as the pipe or fittings produced meet all the requirements of this Section.

2.3 PIPE AND FITTINGS

A. Dimensions: 1. Pipe Dimensions: The nominal inside diameter of the pipe shall be true to

the specified pipe size in accordance with AWWA C901 and AWWA C906. Standard laying lengths shall be 50 feet ± 2-inches.

2. Fitting Dimensions: Fittings such as couplings, wyes, tees, adapters, etc. for use in laying pipe shall have standard dimensions that conform to ASTM D 3261.

B. Pipe and fittings shall be produced from identical materials, meeting the requirements of this Section, by the same manufacturer. Special or custom fittings may be exempted from this requirement.

C. Pipe and fittings shall be pressure rated to meet the service pressure requirements specified by ENGINEER. Whether molded or fabricated, fittings shall be fully pressure rated to at least the same service pressure rating as the pipe to which joining is intended.

D. Molded fittings shall meet the requirements of ASTM D 3261 and this Section. At the point of fusion, the outside diameter and minimum wall thickness of fitting butt fusion outlets shall meet the diameter and wall thickness specifications of the mating system pipe. Fitting markings shall include a production code from which the location and date of manufacture can be determined. The manufacturer shall provide an explanation of the production codes used.

E. Reducing tees with branch diameters of 16-inches or less shall be saddle tees.


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F. Marking: 1. Each standard and random length of pipe and fitting in compliance with this

standard shall be clearly marked with the following information. a. ASTM or AWWA Standard Designation. b. Pipe Size. c. Class and Profile Number. d. Production Code. e. Standard Dimension Ratio (SDR).


A. At a minimum, incoming polyethylene materials shall be inspected for density in accordance with ASTM D 1505 and melt flow rate in accordance with ASTM D 1238. All incoming polyethylene materials shall be certified by the supplier. Certification shall be verified by CONTRACTOR and ENGINEER. Incoming materials shall be approved by Manufacturer's Quality Assurance Program before processing into finished goods.

B. Representative samples of polyethylene materials shall be tested against the physical property requirements required herein. Each extrusion line and molding machine shall be qualified to produce pressure rated products by taking representative production samples and performing sustained pressure tests in accordance with ASTM D 1598.

C. Quality Assurance test for representative pipe and fitting samples shall include:

Test Standard Pipe Fittings

Ring ESCR ASTM F 1248 Yes Not Applicable

Sustained pressure at 176°F/725 psi hoop stress: (f0>100 h) ASTM D 1598 Yes Yes

Sustained pressure at 73°F/1,600 psi hoop stress: (f0>1000 h) ASTM D 1598 Yes Yes

D. The HDPE pipe and fitting manufacturer shall certify that samples of their production pipe have undergone stress regression testing, evaluation, and validation in accordance with ASTM D 2837 and PPI TR-3. Under these procedures, the minimum hydrostatic design basis shall be certified by the pipe and fitting manufacturer to be 1,600 psi at 73.4°F and 1,000 psi at 140°F.

E. Material shall be listed in the name of the HDPE pipe and fitting manufacturer as required by the Plastics Pipe Institute (PPI) in PPI TR-4 with the following Standard Grade ratings:


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73.4°F 140°F 1. Hydrostatic Design Basis (HDB) 1,600 psi 1000 psi 2. Hydrostatic Design Stress (HDS) 1,000 psi 630 psi PPI material listing in the name of the resin supplier is not acceptable in meeting this requirement.

F. Inspection Requirements: 1. Notification: The HDPE pipe and fitting manufacturer shall notify

CONTRACTOR in advance of the date, time, and place of testing of the pipe in order that CONTRACTOR may be represented at the test.

2. Access: The OWNER'S representative shall have free access to the Inspection area of the manufacturer's plant. The manufacturer shall make available to the OWNER'S representative, without charge, all reasonable facilities for determining whether the pipe meets the requirements of this Section.

3. Certification: As the basis of the acceptance of the material, the manufacturer will furnish a certificate of conformance of these Specifications upon request. When prior agreement is being made in writing between ENGINEER, CONTRACTOR and the manufacturer, the manufacturer will furnish other conformance certification in the form of affidavit of conformance, test results, or copies of test reports.

4. All outgoing materials shall be inspected for diameter, wall thickness, length, straightness, out-of-roundness, concentricity, toe-in, inside and outside surface finish, markings, and end cut. Manufacturer's Quality Control Program shall perform tests of density, melt flow rate, carbon content, and carbon dispersion. In addition, samples of the pipe provided shall be tested for hoop tensile strength and ductility by either quick burst in accordance with ASTM D 1599 or ring tensile strength in accordance with ASTM D 2290. Molded fittings shall be subject to x-ray inspection for voids, and tests for knit line strength. All fabricated fittings shall be inspected for fusion quality and alignment.

G. Physical Test Requirements: 1. Sampling: The selection of the sample of pipe shall be as agreed upon by the

ENGINEER, CONTRACTOR and the manufacturer. In case of no prior agreement, any sample selected by the manufacturer shall be deemed adequate.

2. Sample size for flattening test will be one sample for each size and class of pipe for the Project.

3. Conditioning: Conditioning of samples prior to and during test shall be as agreed upon by the ENGINEER, CONTRACTOR and manufacturer. In case of no prior agreement, the conditioning procedure used by the manufacturer shall be deemed adequate.

H. Test Methods:


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1. Flattening: Three specimens of pipe, a minimum of 12-inches long, shall be flattened between parallel plates in a suitable press until the distance between the plates is 40 percent of the outside diameter of the pipe. The rate of loading shall be uniform and such that the compression is completed within two to five minutes. Remove the load, and examine the specimens for splitting cracking or breaking.

2. Pipe Ring Stiffness Constant: The pipe ring stiffness constant shall be determined utilizing procedures similar to those outlined in ASTM D 2412. The stiffness of HDPE pipe is defined in terms of the load, applied between parallel plates, which causes one percent reduction of pipe diameter. Test specimens shall be a minimum of two pipe diameters or four feet in length, whichever is less.

PART 3- EXECUTION

3.1 FIELD QUALITY CONTROL

A. Pipe may be rejected for failure to conform to these Specifications or following: 1. Fractures or cracks passing through pipe wall, except single crack not

exceeding 2-inches in length at either end of pipe which could be cut off and discarded. Pipes within one shipment shall be rejected if defects exist in more than five percent of shipment or delivery.

2. Cracks sufficient to impair strength, durability or serviceability of pipe. 3. Defects indicating improper proportioning, mixing, and molding. 4. Damaged ends, where such damage prevents making satisfactory joint. 5. Gouges or scrapes exceeding ten percent of the specified wall thickness.

B. Acceptance of fittings, stubs or other specifically fabricated pipe sections shall be based on visual inspection at Site and documentation of conformance to these Specifications.

C. CONTRACTOR to provide as-built of pipe end point and angle point coordinates and elevations prior to backfilling trench.

3.2 INSTALLATION

A. Refer to Section 33 05 05, Buried Piping Installation or Section 33 05 23.13 Utility Horizontal Directional Drilling

B. Heat Fusion of Pipe: 1. HDPE pipe and fittings joints shall be heat fused by a qualified technician;

trained and certified by the manufacturer in accordance with the manufacturer's recommended fusion procedures. Training must have occurred within the previous 12 months, or submittals verifying experience


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within the previous 12 months for all technicians performing heat fusion on polyethylene pipe and fittings.

2. Butt-fusion of pipes shall be performed in accordance with the manufacturer's recommendations as to equipment, fitting, appurtenances, and technique. Butt-fusion joining shall be 100% efficient offering joint weld strength equal to or greater than the tensile strength of the pipe.

3. Fusion process shall meet the requirements of ASTM D-3261. 4. At the point of fusion, the outside diameter and minimum wall thickness

shall meet the outside diameter and minimum wall thickness specifications of ASTM F-714.

5. The first butt fusion weld of each day's production welding and for each separate operator shall be tested by bent strap test method. No production welds shall be performed until successful completion of bent strap test.

6. Butt fusion equipment for joining procedures shall be capable of meeting conditions recommended by HDPE pipe manufacturer including, but not limited to, temperature requirements, alignment, and fusion pressures. The equipment used for the heat fusion joints shall be capable of recording the heating and fusion pressures used to join the HDPE pipe, recording heater temperature, and storing this information for future retrieval (data logger). Each field fusion shall be recorded by such equipment and this information shall be made compiled into daily log reports. Log reports shall be submitted to CONTRACTOR and ENGINEER daily. Reports shall also include the results of the bent strap tests.

7. For cleaning pipe ends, solutions such as detergents and solvents, when required, shall be used in accordance with manufacturer's recommendations.

8. Do not bend pipe to greater degree than minimum radius recommended by manufacturer for type and grade. Shop Drawings shall address locations and deflections of required fittings to prevent installation that exceeds a greater degree of bending than the manufacturer's recommended minimum bending radius for each size and class of HDPE pipe.

9. Do not subject pipe to strains that will overstress or buckle piping or impose excessive stress on joints.

10. Branch saddle fusions shall be joined in accordance with manufacturer's recommendations and procedures. Branch saddle fusion equipment shall be of size to facilitate saddle fusion within trench.

11. Before butt fusing pipe, inspect each length for presence of dirt, sand, mud, shavings, and other debris or animals. Remove debris from pipe.

12. Cover open ends of fused pipe at the end of each day's Work. Cap to prevent entry by animals or debris.

C. Flange Jointing: 1. Use on flanged pipe connection sections. 2. Connect slip-on Type 316 stainless steel backup flanges with Type 316

stainless steel nuts and bolts. 3. Butt fuse fabricated flange adapters to pipe. 4. Observe following precautions in connection of flange joints.


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a. Align flanges or flange/valve connections to provide tight seal. Require nitrile-butadiene gaskets if needed to achieve seal. Integral flange adapters and gaskets are required for flange/valve connections.

b. Place U.S. Standard round washers as may be required on some flanges in accordance with manufacturer's recommendations. Bolts shall be lubricated in accordance with manufacturer's recommendations.

c. Tighten flange bolts in sequence and accordance with manufacturer's recommendations. CAUTION: Do not over-torque bolts.

5. Pull bolt down by degrees to uniform torque in accordance with manufacturer's recommendation.

6. Install electrofusion couplers, where used, in accordance with manufacturer's specifications.

D. Mechanical Jointing: 1. Use on mechanical pipe connection sections. 2. Butt fuse fabricated mechanical joint adapters to pipe. 3. Provide internal stainless steel stiffener for adapter. 4. Provide other joint components in accordance with requirements for

mechanical joints in Section 40 05 19 Ductile Iron Process Pipe.

E. Pipe Placement: 1. Grade control equipment shall be of type to accurately maintain design

grades and slopes during installation of pipe. 2. Dewatering: Remove standing water in trench before pipe installation. 3. Unless otherwise specifically stated, install pipe in accordance with

manufacturer's recommendations. 4. Maximum lengths of fused pipe to be handled as one section shall be placed

according to manufacturer's recommendations as to pipe size, pipe SDR, and topography so as not to cause excessive gouging or surface abrasion, but shall not exceed 400 feet.

5. Cap pipe sections longer than single joining (usually 50 feet) on both ends during placement, except during fusing operations.

6. Notify ENGINEER prior to installing pipe into trench and allow time for ENGINEER'S inspection. a. Correct irregularities found during inspection.

7. Complete tie-ins within trench whenever possible to prevent overstressed connections.

8. Allow pipe sufficient time to adjust to trench temperature prior to testing, segment tie-ins or backfilling activity.

9. Install reducers adjacent to laterals and tees. 10. To reduce branch saddle stress, install saddles at slope equal to and

continuous with lateral piping. 11. Pipe shall be snaked in trench to allow a minimum of 12-inches/100 feet for

thermal contraction and expansion. 12. Allow extra length at future connection points to be cut to fit after backfill

and prior to tie-in.


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F. Saddle tees 8-inches and smaller may be field fabricated. Field fabrication may only be performed by persons trained and certified by the manufacturer. Submit certification of qualified persons before fabricating any saddle tees. Saddle tees larger than 8-inches must be factory manufactured.

3.3 LEAKAGE TESTS

A. Refer to Section 33 05 05, Buried Piping Installation.



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SECTION 40 05 53

PROCESS VALVES, FOUR-INCH DIAMETER AND LARGER

PART 1 - GENERAL

1.1 DESCRIPTION


incidentals as shown, specified, and required to furnish and install process valves, four-inch diameter and larger, and appurtenances, complete and operational.

2. Valves for digester gas and air have been specifically identified. All other valves are for liquid service.


installation of items that must be installed with or before process valves Work.

C. Related Sections: 1. Section 05 05 33, Anchor Systems. 2. Section 09 91 00, Painting. 3. Section 33 05 05, Buried Piping Installation. 4. Section 40 05 05, Exposed Piping Installation.

1.2 REFERENCES

A. Standards referenced in this Section are listed below: 1. American Bearing Manufacturers Association (ABMA). 2. ANSI B16.1, Cast-Iron Pipe Flanges and Flanged Fittings. 3. ANSI B16.34, Valves-Flanged, Threaded and Welding end. (ASME

B16.34). 4. ANSI/NSF 61 Drinking Water Components — Health Effects. 5. API STD 594, Check Valves, Flanged Lug, Wafer and Butt-Welding. 6. API STD 598, Valve Inspection and Testing. 7. API STD 609, Butterfly Valves: Double Flanged, Lug-Type and Wafer-

Type. 8. ASTM A126, Specification for Gray Iron Castings for Valves, Flanges and

Pipe Fittings. 9. ASTM A193/A193M, Specification for Alloy-Steel and Stainless Steel

Bolting Materials for High-Temperature Service. 10. ASTM A194/A194M, Specification for Carbon and Alloy Steel Nuts for

Bolts for High Pressure and High Temperature Service, or Both.

40 05 53 - Process Valves Four-inch Diameter and Larger.doc

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11. ASTM A240/A240M, Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications.

12. ASTM A276, Specification for Stainless Steel Bars and Shapes. 13. ASTM A307, Specification for Carbon Steel Bolts and Studs, 60,000 psi

Tensile Strength. 14. ASTM A351/A351M, Specification for Castings, Austenitic, Austenitic-

Ferritic (Duplex), for Pressure-Containing Parts. 15. ASTM A380, Practice for Cleaning, Descaling and Passivation of Stainless

Steel Parts, Equipment and Systems. 16. ASTM A536, Specification for Ductile Iron Castings. 17. ASTM A564/A564M, Specification for Hot-Rolled and Cold-Finished Age-

Hardening Stainless Steel Bars and Shapes. 18. ASTM A743/A743 M, Specification for Castings, Iron-Chromium, Iron-

Chromium-Nickel, Corrosion Resistant, for General Application. 19. ASTM B62, Specification for Composition Bronze or Ounce Metal

Castings. 20. ASTM B98/B98M, Specification for Copper-Silicon Alloy Rod, Bar, and

Shapes. 21. ASTM B138/B138M, Specification for Manganese Bronze Rod, Bar and

Shapes. 22. ASTM B265, Specification for Titanium and Titanium Alloy Strip, Sheet

and Plate. 23. ASTM B584, Specification for Copper Alloy Sand Castings for General

Applications. 24. ASTM D429, Test Methods for Rubber Property - Adhesion to Rigid

Substrates. 25. AWWA C500, Metal-Seated Gate Valves for Water Supply Service. 26. AWWA C501, Cast-Iron Sluice Gates. 27. AWWA C502, Dry-Barrel Fire Hydrants. 28. AWWA C504, Rubber-Seated Butterfly Valves. 29. AWWA C507, Ball Valves, 6-inch through 48-inch. 30. AWWA C508, Swing-Check Valves for Waterworks Service, 2-inch

through 24-inch NPS. 31. AWWA C509, Resilient-Seated Gate Valves for Water Supply Service. 32. AWWA C515, Standard for Reduced-Wall, Resilient-Seated Gate Valves

for Water Supply Service. 33. AWWA C540, Power-Actuating Devices for Valve and Slide Gates. 34. AWWA C550, Protective Interior Coatings for Valves and Hydrants. 35. AWWA Manual M49, Butterfly Valves: Torque, Head Loss, and Cavitation

Analysis. 36. FS TT-C-494, Coating Compound, Bituminous, Solvent Type, Acid-

Resistant. 37. NEMA MG 1, Motors and Generators.


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A. Manufacturer's Qualifications: 1. Manufacturer shall have minimum of five years of experience producing

substantially similar materials and equipment to that required and be able to provide evidence of at least five installations in satisfactory operation for at least five years.

B. Component Supply and Compatibility: 1. Obtain each type of equipment and appurtenances included in this Section,

regardless of the component manufacturer, from a single manufacturer of the type of process valve. For each type of valve, do not furnish valves of more than one manufacturer.

2. Supplier of each type of equipment specified shall review and approve or prepare all Shop Drawings and other submittals for all components associated with the type of process valve Supplier is furnishing.

3. Components shall be suitable for use in the specified service conditions. Components shall be integrated into the overall assembly by the process valve manufacturer.

1.4 SUBMITTALS


a. Installation drawings showing orientation of valve in both plan and elevation view. Drawings shall clearly identify valve and its appurtenances, including controls, actuators, valve stems, and other components. Show dimensions of valves and appurtenances in relation to piping and structural and architectural components, where applicable.

b. Controls for and control characteristics of modulating valves. c. Power and control wiring diagrams, including terminals numbers for

electric-motor actuators. d. Calculations for sizing of electric actuators. e. Calculations for sizing of operating mechanism with extension stems. f. Calculations for sizing of gear actuators.

2. Product Data: a. Product data sheets. b. Complete catalog information, including dimensions, weight,

specifications, and identification of materials of construction of all parts.


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c. Corrosion resistance information to confirm suitability of valve materials for the application. Furnish information on chemical resistance of elastomers from elastomer manufacturer.

d. Cv values and hydraulic headloss curves.

3. Samples: a. If requested by ENGINEER, furnish one foot of chain for chainwheel-

operated valves. 4. Testing Plans:

a. Submit plan for shop testing of each valve for which shop testing is specified, including testing plan's and test facility's limitations proposed.


a. Certificates of compliance with referenced standards, where applicable, including those of AWWA, NSF, and others required by ENGINEER.

2. Manufacturer Instructions: a. Submit manufacturer's instructions for handling, storing, and installing

valves and appurtenances. Provide templates and setting drawings for valves and appurtenances that require anchor bolts or similar anchorages.

3. Source Quality Control Submittals: a. Submit copies of shop test results and inspection data, certified by

manufacturer. 4. Field Quality Control Submittals:

a. Submit results of field tests required. 5. Supplier's Reports:

a. When requested by ENGINEER, submit written report of results of each visit to Site by Supplier's serviceman, including purpose and time of visit, tasks performed and results obtained.

6. Qualifications Statements: a. When requested by ENGINEER, submit manufacturer's qualifications

demonstrating compliance with the Specifications, including list of existing installations with contact names and telephone number(s) for each.

C. Closeout Submittals: Submit the following: 1. Operations and Maintenance Data:

a. Furnish operation and maintenance manuals in accordance with Section 01 78 23, Operations and Maintenance Data.

b. Furnish in operations and maintenance manuals complete nameplate data for each valve and electric actuator.

D. Maintenance Material Submittals: Submit the following:


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1. Spare Parts, Extra Stock Materials, and Tools: a. Spare Parts and Extra Stock Materials: Furnish as specified for each

valve type. b. Tools: Furnish two sets of special tools (excluding metric tools, if

applicable) for each size and type of valve furnished. 1.5 DELIVERY, STORAGE AND HANDLING

A. Packing, Shipping, Handling, and Unloading: 1. Deliver materials and equipment to Site to ensure uninterrupted progress of

the Work. Deliver anchorage products that are to be embedded in concrete in ample time to prevent delaying the Work.

2. Inspect boxes, crates, and packages upon delivery to Site and notify ENGINEER in writing of loss or damage to materials and equipment. Promptly remedy loss and damage to new condition in accordance with manufacturer's instructions.

3. Conform to Section 01 65 00, Product Delivery Requirements.

B. Storage and Protection: 1. Keep products off ground using pallets, platforms, or other supports. Store

equipment in covered storage and prevent condensation and damage by extreme temperatures. Store in accordance with manufacturer's recommendations. Protect steel, packaged materials, and electronics from corrosion and deterioration.

2. Conform to Section 01 66 00, Product Storage and Handling Requirements.

PART 2- PRODUCTS

2.1 GENERAL

A. Valves, General: 1. Provide each valve with manufacturer's name and rated pressure cast in

raised letters on valve body. 2. Provide valves with brass or Type 316 stainless steel nameplate attached

with Type 316 stainless steel screws. Nameplates shall have engraved letters displaying the following minimum information: a. Valve size. b. Pressure and temperature ratings. c. Application (other than water and wastewater). d. Date of manufacture. e. Manufacturer's name.

3. Provide valves to turn clockwise to close, unless otherwise specified. 4. Provide valves with permanent markings for direction to open. 5. Manually operated valves, with or without extension stems, shall require not

more than 40-pound pull on manual operator to open or close valve against specified criteria. Gear actuator and valve components shall be able to

40 05 53 Process Valves Four-inch Diameter and Larger.doc

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withstand minimum pull of 200 pounds on manual operator and input torque of 300-foot pounds to actuator nut. Manual operators include handwheel, chainwheel, crank, lever, and T-handle wrench.

B. Valve Materials: 1. Valve materials shall be suitable for the associated valve's service or

application, as shown. 2. Protect wetted parts from galvanic corrosion caused by contact of different

metals. 3. Wetted components and wetted surfaces of valves used with potable water

or water that will be treated to become potable shall conform to ANSI/NSF 61.

4. Valves used on drinking water shall be certified lead free in compliance with Public Law 111-380 Reduction of Lead in Drinking Water Act.

5. Clean and descale fabricated stainless steel items in accordance with ASTM A380 and the following: a. Passivate all stainless steel welded fabricated items after manufacture

by immersing in pickling solution of six percent nitric acid and three percent hydrofluoric acid. Temperature and detention time shall be sufficient for removing oxidation and ferrous contamination without etching surface. Perform complete neutralizing operation by immersing in trisodium phosphate rinse followed by clean water wash.

b. Scrub welds with same pickling solution or pickling paste and clean with stainless steel wire brushes or by grinding with non-metallic abrasive tools to remove weld discoloration, and then neutralize and wash clean.

C. Valve Joints: 1. Exposed Valves: Unless otherwise specified, provide with flanged ends

conforming to ANSI B16.1. Pressure class of flanges shall be equal to or greater than specified pressure rating of the associated valve.

2. Buried Valves: Unless otherwise specified, provide with mechanical or push-on joints, restrained or unrestrained, as required by piping with which valve is installed.

3. For stainless steel bolting, except where nitrided nuts are required, use graphite-free anti-seize compound to prevent galling. Strength of joint shall not be affected by using anti-seize compound.

2.2 RESILIENT-SEATED GATE VALVES

A. Manufacturers: Provide products of one of the following: 1. American 2. Clow 3. Muller 4. Or equal.


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B. General: 1. Provide valves conforming to AWWA C515 and as specified in this Section. 2. Sizes: Four-inch through 12-inch diameter, 16-inch and 20-inch diameter. 3. Type:

a. Provide non-rising stem (NRS) valves which open to the left for buried service.

b. For interior and exposed service, provide outside screw and yoke (OS&Y) rising-stem valves, unless otherwise specified.

c. Provide position indicators for NRS valves used in exposed service. 4. Minimum Rated Working Pressure:

a. Valves 12-inch Diameter and Smaller: 200 psig. b. Valves 16-inch and 20-inch Diameter: 150 psig.

5. Maximum Fluid Temperature: 150 degrees F. 6. Provide valves with fully encapsulated resilient wedges, unless otherwise

specified.

C. Materials of Construction: Shall conform to AWWA C515 and shall be as follows: 1. Valve Body, Bonnet, and Stuffing Box: Cast-iron. 2. Wedge: Cast-iron, symmetrically and fully encapsulated with molded rubber

having minimum 1/8-inch thickness. 3. Stem: Manganese bronze. 4. Rubber Items: Buna-N or other synthetic rubber suitable for the application. 5. Internal and external bolting and other hardware including pins, set screws,

plug, studs, bolts, nuts, and washers shall be Type 316 stainless steel.

D. Interior Coating: 1. Valves shall be coated inside. Steel, cast-iron and ductile iron surfaces,

except machined surfaces, shall be epoxy coated in accordance with AWWA C550.

E. Testing: 1. Test valves in valve manufacturer's shop in accordance with AWWA C515.

2.3 BUTTERFLY VALVES

A. Manufacturers: Provide products of one of the following: 1. DeZurik. 2 Henry Pratt Company. 3. Or equal.

B. General: 1. Provide butterfly valves conforming to AWWA C504 and as specified

herein. 2. Sizes:


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a. Flanged: Four-inch through 72-inch diameter. b. Mechanical Joint: Four-inch through 48-inch diameter.

3. Rated Working Pressure: 250 psig, Class 250B. 4. Maximum Fluid Temperature: 150 degrees F. 5. Valves shall provide drip-tight bi-directional shutoff at rated pressures. 6. Mount valve seats in valve body. Rubber seats for 24-inch diameter and

larger valves shall be replaceable in the field. 7. Valves shall be capable of being maintained in open or partially open

position for manual operation, and for automatic operation. When valve disc is maintained, there shall be no chatter or vibration of disc or operating mechanism.

8. Valve packing shall be replaceable without dismantling valve. 9. Disc shall be offset from shaft to provide uninterrupted 360-degree seat seal.

C. Materials of Construction: materials of construction shall conform to AWWA C504 and shall be as follows: 1. Body: Cast-iron, ductile iron, or alloy cast-iron. 2. Shaft: Type 316 stainless steel. 3. Discs:

a. Valves Smaller than 30-inch Diameter: Cast-iron. b. Valves 30-inch Diameter and Larger: Ductile iron.

4. Seats: Buna-N or other synthetic rubber suitable for the application. 5. Seating Surfaces: Type 316 stainless steel. 6. Bearings:

a. Valves Smaller than 24-inch Diameter: Nylon. b. Valves 24-inch Diameter and Larger: Fiberglass with Teflon lining.

7. Shaft Seals: Externally adjustable, material same as for seats. For services that are either buried or submerged, self-adjusting V-type chevron, material same as for seats.

8. Tapered Pins for Attachment of Shaft to Disc: Type 316 stainless steel. 9. Internal and external bolting and other hardware; including pins, set screws,

studs, bolts, nuts, and washers shall be Type 316 stainless steel.

D. Interior Coating: 1. Valves shall be coated inside. Steel, cast-iron, and ductile iron surfaces,

except machined surfaces, shall be epoxy-coated in accordance with AWWA C550.

E. Testing: 1. Test each valve in the manufacturer's shop in accordance with AWWA

C504.

F. Gear Actuators for Manual Valves: 1. Provide gear actuators conforming to AWWA C540.


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2. Gear actuators for valves 20-inch diameter and smaller shall be constructed for 250 psi differential pressure and 16 feet per second port velocity.

3. Gear actuators for valves 24-inch diameter and larger shall be constructed for maximum differential pressures and velocities as specified below: a. Valve Size and Location: See Drawings.

2.4 PUMP CONTROL VALVES

A. Manufacturers: Provide products of one of the following: 1. GA Industries, Inc, Series 1600-M "CHECKtronic*" and Model 7700A

Pump Director Controller. 2. Or equal.

B. General: 1. Application: Valve shall function to minimize surges associated with the

normal starting and stopping of pumps. The valve shall slowly open after the pump has come up to speed and pressure at pump start. A normal pump shutdown shall be initiated by the valve slowly closing against the running pump, turning off the pump only after the valve has completely closed. The valve shall quickly close independently of the actuator upon flow reversal resulting from power outage, pump or pump motor failure or other sudden stoppages of pumping.

2. Rated Working Pressure: a. Smaller than 14-inch Diameter: 400 psig, Class 125 Flanges. b. 14-inch through 24-inch Diameter: 300 psig, Class 250 Flanges.

3. Size: As shown on the Drawings. 4. Provide pressure switch with valve assembly. Pressure switch shall be in

accordance with Section 40 70 05, Primary Sensors and Field Instruments.

C. Materials of Construction: 1 Body and Cover: Cast-iron, ASTM A126 Class B. 2. Disc: Ductile Iron, ASTM A536. 3. Body Seat, Seat Follower: Type 316 Stainless Steel. 4. Stem: Type 303 Stainless Steel. 5. Disc Seat Ring: Ultra High Molecular Weight Polyethylene (LTHMWPE). 6. 0-Rings and Gaskets: Buna N. 7. Gland, Bushing: Brass, C36000 8. Internal Wetted Fasteners: Type 18-8 Stainless Steel. 9. Actuator Bracket and Adapter: Steel, ASTM A36. 10. Spring: Steel, ASTM A229. 11. External Fasteners: Steel, ASTM A307. 12. Threaded Stem: Type 18-8 Stainless Steel.

D. Electric Motor Actuators: 1 Pump control valves shall be installed with electric motor actuators.

Electric motor actuators shall be multi-turn, non-modulating with integral


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limit switches, torque switches, visual position indicator and manual hand wheel.

2. Controls shall include reversing starter, control transformer, local-off-remote selector, indicating lights and open/close push buttons. The actuator shall provide a minimum valve operating time of 60 seconds with an integral stepping mode to extend the operating time over any portion of the valve stroke. The start/end and the on/off pulse time shall be field adjustable.

3. Electric motor actuators shall be as specified in Paragraph 2.5 of this section.

E. Interior Coating: 1. Valves shall be coated inside. Steel, cast-iron and ductile iron surfaces shall

be epoxy coated in accordance with AWWA C550.

F. Testing: 1. Test each assembled valve, except control piping, hydrostatically at 1.5

times the rated working pressure for minimum of five minutes per valve. 2. Test each valve for leakage at valve's rated working pressure against closed

valve. Test duration shall be minimum 15 minutes per valve and allowable leakage shall be zero.

3. Perform functional test on each valve to verify proper operation at specified performance.

G. Pump Control Valve Local Control Panel: 1. General:

a. Provide three Local Control Panels for Pump Control Valves at Benner Road Pump Station as specified below.

b. Provide four Local Control Panels for Pump Control Valves at Heincke Road Pump Station as specified below, except: 1) PLC I/O is future. 2)Pump number 4 control valve is existing. Coordinate with existing

valve in field. 2. Provide a Local Control Panel for each Pump Control Valve. Local Control

Panel shall include the following: a. Solid state processor and I/0 cards capable of logic described below

(Paragraph 9). b. LCD touchscreen front panel. Minimum 5.7" screen size, 256 color.

Local operator status shall be illuminated on touchscreen. Data input shall be possible by virtual keypad via the touchscreen panel.

c. Panel heater with integral thermostat. d. Local-off-Remote selector switch. e. Emergency Stop pushbutton. f. Screw-type terminal blocks for I/O points. Provide minimum of eight

spare terminal blocks.


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3. Enclosure: NEMA 4X fiberglass with gasketed door, gasketed touchscreen panel, continuous stainless steel hinge, stainless steel twist/latch door fasteners, and padlockable door hasp.

4. Provide "LOCAL/OFF/REMOTE" selector switch. a. When the selector switch is in the "LOCAL" position:

1) "OPEN/CLOSE" commands via control panel touch screen shall operate the valve. 2) "START" command via control panel touch screen shall initiate the Booster Pump Start Sequence.

3) "STOP" command via control panel touch screen shall initiate the Booster Pump Stop Sequence.

b. When the selector switch is in the "OFF" position, actuator shall be disabled from local and remote operation.

c. When the selector switch is in the "REMOTE" position, the valve shall open/close, and booster pump start/stop and speed control shall be in accordance with the logic as described below (Paragraph 9). Provide contact when switch is in "REMOTE" position for remote indication.

5. Provide "OPEN/CLOSE" commands via control panel touch screen. 6. Provide "START/STOP" commands via control panel touch screen. 7. Provide "OPENED/CLOSED" indication via control panel touch screen. 8. Provide "DISCHARGE PRESSURE MADE" indication via control panel

touch screen. 9. Dry contact inputs:

a. From PLC: 1) Start/stop control to initiate Booster Pump Start or Stop Sequence.

b. Discharge high pressure switch. c. Pump control valve opened from actuator. d. Pump control valve closed from actuator. e. Pump control valve "full closed" from actuator.

10. Dry contact outputs: a. To PLC:

1) Pump control valve open. 2) Pump control valve close. 3) Pump control valve LCP in remote. 4) Pump control valve LCP common fault.

b. Booster pump start/stop to VFD. c. Pump control valve open/close to actuator.

11. Provide logic to achieve the following: a. Booster Pump Start Sequence:

1) Initiate Sequence: Pump "START" pressed on LCP touch screen (local start) or dry contact closes (remote start from PLC). 2) Start booster pump. 3) After proof of pump discharge pressure received from pressure

switch, then open pump control valve. 4) Valve open — pump running.


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5) Additional start sequence logic as recommended by valve manufacturer.

b. Booster Pump Stop Sequence: 1) Initiate Sequence: Pump "STOP" pressed on LCP touch screen (local stop) or dry contacts disengage (remote stop from PLC). 2) Pump control valve begins to close while pump motor continues to run. 3) When valve is fully closed, stop booster pump. 4) Pump control valve continues to fully closed position as pump fully stops. 5) Valve closed — pump stopped. 6) Additional stop sequence logic as recommended by valve

manufacturer.

2.5 SURGE RELIEF VALVES

A. Products and Manufacturers: Provide one of the following: 1. GA Industries, Model 6600-D. 2. Or equal.

B. General: 1. Surge relief valves shall consist of a main valve assembly and a pilot

system, completely assembled and tested as a unit and ready for field installation.

C. Materials of Construction: 1. Body: angle style, constructed of high-strength cast iron conforming to

ASTM A126 Class B with 125 lb. flanges. 2. Type: "full-ported" with a flow area through the valve no less than the area

of its nominal pipe size. 3. The main valve shall operate on the differential piston principle such that

the area on the underside of the piston is no less than the pipe area and the area on the upper surface is greater than that of the underside. There shall be no diaphragms or springs in the main valve.

4. The valve piston shall be fully guided on its outside diameter and all guiding and sealing surfaces shall be bronze. To minimize the consequences of throttling, throttling shall be by long, stationary vee-ports located downstream of the seat and not by the seat itself

5. The valve shall be fully capable of operating in any position without the need of springs and shall not incorporate stems, stem guides or spokes in the waterway. A visual position indicator shall be provided.

6. The main valve shall be serviceable in the line through a single flanged cover which provides easy access to all internal components.

7. Pressure Rating: 250 psi

D. Pilot system:


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1. Provide a system of pilots and controls to enable the valve to perform the function listed below. All controls and control piping shall be non-corrosive and suitable for the working pressure.

2. System shall include a normally closed, direct-acting, diaphragm operated, spring loaded bronze pressure relief pilot. Pilot shall be easily field adjustable from near zero to a minimum of 10% above the factory setting. Controls shall include adjustable closing speed control, y-strainer and pilot isolating valves.

3. Provide a SPDT double-break limit switch mounted on the valve cover and actuated by the visual travel indicator.

E. Function: 1. The valve shall open when system pressure exceeds its pressure setting and

throttle as necessary to limit system pressure to a pre-set maximum pressure. When pressure subsides below the pre-set maximum the valve shall close tight.

F. Interior Coating: 1. Valves shall be coated inside. Steel, cast-iron and ductile iron surfaces,

except machined surfaces, shall be epoxy coated in accordance with AWWA C550.

2.6 WET TAP VALVES

A. Manufacturers: Provide products of one of the following: 1. InsettValve 2. Or equal

B. General: 1. Application: Resilient wedge gate valve designed for use in potable water,

systems. Designed to allow the valve to be installed into an existing pressurized pipeline while maintaining constant pressure and service. After closing the wedge abd adequately restraining the valve body the downstream pipe can be completely removed and replaced. The host pipe shall not be a permanent component of the wet tap valve.

2. Certified Installer: Wet tap valves must be installed by an individual who is company trained, authorized and certified by the manufacturer. Individual shall provide documentation validating their certification.

3. Rated Working Pressure: a. 250 psig maximum working pressure

4. For use on ductile iron pipe and cast iron pipe 5. Shall be NSF-61 certified 6. All wet tap valves shall be supported by blocking beneath the pipe

C. Materials of Construction: 1. Valve body, bonnet and wedge: Ductile iron; ASTM A536 Grade 65-45-12


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2. Resilient wedge assembly: Shall comply with AWWA C509 and shall be fully encapsulated with EPDM.

3. Stem seals: Triple 0-Ring 4. Valve stem and wedge nut: copper alloy in accordance with Section 4.4.5.1

of AWWA C515 a. 2" square nut which opens to the left

5. Split restraint devices: multiple gripping wedges meeting ANSI/AWWA C110/A21.10 a. Working pressure of 350 psi b. Gland body wedges: ductile iron ASTM A536, grade 65-45-12

D. Coatings:

1. Interior and exterior: a minimum of 10 mils of fusion-bonded epoxy in compliance with AWWA C550 and certified by ANSI/NSF-61.

E. Testing:

1. After the installation of the body on the existing pipe a pressure test of 1.1 times that of the maximum pressure of the exiting potable water system shall be sustained for 15 minutes. The wet tap valve must not be moved or repositioned once the pressure test is achieved.

2.7 LINE STOPS

A. Manufacturers: Provide products of one of the following: 1. Hydra-Stop (Hydra-Stopper) 2. Or equal

B. General: 1. Application: modular line stopping system capable of water system isolation

for repair maintenance, or replacement of valves and hydrants. No valve will be left in place using this method.

2. Rated working pressure: a. 250 psi

3. 95% to 200% water stop achieved at the point of repair 4. For use on ductile iron, cast iron and PVC pipe

C. Material of Construction: 1. Mounting Sleeve: 304 Stainless Steel 2. Sleeve Sealing Gasket: NBR Rubber 3. Outlet & Flange: 304 Stainless Steel 4. Blind Flange:HSF 250 Epoxy Coated Carbon Steel

2.8 FIRE HYDRANTS

A. Products and Manufacturers: Provide one of the following: 1. American-Darling, Model: B62B


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2. Mueller, Model: Centurion. 3. Clow, Model: Medallion.

B. General: 1. Provide fire hydrants that meet the OWNERS standard for fire hydrants

within the City of Miamisburg and within the Miami Valley Fire District. 2. Provide fire hydrants conforming to AWWA C502, Underwriters'

Laboratories-listed and Factory Mutual approved, and as specified herein. 3. Rated Working Pressure: 200 psig, minimum. 4. Rated Hydrostatic Test Pressure: 400 psig, minimum.

C. Construction: 1. Type: Three-way fire hydrants with two hose nozzles and one

pumper/streamer nozzle. 2. Nozzles:

a. Provide one 4.5-inch diameter streamer nozzle (one piece design compatible with 5" Storz hose coupling. The nozzle shall be an integral part of the fire hydrant and must be furnished by the manufacturer or authorized distributor designated by the manufacturer.)

b. Provide two 2.5-inch hose nozzles (3-15/16" OD-6 TPI-Higbee-Dayton standard tread).

3. Main Valve and Drainage Assembly: a. Opening: 5.25-inch diameter. b. Main valve shall be compression type provided with upper and lower

metal plates and lower valve plate nut. c. Barrel drainage shall be through dual drain valves. Opening and

closing of main valve shall cause force-flush of dual drain ports. d. Main valve seat ring shall be easily replaceable from above-ground.

4. Shall be "traffic model" with traffic flange in barrel and safety coupling in stem. Nozzle section must be able to be rotated 360 degrees.

5. Inlet Connection: Six-inch diameter mechanical joint, restrained. 6. Provide one 1.50-inch pentagon left opening operating nut.

D. Materials of Construction: Materials of construction shall conform to the requirements of AWWA C502.

E. Testing: 1. Test each fire hydrant in manufacturer's shop in conformance with AWWA

C502.

F. Interior Coating: 1. Hydrants shall be coated on the interior. Steel, cast-iron, and ductile iron

surfaces, except machined surfaces, shall be epoxy coated in accordance with AWWA C550.

G. Exterior Painting:


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1. Below- and above-ground painting shall be as specified under Article 2.27 of this Section and Article 2.28 of this Section. Hydrants shall be painted yellow.

2.9 ELECTRIC ACTUATORS (OPEN/CLOSE)

A. Manufacturers: Provide products of one of the following: 1. Limitorque. 2. Or equal.

B. Application Criteria: 1. Ambient Temperature Rating: -20 to +158 degrees F. 2. Ambient Humidity: 100 percent. 3. Maximum Differential Pressures Across Closed Valves: Refer to Schedule

of Valves with Electric Actuators at the end of this Section. 4. Maximum Flows Through Full-Open Valves: Refer to Schedule of Valves

with Electric Actuators located at end of this Section. 5. Power Supply: 480-volt, three-phase, 60 Hertz. 6. Control Voltage: 120 VAC, single phase, 60 Hertz. 7. Torques: As determined by valve manufacturer. 8. Duty Cycle: Sixty starts per hour, minimum.

C. General: 1. Conform to AWWA C540 and this Section. 2. Provide actuator operable with handwheel or chainwheel, even after

disengaging and removing electric motor. 3. Provide valves with electric actuators that are located more than five feet

above operating floor with separate control panels installed so that panel controls and indicators are approximately five feet above operating floor, at location approved by ENGINEER. Modify electrical wiring as required for remote location of control panels.

4. Coordinate sizing of each electric actuator with valve manufacturer, who shall furnish valve and associated electric actuator and appurtenances as a unit.

5. Electric actuators shall be suitable for valve orientation as shown.

D. Electric Motor: 1. General:

a. Provide motors suitable for "open/close" service, with high torque characteristics and minimum 70 degree C temperature rating.

2. Motor Construction: a. Enclosure: NEMA 6. b. Insulation: Class F. c. Service Factor: 1.15. d. Power Supply: 480-volt, three-phase, 60 Hertz.


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e. Motor Size: Horsepower as determined by Manufacturer. f. RPM: As determined by Manufacturer. g. Provide winding thermostats for overcun-ent protection. h. Efficiency: High-efficiency conforming to NEMA MG 1. i. Bearings: Anti-friction with minimum B-10 life of 100,000 hours,

lifetime pre-lubricated and sealed.

E. Actuator Gearing: 1. Housing: Die-cast aluminum or cast-iron. 2. Close-coupled to electric motor. 3. Input Shaft Gearing: Spur or bevel gear assembly. 4. Output Shaft Gearing: Self-locking worm gears with minimum gear

backlash to prevent valve disc chatter or vibration. 5. Gearing shall be of hardened alloy steel or combination of hardened alloy

steel and alloy bronze, accurately cut by hobbing machine. 6. Lubrication: Grease or oil bath. 7. Bearings: Ball or roller with minimum B-10 life of 100,000 hours, lifetime

pre-lubricated and sealed. 8. Input Shaft: Hardened alloy steel. 9. Provide mechanical stops adjustable to plus-or-minus five degrees at each

end of travel.

F. Limit Switches: 1. Provide each actuator with "end of travel" limit switches to allow control of

desired end position for each direction of travel. 2. Provide open and close limit switches geared to drive mechanism and in

step at all times, whether unit is operated electrically or manually, and whether or not actuator is powered by electric power supply. Friction devices or set-screw arrangements shall not be used to maintain the setting.

3. Limit switch gearing shall be appropriately lubricated. 4. Provide driven mechanism totally enclosed to prevent entrance of foreign

matter and loss of lubricant. 5. Provide each limit switch with four auxiliary contacts. Two contacts shall

close and two contacts shall open at a desired end position for each direction of travel.

6. Switches shall be rated five amperes at 120 volts.

G. Torque Switches: 1. Provide adjustable torque switches with each valve actuator. Torque

switches shall operate during complete valve cycle without using auxiliary relays, linkages, latches, or other devices.

2. Wire torque switches to de-energize valve actuator motor when excessive torque is developed during each direction of travel.

3. It shall be possible to select the torque switches to control open and close limit positions in each direction of valve travel.

4. Provide dry contacts (five-amp, 120 VAC) for remote high torque alarm.

40 05 53 Process Valves Four-inch Diameter and Larger.doc

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H. Handwheel and Chainwheel Operation: 1 Provide actuator with handwheel (or chainwheel as required) for manual

operation, so connected that operation by motor will not cause handwheel or chainwheel to rotate.

2. Should electric power be returned to motor while handwheel or chainwheel is in use, unit shall prevent transmission of motor torque to handwheel or chainwheel.

3. Handwheel or chainwheel shall require no more than 80-pound effort on rim for seating or unseating load, and no more than 60 pounds on running load.

4. Handwheel or chainwheel shall have an arrow and the word "OPEN" or "CLOSE" indicating required rotation. Handwheel or chainwheel shall operate in clockwise direction to close.

5. Chain Operators: a. Valves more than five feet above operating floor level shall be

equipped with chain operators. 6. Handwheels and chain operators shall be as specified in Article 2.6 of this

Section. 7. Provide stem covers for rising stem gate valves as specified in Article 2.6 of

this Section.

I. Controls: 1. Provide the following controls in separate compartment integral with

actuator. 2. Enclosure: NEMA 4X. 3. Starter: Combination reversing magnetic starter with circuit breaker and

disconnect switch. 4. Control Power Transformer: Provide transformer to transform rated three-

phase, 60 Hertz power to 120 volts, single-phase. Transformer shall be complete with grounded and fused secondary and dual primary fuses.

5. Provide "LOCAL/OFF/REMOTE" selector switch. In "LOCAL" position actuator shall be operated by "OPEN/CLOSE/STOP" pushbuttons. In "OFF" position, actuator shall be disabled from local and remote operation. In "REMOTE" position, "open/close/stop" control from remote source shall be enabled.

6. Provide "OPEN/CLOSE/STOP" pushbuttons with hold-to-run or momentary contact selection.

7. Provide "OPEN/CLOSE/STOP" indicating lights and zero-to-100 percent position indication in liquid crystal display window.

8. Provide thermal overload and single-phasing protection of motor. 9. Provide set of dry contacts to remotely indicate that actuator is available for

remote operation. 10. Actuator circuit boards shall be rated for high temperature service, minimum

55 degrees C. 11. Provide electrical interlocks as shown.


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12. Provide 120 VAC space heater to maintain internal housing temperature at 20 degrees C.

J. Remote-mounted Control Stations: 1. Where required by valve location or as indicated, provide remote control

panels. 2. Enclosure: NEMA 4X, Type 316 stainless steel. 3. Provide "LOCAL/OFF/REMOTE" selector switch. In "LOCAL" position

actuator shall be operated by "OPEN/CLOSE/STOP" pushbuttons. In "OFF" position, actuator shall be disabled from local and remote operation. In "REMOTE" position, "open/close/stop" control from remote source shall be enabled Provide contact when switch is in "REMOTE" position for remote indication.

4. Provide "OPEN/CLOSE/STOP" pushbuttons with hold-to-run or momentary contact selection.

5. Provide "OPEN/CLOSE/STOP" indicating lights and zero-to-100 percent position indication with liquid crystal display.

K. Testing: 1. Test each actuator in manufacturer's shop in conformance with AWWA

C540.

2.10 APPURTENANCES FOR EXPOSED METALLIC VALVES

A. General: 1. For valves located less than five feet above operating floor, provide levers

on four-inch diameter quarter-turn valves, and provide handwheels on all other valves, unless otherwise shown or specified.

2. For valves located five feet or more above operating floor, provide chain operators.

3. Where indicated, provide extension stems and floorstands.

B. Handwheels: 1. Conform to applicable AWWA standards. 2. Material of Construction: Ductile iron, or cast aluminum. 3. Arrow indicating direction of opening and word "OPEN" shall be cast on

trim of handwheel. 4. Maximum Handwheel Diameter: 2.5 feet.

C. Chain Operators: 1. Chains shall extend to three feet above operating floor. 2. Provide 1/2-inch stainless steel hook bolt to keep chain out of walking area. 3. Materials of Construction:

a. Chain: Type 316L stainless steel.


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b. Chainwheel: Recessed groove type made out of Type 316 stainless steel.

c. Guards and Guides: Type 316L stainless steel. 4. Chain Construction:

a. Chain shall be of welded link type with smooth finish. Chain that is crimped or has links with exposed ends is unacceptable.

5. Provide geared operators where required to position chainwheels in vertical position.

D. Crank Operator: 1. Crank operator shall be removable and fitted with rotating handle. 2. Maximum Radius of Crank: 15 inches. 3. Materials:

a. Crank: Cast-iron or ductile iron. b. Handle: Type 304 stainless steel. c. Hardware: Type 304 stainless steel.

E. Extension Stems and Floor Stands for Gate Valves: 1. Conform to the applicable requirements of AWWA C501 for sizing of

complete lifting mechanism. 2. Bench and Pedestal Floor Stands:

a. For valves requiring extension stems, provide bench or pedestal floor stands with handwheel or crank as indicated. Provide provisions for using portable electric actuator for opening and closing of valves.

b. Type: Heavy-duty with tapered roller bearings enclosed in a weatherproof housing, provided with positive mechanical seals around lift nut and pinion shaft to prevent loss of lubrication and to prevent moisture from entering housing. Provide lubrication fitting for grease. For valves conveying water that is potable or that will be treated to become potable, grease shall be food-grade and ANSI/NSF 61-listed. Base shall be machined.

c. Materials of Construction: 1) Housing: Cast-iron, ASTM A126, Class B. 2) Lift Nut: Cast bronze, ASTM B98/B98M. 3) Grease Fitting: Stainless steel. 4) Bolting: Type 316 stainless steel.

3. Wall brackets for floor stands shall be Type 316L stainless steel construction.

4. Extension Stems: a. Materials of Stems and Stem Couplings: Type 316 stainless steel. b. Maximum Slenderness Ratio (L/R): 100. c. Minimum Diameter: 1.5-inch. d. Threads: Acme. e. Provide stem couplings where stems are furnished in more than one

piece. Couplings shall be threaded and keyed or threaded and bolted and shall be of greater strength than the stem.


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f. Weld to bottom of extension stem a Type 316 stainless steel cap suitable for square end of valve stem.

5. Bottom Couplings: Ductile iron with Type 316 stainless steel pin and set screw.

6. Stem Guides: a. Material: Type 316 cast stainless steel with bronze bushing for stem.

For submerged service, Type 316 cast stainless steel with stainless steel bushing for stem.

b. Maximum Stem Length Between Guides: Seven feet. c. Stem guides shall be adjustable in two directions.

7. Furnish stem cover of clear butyrate plastic or Grade 153 Lexan with cast adapter for mounting cover to bench and floor stands. Provide stem cover with gasketing and breathers to eliminate water intrusion into operator and condensation within cover. Provide stem cover with mylar tape with legible markings showing valve position at one-inch intervals and open and close limits of valve.

F. Floor Boxes: Provide cast-iron floor boxes for valves that are to be operated from floor above valve. Boxes shall be equal in depth to floor slab. Boxes shall have cast-iron covers and be fitted with bronze bushing.

2.11 APPURTENANCES FOR BURIED METALLIC VALVES

A. Wrench Nuts: 1. Provide wrench nuts on buried valves of nominal two-inch size, in

accordance with AWWA C500. 2. Arrow indicating direction of opening the valve shall be cast on the nut

along with the word "OPEN". 3. Material: Ductile iron or cast-iron. 4. Secure nut to stem by mechanical means.

B. Extension Stems for Non-Rising Stem Gate Valves and Quarter-turn Buried Valves: 1. Provide extension stems to bring operating nut to six inches below valve

box cover. 2. Materials of Stems and Stem Couplings: Type 316 stainless steel. 3. Maximum Slenderness Ratio (L/R): 100

4. Provide top nut and bottom coupling of ductile iron or cast-iron with pins and set screws of Type 316 stainless steel.

C. Valve Boxes: 1. Valve boxes shall be as indicated and as required. 2. Type: Heavy-duty, suitable for highway loading, two-piece telescopic, and

adjustable. Lower section shall enclose valve operating nut and stuffing box and rest on valve bonnet.


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3. Material: Cast-iron or ductile iron. 4. Coating: Two coats of asphalt varnish conforming to FS TT-C-494. 5. Marking: As required for service.

2.12 ANCHORAGES AND MOUNTING HARDWARE

A. General: 1. Comply with Section 05 05 33, Anchor Systems, except as modified in this

Section. 2. Obtain bolts, nuts, and washers for connection of valve and appurtenances to

concrete structure or other structural members from valve Supplier. 3. Bolts, nuts, and washers shall be of ample size and strength for purpose

intended. Anchorages in concrete shall be at least 5/8-inch diameter. 4. Provide stem guide anchorages of required strength to prevent twisting and

sagging of guides under load. 5. Materials: Provide bolts and washers of Type 316 stainless steel and nitrided

nuts. Bolts shall have rolled threads. Bolts and nuts shall be electropolished to remove burrs.

2.13 TOOLS, LUBRICANTS, AND SPARE PARTS

A. Provide the following T-handle operating wrenches for buried valves: 1. Length of T-Handle Operating Wrench: 6 feet 2. Quantity: 4

B. Lubricants: For valves, actuators, and appurtenances requiring lubricants, provide suitable lubricants for initial operation and for first year of use following Substantial Completion. Lubricants for equipment associated with conveying potable water or water that will be treated to become potable shall be food-grade and ANSI/NSF 61-listed.

D. Tools, spare parts, and maintenance materials shall conform with Section 01 78 43, Spare Parts and Extra Materials.

2.14 PAINTING OF EXPOSED VALVES, HYDRANTS, AND APPURTENANCES

A. Exterior steel, cast-iron, and ductile iron surfaces, except machined surfaces of exposed valves and appurtenances, shall be finish painted in manufacturer's shop. Surface preparation, priming, finish painting, and field touch-up painting shall conform to Section 09 91 00, Painting.

2.15 PAINTING OF BURIED VALVES

A. Exterior steel, cast-iron, and ductile iron surfaces, except machined or bearing surfaces of buried valves, shall be painted in valve manufacturer's shop with two coats of asphalt varnish conforming to FS TT-C 494.


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PART 3- EXECUTION

3.1 INSPECTION

A. Examine conditions under which materials and equipment are to be installed and notify ENGINEER in writing of conditions detrimental to proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. General: 1. Install valves and appurtenances in accordance with:

a. Supplier's instructions and the Contract Documents. b. Requirements of applicable AWWA standards. c. Applicable requirements of Section 33 05 05, Buried Piping

Installation, and Section 40 05 05, Exposed Piping Installation. 2. Install valves plumb and level. Install all valves to be free from distortion

and strain caused by misaligned piping, equipment, and other causes. 3. Position swing check valves and butterfly valves so that, when valve is fully

open, valve disc does not conflict with piping system elements upstream and downstream of valve.

B. Exposed Valves: 1. Provide supports for large or heavy valves and appurtenances as shown or

required to prevent strain on adjoining piping. 2. Operators:

a. Install valves so that operating handwheels or levers can be conveniently turned from operating floor without interfering with access to other valves, piping, structure, and equipment, and as approved by ENGINEER.

b. Avoid placing operators at angles to floors or walls. c. Orient chain operators out of way of walking areas. d. Install valves so that indicator arrows are visible from floor level. e. For motor-operated valves located lower than five feet above operating

floor, orient motor actuator to allow convenient access to pushbuttons and handwheel.

3. Floor Stands and Stems: a. Install floor stands as shown and as recommended by manufacturer. b. Provide lateral restraints for extension bonnets and extension stems as

shown and as recommended by manufacturer. c. Provide sleeves where operating stems pass through floor. Extend

sleeves two inches above floor.


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C. Buried Valves: 1. Install valve boxes plumb and centered, with soil carefully tamped to a

lateral distance of four feet on all sides of box, or to undisturbed trench face if less than four feet.

2. Provide flexible coupling next to each buried valve.


A. Field Tests: 1. Adjust all parts and components as required to provide correct operation of

valves. 2. Conduct functional field test on each valve in presence of ENGINEER to

demonstrate that each valve operates correctly. 3. Verify satisfactory operation and controls of motor operated valves. 4. Demonstrate satisfactory opening and closing of valves at specified criteria

requiring not more than 40 pounds effort on manual actuators. 5. Test ten percent of valves of each type by applying 200 pounds effort on

manual operators. There shall be no damage to gear actuator or valve.

B. Supplier's Services: 1. Provide services of qualified factory-trained service technicians to check and

approve installation of the following types of valves: a. Pump Control Valves.

2. Supplier's serviceman shall perform the following: a. Instruct CONTRACTOR in installing equipment. b. Supervise installation of equipment. c. Inspect and adjust equipment after installation and ensure proper

operation. d. Instruct OWNER's personnel in operating and maintaining the

equipment. 3. Manufacturer's representative shall make a minimum of 2 visits, with a

minimum of 8 hours onsite for each visit. First visit shall be for unloading supervision (if specified) and instruction of CONTRACTOR in installing equipment; second visit shall be for assistance in installing equipment; third visit shall be for checking completed installation and start-up of system; fourth visit shall be to instruct operations and maintenance personnel. Representative shall revisit the Site as often as necessary until installation is acceptable.

4. Training: Furnish services of Supplier's qualified factory trained specialists to instruct OWNER's operations and maintenance personnel in recommended operation and maintenance of equipment. Training requirements, duration of instruction and qualifications shall be in accordance with Section 01 79 23, Instruction of Operations and Maintenance Personnel.


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5. All costs, including expenses for travel, lodging, meals and incidentals, and cost of travel time, for visits to the Site shall be included in the Contract Price.

3.4 SUPPLEMENTS

A. The supplements listed below are a part of this Specification Section: 1. Table 40 05 53-A, Schedule of Valves with Electric Actuators.


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TABLE 40 05 53-A SCHEDULE OF VALVES

Valve Number Location Type Service

Valve Size (in)

Operator (Manual, Electric,

Pneumatic)

Actuator (Open/Close or Modulating.)

Specification Paragraph Notes

BFV-1 Trench BFV PW 16 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-2 Trench BFV PW 16 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-3 Trench BFV PW 16 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-4 Pump Room BFV PW 10 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-5 Pump Room BFV PW 10 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-6 Pump Room BFV PW 10 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-7 Pump Room BFV PW 10 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-8 Pump Room BFV PW 10 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-9 Pump Room BFV PW 10 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-10 Pump Room BFV PW 16 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-11 Pump Room BFV PW 16 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-12 Pump Room BFV PW 16 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-13 Pump Room BFV PW 16 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-14 Trench BFV PW 16 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-15 Pump Room BFV PW 6 Manual Open/Close 2.3 Provide Valve with #125 Flanges. BFV-16 Pump Room BFV PW 6 Manual Open/Close 2.3 Provide Valve with #125 Flanges. PCV-1 Pump Room PCV PW 10 Electric Open/Close 2.4 Provide Valve with #125 Flanges. PCV-2 Pump Room PCV PW 10 Electric Open/Close 2.4 Provide Valve with #125 Flanges. PCV-3 Pump Room PCV PW 10 Electric Open/Close 2.4 Provide Valve with #125 Flanges. PCV-4 Pump Room PCV PW 8 Electric Open/Close 2.4 Provide Valve with #125 Flanges. PCV-5 Pump Room PCV PW 8 Electric Open/Close 2.4 Provide Valve with #125 Flanges. PCV-6 Pump Room PCV PW 8 Electric Open/Close 2.4 Provide Valve with #125 Flanges. SRV-1 Pump Room SRV PW 6 Manual Open/Close 2.5 Provide Valve with #125 Flanges. GV-RS Water Main GV-RS PW 12 & 16 Manual Open/Close 2.2 Mechanical Joints

Notes: 1. The Valve Schedule is provided for the CONTRACTOR'S convenience and does not relieve the CONTRACTOR from his responsibility to

provide all valves and appurtenances as shown on the drawings and specifications.


02270037.D001 7/31/15 10:13:17 AM 40 05 53-27

The following abbreviations are used in Table 40 05 53-A.

A. Valve Type Abbreviations

Valve Type Abbrev Valve Type Abbrev. Metal-seated Gate Valve GV-MS Swing Check Valve SCV Resilient-seated Gate Valve GV-RS Automatic Pressure-reducing

Valve PRV

Eccentric Plug Valve PV Automatic Pressure-sustaining Valve

PS V

Eccentric Plug Valve (digester gas service)

PV-DI Automatic Electric Check Valve ECV

Rubber-seated Ball Valve BV-RS Check Valve (air service) CV-AS Butterfly Valve BFV Check Valve (digester gas

service) CV-DI

Butterfly Valve (air service, open- close applications)

BV-AS Telescopic Valve TEL

High-performance Butterfly Valve (air service, modulating)

HBV-AS Mud Valve MUD

Butterfly Valve (digester gas service, open-close applications)

BV-DI Fire Hydrant HYD

Surge Relief Valve SRV Pump Control Valve PCV

B. Service Abbreviations

Service Abbrev Service Abbrev. Sanitary Sewer SAN Wastewater WW Storm Sewer ST Overflow OF Combined Sewer CS Centrate CEN Sanitary Force Main SFM Filtrate FILT Raw Water RW Sciim SCUM Potable Water PW Primary Sludge PS City Water CW Return Activated Sludge RAS Non-Potable Water NPW Waste Activate Sludge WAS Plant Effluent Water PEW Thickened Sludge TS Spray Water SPW Mixed Sludge MS Backwash Water BW Digested Sludge DS Hot Water Supply HWS Chlorine Solution CLS Hot Water Return HWR Sodium Hydroxide NAOH Influent INF Sodium Hypochlorite NAOCL Effluent EFF Polymer Solution POLY S Drain DR Alum AL Process Air PA Hydraulic Fluid HF Instrument Air IA Fuel Oil FO Digester Gas DIG Lube Oil LO Chlorine Gas CLG



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SECTION 40 05 86

AIR VALVES FOR WATER SERVICE

PART 1— GENERAL

1.1 DESCRIPTION


incidentals as shown, specified, and required to furnish, install, and test Air Valves for water service complete with appurtenances.

2. This Section does not include valves used for: a. Plumbing. b. Heating, ventilating, air conditioning, steam, or condensate systems. c. Instrumentation. d. Sprinkler systems. e. Chemical feed systems f. Sewage sludge, process sludge, and grit

3. This Section does not include: a. Valves specified in other Sections b. Valves furnished with equipment c. Non-metallic valves.

B. Coordination: 1. Review installation procedures for this and other Specification sections and

coordinate Work that must be installed with or before Work under this Section.

C. Related Sections: 1. Section 09 91 00, Painting 2. Section 40 05 53, Process Valves, Four-inch Diameter and Larger

1.2 REFERENCES

A. Standards referenced in this Section are: 1. ANSI/AWWA C512, Air Release, Air Vacuum and Combination Air

Valves for Waterworks Service 2. ANSI/AWWA C550, Protective Interior Coatings for Valves and Hydrants. 3. ANSI/NSF 61 Drinking Water Components — Health Effects

1.3 DEFINITIONS

A. The following definitions apply to this Section.

40 05 86 - Air Valves for Water Service.doc

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1. Air Release Valve: A hydromechanical device designed to automatically release to atmosphere small pockets of air as they accumulate in a pipeline when pipeline system is full and operating under pressure.

2. Air/Vacuum Valve: Direct-acting, float-operated, hydromechanical device designed to automatically release or admit large volumes of air during filling or draining of a pipeline or piping system. Valve will open to relieve negative pressures and will not reopen to vent air when system is full and under pressure.

3. Air Valve: Valve of one of the following types: Air Release Valve, Air/Vacuum Valve, or Combination Air Valve.

4. Combination Air Valve: Device having features of an Air Release Valve and Air/Vacuum Valve.

5. Maximum and Minimum Working Pressure: Pressure range at which valve is designed to function.

6. Orifice: Opening in valve mechanism through which air is expelled from or admitted into pipeline or piping system.

7. Valve Design Pressure: Maximum pressure to which a valve may be subjected without exceeding allowable stress of its components.


A. Manufacturer's Qualifications: 1. Manufacturer shall be able to provide documentation of at least five

installations of substantially similar equipment to that specified, in satisfactory operation for at least five years.

B. Component Supply and Compatibility: 1. Valves of the same type, including specified accessories, shall be products

of or furnished by a single air valve manufacturer.

C. Regulatory Requirements. 1. Drinking Water Requirements: Valves that will be in contact with potable

water or water that will be treated to become potable shall comply with ANSI/NSF 61 and Annex G for low lead content and the Safe Drinking Water Act.

1.5 SUBMITTALS

A. Action Submittals. 1. Product Data: Submit the following for each type and size of valve

specified: a. Product data sheet. b. Complete catalog information, including dimensions, weight,

performance data, Orifice size, specifications, and identification of materials of each part.


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B. Informational Submittals: 1. Certifications:

a. Submit a certificate signed by manufacturer of each product stating that product conforms to applicable referenced standards and specified requirements.

2. Test Reports: a. Provide results of successful factory tests prior to shipping products to

the Site. 3. Manufacturer's Reports:

a. Submit written report of results of each visit to Site by a manufacturer's serviceman, including purpose and time of visit, tasks performed, and results obtained.

C. Closeout Submittals. 1. Operation and Maintenance Data:

a. Submit complete operation and maintenance manual for all Air Valves in the Contract, including maintenance data and schedules in sufficient detail for disassembly and assembly of valve, and identifying parts that can be replaced.

b. Furnish operation and maintenance manuals per Section 01 78 23, Operations and Maintenance Data.

2. Spare Parts: a. Provide spare parts and list of recommended spare parts as specified in

this Section:

1.6 DELIVERY, STORAGE, AND HANDING

A. Packing, Shipping, Handling, and Unloading: 1. Prepare valves for shipping per Section 6.2 of ANSI/AWWA C512. 2. Conform to Section 01 65 00, Product Delivery Requirements.

B. Acceptance at Site: 1. Inspect all boxes, crates, and packages upon delivery to Site and notify

ENGINEER in writing of loss or damage to products. Promptly remedy loss and damage to new condition per manufacturer's instructions.

C. Storage and Protection: 1. Keep all products off ground using pallets, platforms, or other supports.

Protect products from corrosion and deterioration. 2. Conform to Section 01 66 00, Product Storage and Handling Requirements.


02270037.D001 7/31/15 10:15:15 AM 40 05 86-3

PART 2 — PRODUCTS

2.1 GENERAL

A. Extent: 1. Provide valves included in this Section, per the schedule included in this

Section and as shown on the Drawings.

B. Requirements: 1 Valve Design Pressure: Unless otherwise specified, Valve Design Pressure

shall be equal to or exceed design pressure of pipe or equipment on which the valve is installed.

2. Valve Type, Service, Inlet Size, Orifice Size, Accessories, and Required Features: Provide per the schedule in this Section.

3. Materials: Air Valve materials shall be suitable for long-term use in the service specified.

4. Ends: a. Provide per the schedule in this Section. b. Comply with valve connection requirements in Section 4.3 of

ANSI/AWWA C512. 5. Operating Pressure Range: Valves shall be suitable for pressure range

specified in the schedule in this Section. Valve Design Pressure shall be greater than the valve's Maximum and Minimum Working Pressure.

6. Air Valves in water service shall comply with ANSLAWWA C512 unless otherwise shown or specified.

C. Markings: 1. Mark valves per Section 6.1 of ANSI/AWWA C512.

D. Manufacturers and Model Numbers: 1. Valve manufacturers and model numbers are in the schedule included in this

Section.

2.2 ACCESSORIES

A. Isolating Valves: 1. Provide isolating valves in the schedule included in this Section and as

shown. Isolating valves shall conform to applicable requirements of Section 40 05 53, Process Valves, Four-inch Diameter and Larger

2. Valve Design Pressure of isolating valve shall equal or exceed Valve Design Pressure of the connected Air Valve.

B. Anti-Slam Devices: 1. Provide anti-slam devices on inlet to air/vacuum valves and combination air

valves where indicated. 2. Pressure rating of anti-slam device shall equal or exceed Valve Design

Pressure of connected Air Valve.


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3. Ends shall be as required for connecting to Air Valve. 4. Anti-slam devices shall be as normally furnished by specified Air Valve

manufacturers and be cast iron or ductile iron with bronze or stainless steel disc and trim.

C. Vacuum Check Valves: 1. Provide vacuum check valves for Air Release Valves where indicated. 2. Vacuum check valves shall be as normally furnished by Air Valve

manufacturer.

D. Throttling Devices 1. Provide throttling device on discharges of Air/Vacuum Valves where

indicated. 2. Throttling device shall have a field-adjustable Orifice and be as normally

furnished by Air Valve manufacturer.

2.3 FACTORY PAINTING

A. Interior Surfaces 1. Extent: Paint ferrous surfaces except stainless steel surfaces. 2. Paint: Paint shall be as normally provided by Air Valve manufacturer for the

specified application, except for potable water service valves which shall be coated with paint complying with ANSI/AWWA C550 and ANSI/NSF-61.

B. Exterior Surfaces 1. Exterior surfaces of cast-iron, ductile iron, and steel other than stainless

steel, except machined surfaces of valves and appurtenances, shall be finish painted.

2. Surface preparation, painting, and field touch-up painting shall be per Section 09 91 00, Painting.

3. Furnish valve with only a prime coat if so indicated.


A. Test and inspect Air Valves per Section 5 of ANSI/AWWA C512. Do not ship valves that are not successfully tested.

PART 3- EXECUTION

3.1 INSPECTION

A. Examine conditions under which Work is to be installed and notify ENGINEER in writing of conditions detrimental to proper and timely completion of Work. Do not proceed with Work until unsatisfactory conditions have been corrected.


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B. Examine valves and remove packing and foreign materials from interior of valve. Report defects to ENGINEER

3.2 INSTALLATION

A. Install valves and appurtenances as shown on the Drawings and per Air Valve manufacturer's recommendations, approved Shop Drawings, and applicable codes and standards.

B. Install valves plumb and vertical.

C. Install with an isolating valve. Remove isolating valve's operating handle or lever and deliver to OWNER.

D. Adjust throttling devices, if provided, for smooth, non-slam and waterhammer-free operation.


A. Provide services of a factory-trained manufacturer's representative for start-up, testing, and training of operation and maintenance personnel for valves listed in Paragraph 3.3.A.1 of this Section. Factory-trained manufacturer's representative shall be at Site for a minimum of 8 hours during start-up and testing and 8 hours for training of operations and maintenance personnel. Refer to Section 01 79 23, Instruction of Operations and Maintenance Personnel, for training requirements. Factory-trained manufacturer's representative shall test operate the valves in presence of ENGINEER and verify that Air Valve Work conforms to the Contract Documents. Factory-trained manufacturer's representative shall revisit the Site as often as necessary until all unsatisfactory conditions are corrected.

3.4 SCHEDULE

A. The schedules listed below, following the "End of Section" designation, are a part of this Specification section. 1. Table 40 05 86-A, Air Valve Schedule.



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TABLE 40 05 86-A AIR VALVE SCHEDULE

No. Valve Type Service Location

Inlet Dia.

(inch)

Inlet Connection

Type Orifice (inch)

Working Pressure

Range (psi)

Valve Design

Pressure (psi)

Isolating Valve Type

Access- ones

Mfr. & Model*

Reg' d Features

ARV-1 CA PW Pump Room Discharge 2 Threaded -- 200 150 GA SV

VM- 202CSS --

ARV-2 CA PW Pump Room Bypass

2 Threaded -- 200 150 GA SV VM- 202CSS

--

ARV-3 CA PW Air Relief

Valve Vault 3 Flanged -- 50 150 GA SV

VM- 203CSS

--

* Valves shall be the Supplier's models shown or equal.


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Abbreviations that may be used in the Schedule:

Valve Type

Air Release Valve AR Air/Vacuum Valve AV Combination Air Valve CA

Service

Water (non-potable) WAT Potable Water PW Waste Water WW

Inlet Connection

Flanged Threaded NPT

Isolating Valve Type

Ball Valve BA Butterfly Valve BU Plug Valve PL Gate Valve GV

Accessories

Vacuum Check VC Throttling Device TD Anti-slam Device S V Outlet Cowl or Hood OC Inflow Prevention Device IP

Manufacturer

Val-Matic VM GA Industries GA Crispin CR Valve and Primer APCO

Location

As shown on Drawings


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Required Features

Cast stainless steel body and cover (1) Fusion bonded exterior coating (2) Backflush attachments not required for Air Valve in wastewater service (3) Exterior surface to be painted with prime coat only (4)


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SECTION 40 61 13

PROCESS CONTROL SYSTEM GENERAL PROVISIONS

PART 1— GENERAL

1.1 DESCRIPTION

A. Scope: 1. CONTRACTOR shall coordinate with CONTROL SYSTEM SUPPLIER

and RADIO SYSTEM SUPPLIER to provide all labor, materials, equipment, and incidentals as shown, specified, and required to furnish, install, calibrate, test, start-up and place in satisfactory operation a complete process control system (PCS). CONTRACTOR's scope shall also include: a. Procurement and installation of field-mounted instruments and

devices. b. Work not covered under the scopes of the CONTROL and RADIO

SYSTEM SUPPLIERS. 2. CONTROL SYSTEM SUPPLIER shall provide all equipment, labor, and

required engineering to put into service a complete PCS including, but not limited to, project management, detailed system design and integration, PCS hardware and equipment, shipment, job site delivery, programming and configuration, installation supervision, training, calibration, testing, and startup. Work shall be in accordance with the Contract Drawings and related Sections of Division 40 (except for Section 40 66 53, by others). The system shall include the following major components: a. Panels and panel-mounted instruments and devices. b. Programmable logic controllers (PLC) and software. c. Operator interface terminal (OIT) units. d. Servers, personal computers, and human-machine interface (HMI)

software. e. Local area network hardware and software. f. Uninterruptible power supplies.

3. RADIO SYSTEM SUPPLIER shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish, install, configure, test, start-up and place in satisfactory operation the City of Miamisburg Telemetry System. The telemetry system shall be completely compatible and interoperable with the Water Treatment Plant PCS.

B. PCS shall monitor, store, display, and log process and equipment operating information; perform various process control functions; and generate various reports.

C. The Contract Documents describe the required PCS and PCS functions and operational requirements.

D. Coordination:

40 61 13 - Process Control Systems General Provisions.doc

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1. Process Controls: a. Process control description of process system and its associated

equipment is included in Section 40 61 96, Process Control Descriptions. The programming of computer systems and PLC logic shall be performed by the CONTROL SYSTEM SUPPLIER. The CONTRACTOR, CONTROL SYSTEM SUPPLIER, and RADIO SYSTEM SUPPLIER shall coordinate the Work so that the control system is ready for startup.

b. Some panels and equipment are furnished under other Specification Sections under this Contract, and computer system hardware and software are provided under allowance. CONTRACTOR shall coordinate with Suppliers of panels and equipment to provide fully functional system complying with the Contract Documents and that interfaces with the computer system.

c. Use PLC input/output list for coordinating signals between equipment provided under this contract.

2. To centralize responsibility, I&C materials and equipment provided under this Contract shall be furnished by a single CONTROL SYSTEM SUPPLIER, except for field-mounted instruments and devices. CONTRACTOR shall coordinate with a single Supplier to furnish all field-mounted instruments and devices.

3. With CONTRACTOR, CONTROL SYSTEM SUPPLIER shall assume the responsibility for adequacy and performance of materials and equipment provided under this Section.

4. To the greatest extent possible, provide I&C materials and equipment from a single manufacturer.

5. CONTROL SYSTEM SUPPLIER's Responsibilities: a. Preparing all process control equipment submittals in accordance with

the Contract Documents. b. Proper interfacing of instrumentation and control equipment with field

equipment, instruments, devices, and panels, including required interfacing with packaged control systems furnished by other equipment Suppliers, and required interfacing with the Site's electrical system.

c. Review and coordination with manufacturers, other Suppliers, and other contracts of Shop Drawings and other CONTRACTOR submittals for equipment, valves, piping, and appurtenances for ensuring proper interfacing of hardware, and locations and installation requirements of inline devices and instrument taps.

d. Direct, detailed oversight of installation of instruments, panels, consoles, cabinets, wiring and other components, and related wiring and piping connections.

e. Calibrating, source quality control, field quality control, and start-up of the system.

f. Responsibility for correction period obligations for the PCS. g. Training operations and maintenance personnel in operation and

maintenance (including calibration and troubleshooting) of the PCS.


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E. PCS detailed system design, equipment, programming, and integration shall be in accordance with the Contract Drawings and related Sections of Division 40, and shall be covered under cash allowance specified in Section 01 21 00, Allowances.

1.2 REFERENCES

A. Standards referenced in this Section are: 1 ANSI/ASQ Z1.4, Sampling Procedures and Tables for Inspection By

Attributes. 2. ISA 5.4, Instrument Loop Diagrams. 3. ISA 20, Specification Forms for Process Measurement & Control

Instruments, Primary Elements & Control Valves. 4. NFPA 79, Electrical Standard for Industrial Machinery.


A. Qualifications: 1. CONTROL SYSTEM SUPPLIER:

a. Shall be financially sound with at least five years of continuous experience in designing, implementing, supplying, and supporting process control systems for municipal water treatment facilities comparable to PCS required for the Project, relative to hardware, software, cost, and complexity.

b. Shall have record of successful process control system equipment installations. Upon ENGINEER's request, submit record of experience for at least five projects, each with the following information: project name, owner name and contact information, name and contact information for contractor, name and contact information for engineer or architect, approximate and contract value of process control systems Work for which CONTROL SYSTEM SUPPLIER was responsible,

c. Shall have at time of Bid experienced engineering and technical staff capable of designing, supplying, implementing, and supporting the instrument and control system and complying with submittal and training requirements of the Contract Documents.

d. Shall be capable of training operations and maintenance personnel in PCS applications, and in operating, programming, and maintaining the control system and equipment.

e. Shall have UL-approved panel shop. f. Supply and support system hardware components and software

packages of fully developed and field-proven standardized designs that are not a highly unique, custom, or one-of-a-kind systems.

g. Offer standard courses in general process control applications, programming, and maintenance of the PCS and equipment at a facility specifically utilized for training. Training facility shall have been in operation continuously for the previous two years, minimum.


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h. Possess a thorough, working knowledge of water treatment processes and control philosophy in accordance with standard practices of the water treatment industry.

i. Possess and maintain a documented program of failure analysis. 2. Manufacturers:

a. Manufacturers of instrumentation and control equipment furnished for the PCS shall be experienced producing similar equipment and shall have the following qualifications: 1) Shall manufacture instrumentation and control system components

that are fully-developed, field-proven, and of standardized designs. 2) Shall have system of traceability of manufactured unit through

production and testing in accordance with ANSI/ASQ Z1.4. 3) Shall have guaranteed availability clause (99.99 percent, minimum

for one year) for microprocessor-based components and appurtenances.

4) Shall have documented product safety policy relevant to materials and equipment proposed for the Work.

3. CONTROL SYSTEM SUPPLIER shall be: a. Emerson Power and Water Solutions, Inc.

200 Beta Drive Pittsburgh, PA 15238 (313) 655-0055

B. Component Supply and Compatibility: 1. PCS components shall be furnished by a single CONTROL SYSTEM

SUPPLIER who shall have responsibility for furnishing a complete and integrated system.

2. CONTROL SYSTEM SUPPLIER shall have responsibility for adequacy and performance of all items furnished.

3. CONTROL SYSTEM SUPPLIER shall prepare, or shall review and approve, all Shop Drawings and other submittals for the PCS.

C. Pre-submittal Conference 1. Schedule and conduct a pre-submittal conference for the PCS within 60

days after the Contract Times commence running. 2. Required Attendance for Pre-submittal Conference: CONTRACTOR,

CONTROL SYSTEM SUPPLIER, ENGINEER, and OWNER. Pre-submittal conference will be 4 hours. Conference will be held at City of Miamisburg Project office unless otherwise acceptable to the entities attending.

3. Purpose of pre-submittal conference is to review manner in which CONTROL SYSTEM SUPPLIER intends to comply with requirements of the Contract Documents relative to PCS submittals before submittals are prepared.

4. Bring to pre-submittal conference a list of proposed personnel committed to assignment to the Project. The list shall include CONTROL SYSTEM SUPPLIER project manager, project engineer, field representative, local


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service representative, and sales representative(s). Indicate addresses of personnel not based at CONTROL SYSTEM SUPPLIER's office nearest to the Site.

5. Prepare items listed below for presentation at pre-submittal conference. Submit information to ENGINEER two weeks prior to pre-submittal conference. a. List of materials and equipment required for PCS, and manufacturer

and model proposed for each item. b. List of currently-known requests for interpretations of which

CONTRACTOR, and CONTROL SYSTEM SUPPLIER are currently aware.

c. List of proposed exceptions to the Contract Documents along with brief explanation of each.

d. Proposed PCS network architecture diagram. e. Sample of each type of process control submittal required by the

Contract Documents. These may be submittals prepared for other projects.

f. Flow chart showing steps to be taken in preparing and coordinating PCS submittals.

g. General outline of types of tests to be performed to verify that all sensors and transducers, instruments, and digital processing equipment are functioning properly.

1.4 SUBMITTALS


a. Field Instruments: 1) Manufacturer's product name and complete model number of

devices proposed for use, including manufacturer's name and address.

2) Instrument tag number in accordance with the Contract Documents.

3) Data sheets and manufacturer's catalog literature. Provide data sheets in accordance with ISA 20 and annotated for features proposed for use. For instruments not included in ISA 20, submit data sheets using a format similar to ISA 20.

4) Description of construction features. 5) Performance and operation data. 6) Installation, mounting, and calibration details; instructions and

recommendations. 7) Service requirements. 8) Dimensions of instruments and details of mating flanges and

locations of closed tanks, pipe sizes for insertion instruments, and upstream/downstream straight run pipe lengths required.

9) Range of each device and calibration information


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10) Descriptions of materials of construction and listing of NEMA ratings for equipment

b. Panels, Consoles, and Cabinets: 1) Layout drawings that include:

a) Front, rear, and internal panel views to scale. b) Tag number and functional name of components mounted in

and on panel, console, or cabinet, as applicable. c) Product information on panel components. d) Nameplate location and legend including text, letter size and

colors to be used. e) Location of anchorage connections. 1) Location of external wiring and piping connections. g) Mounting and installation details, coordinated with actual

application. h) Proposed layouts and sizes of operator interface graphic display

panels. i) Calculations substantiating panel heating and cooling provisions

proposed. j) Subpanel layouts and mounting details for items located inside

control panels. 2) Product information on panel components including:

a) Manufacturer's product name and complete model number of devices being provided, including manufacturer's name and address.

b) Instrument tag number in accordance with the Contract Documents.

c) Data sheets and catalog literature. Submit data sheets as shown in ISA 20 and annotated for features proposed for use. For instruments not included in ISA 20, submit data sheets with format similar to ISA 20.

d) Description of construction features. e) Performance and operation data. 1) Installation, mounting, and calibration details; instructions and

recommendations. g) Service requirements

3) Wiring and piping diagrams, including the following: a) Name of each panel, console, or cabinet. b) Wire sizes and types. c) Pipe sizes and types. d) Terminal strip and terminal numbers. e) Wire color coding. t) Functional name and manufacturer's designation for

components to which wiring and piping are connected. g) Lightning and surge protection grounding.

4) Electrical control schematics in accordance with NFPA 79. Control schematics shall be in accordance with convention indicated in Annex D of NFPA 79. Standardized wiring diagrams that do not


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accurately reflect actual wiring to be furnished are unacceptable. Tables or charts for describing wire numbers are unacceptable.

5) Stock list or bill of materials for each panel including tag number, functional name, manufacturer's name, model number and quantity for components mounted in or on the panel or enclosure.

6) Detail showing anchorage plan of wire bundles between subpanels and front panel mounted devices.

c. Field wiring and piping diagrams, include the following: 1) Wire and pipe sizes and types. 2) Terminal numbers at field devices and in panels. 3) Fiber optic termination designations in the field and in panels. 4) Color coding. 5) Conduit numbers in which wiring will be located. 6) Locations, functional names, and manufacturer's designations of

items to which wiring or piping are connected. d. Process Control System:

1) Submit the following general information: a) Detailed block diagram showing system hardware configuration

and identifying model numbers of system components. b) Software listings for operating system, applications, and HMI. c) Software language and organization. d) Format, protocol and procedures for data transmission and

communications with input/output modules and peripheral devices, including wide area network (WAN) or local area network (LAN).

e) HMI interfacing details, licensing structure, and included functions.

f) Control and failure modes. g) Online and offline capabilities for programming, system

utilities, and diagnostics. 2) Hardware:

a) Layout drawings showing front, rear, end, and plan views to scale of equipment, I/O components, power supplies, and peripheral devices.

b) Equipment ventilation and cooling requirements. c) Interconnection diagrams, including termination details, cable

identification list, and cable length. d) Drawings showing equipment layout. e) Installation requirements, instructions, and recommendations.

3) Documentation describing memory type, size and structure and listing size of system memory, I/O and data table memory and size of memory available for control programs.

4) System I/O Loop Wiring Diagrams: Prepare Shop Drawings on module-by-module basis and include the following information: a) Rack numbers, module type and slot number, and module

terminal point numbers. Include location and identification of intermediate panel and field terminal blocks and terminal


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numbers to which I/O wiring and power supply wiring is connected. Identify power supply circuits with designation numbers and ratings.

b) Wiring types, wire numbers, and color coding. c) Designation of conduits in which field 1/0 wiring will be

installed. d) Location, functional name, tag numbers and manufacturer's

module numbers of panel and field devices and instruments to which I/O wiring will be connected.

e) Prepare loop wiring diagrams in accordance with ISA 5.4. e. Complete point-to-point interconnection wiring diagrams of field

wiring associated with the system. Diagrams shall include the following: 1) Field wiring between each equipment item, panel, instruments, and

other devices, and wiring to control stations, panelboards, and motor starters. Some of this equipment may be specified in other Divisions. CONTRACTOR is responsible for providing complete point-to-point interconnection wiring diagrams for control and monitoring of that equipment.

2) Numbered terminal block and terminal identification for each wire termination.

3) Identification of assigned wire numbers for interconnections. Assign each wire a unique number.

4) Schedule showing the wiring numbers and the conduit number in which the numbered wire is installed.

5) Junction and pull boxes through which wiring will be routed. 6) Identification of equipment in accordance with the Contract

Documents.

2. Product Data: a. Product data for field instruments in accordance with requirements for

Shop Drawings in this Section. b. Product data for panels, consoles, and cabinets in accordance with

requirements for Shop Drawings in this Section. c. Product data for field wiring and piping provided for instrumentation

and control service and not included under other Sections or contracts. d. Product data for Process Control System.

3. Samples: a. Color charts for finish paint for metallic panels. Provide full range of

paint manufacturer's standard and custom colors. Color selection will be by ENGINEER.

b. Color charts for fiberglass-reinforced panels. Provide full range of panel manufacturer's standard and custom colors. Color selection will be by ENGINEER.

4. Factory Acceptance Test Procedure: Submit proposed procedures for factory testing required to comply with the Contract Documents. Test procedure shall include the following: a. Visual inspection of components and assembly.


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b. Description of hardware operational testing. c. Description of software demonstration. d. Description of testing equipment to be used. e. Sign-off sheets to be used at time of testing.

B. Informational Submittals: Submit the following: 1. Documents to be submitted prior to pre-submittal conference, in accordance

with Article 1.3 of this specification. 2. Manufacturer's Instructions:

a. Shipping, handling, storage, installation, and start-up instructions. b. Templates for anchorage devices for materials and equipment that will

be anchored to concrete or masonry. 3. Source Quality Control Submittals:

a. Results of factory testing. 4. Special Procedure Submittals:

a. Notification to OWNER and ENGINEER at least 14 days before readiness to begin system checkout at the Site. Schedule system checkout on dates acceptable to OWNER and ENGINEER.

b. Written procedure for system checkout. Submit not less than 90 days prior to starting system checkout.

c. Ninety days prior to starting system checkout submit written procedure for start-up.

5. Field Quality Control Submittals: a. Submit the following prior to commencing system checkout and start-

up. 1) Completed calibration sheets for each installed instrument showing

five-point calibration (zero, 25, 50, 75, 100 percent of span), signed by factory-authorized serviceman.

b. Field calibration reports c. Field testing reports.

6. CONTROL SYSTEM SUPPLIER's Reports: a. Installation inspection and check-out report. b. Submit written report of results of each visit to Site by CONTROL

SYSTEM SLTPPLIER's service technician, including purpose and time of visit, tasks performed, and results obtained. Submit within two days of completion of visit to the Site.

C. Closeout Submittals: Submit the following: 1. Operations and Maintenance Data:

a. Submit in accordance with Section 01 78 23, Operation and Maintenance Data.

b. Include complete up-to-date system software documentation. Provide hardcopy and electronic copies.

2. Record Documentation: a. Prepare and submit record documents in accordance with Section

01 78 39, Project Record Documents.


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b. Revise all PCS Shop Drawings to reflect as-built conditions in accordance with the following. 1) Use "as-built" updates of approved Shop Drawings and submittals

in operation and maintenance manuals. 2) Half-size black line prints of wiring diagrams applicable to each

control panel shall be placed in clear plastic envelopes inside a suitable print pocket or container inside each control panel.

3) Submit drawings of the point-to-point interconnection wiring diagrams updated to reflect final as-built equipment information and as-installed field installation information.

D. Maintenance Materials Submittals: Submit the following: 1. Spare Parts and Test Equipment

a. General 1) Furnish the spare parts and test equipment in accordance with the

Contract Documents, identical to and interchangeable with similar materials and equipment provided for the PCS under the Contract.

2) Provide source quality control for spare parts as part of factory testing prior to shipment of process control system equipment.

3) For process sensors and other analog instruments, Supplier shall submit a separate quotation for recommended list of spare parts and test equipment. Separately list and price each item recommended. Spare parts quotation shall include a statement that prices quoted are valid for a period of one year from date of equipment installation and that Supplier understands that OWNER reserves the right to purchase none, any, or all parts quoted. Upon request, Supplier shall submit documentation that stock of spare parts and test equipment is obtainable within 48 hours of receipt of OWNER's order.

b. Furnish the following spare parts: 1) Five of each type of input/output relay for each quantity of forty or

fraction thereof provided under the Contract. 2) One of each type of PLC input/output module or card used. 3) One replacement power supply for each type and size provided

under the Contract. 4) One-year supply of all expendable or consumable materials. 5) One per quantity of five or fraction thereof of gauges, indicators,

and switches provided. 6) One per quantity of ten of fraction thereof provided, per range of

field instruments. No spares are required for inline instruments such as magnetic flow meters and flumes or venturis that include flow tubes through which flow is conveyed.

7) Twelve of each type and size of fuse used in instruments.

1.5 DELIVERY, STORAGE, AND HANDLING


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A. Prior to packaging, each manufacturer or Supplier shall securely attach tag number and instructions for proper field handling and installation to each instrument.

PART 2— PRODUCTS

2.1 PCS — GENERAL PROVISIONS FOR PRODUCTS

A. General: 1. All electrically-powered equipment and devices shall be suitable for

operation on 115-volt plus-or-minus 10 percent, 60 Hertz plus-or-minus two Hertz power. If different voltage or closer regulation is required, provide suitable regulator or transformer.

2. Provide appropriate power supplies for all two-wire transmitters, loops for monitoring discrete inputs and necessary outputs. Install power supplies mounted in enclosures, and install in appropriate control room or field panel.

3. Power supplies shall be suitable for minimum of 130 percent of the maximum simultaneous current draw.

4. Provide power on-off switch or air circuit breaker for each item requiring electrical power.

5. Provide isolation transformers, line voltage regulators and power distribution panels for the distributed digital portions of the PCS to eliminate electrical noise and/or transients entering on the primary power line.

6. Unless otherwise shown or indicated in the Contract Documents, control system shall be furnished to use 4 to 20 mADC analog signals.

7. Provide signal converters and repeaters where required. Analog inputs to distributed control system shall be through appropriate repeaters to provide signal isolation where series-looped with other devices and to allow loop to maintain integrity even when distributed control system is out of service. Power supplies shall adequate for signal converter and repeater loads.

8. Signals shall be isolated from ground. 9. Signals shall not have a transient DC voltage exceeding 300 volts over one

millisecond nor a DC component over 300 volts. 10. PCS and associated input/output wiring will be used in a facility

environment where there can be high-energy AC fields, DC control pulses, and varying ground potentials between the sensors/transducers or input contact locations and PCS components. PCS shall be adequate to provide proper protection against interferences from all such possible situations.

11. Instrumentation and PCS components shall be heavy-duty types, suitable for continuous service in a municipal water treatment plant environment. Furnish products that are currently in production at the time products are shipped from the factory. All equipment furnished shall be of modular construction and be capable of field expansion through installation of


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plug-in circuit cards and additional cabinets as necessary. Logic and control loops shall be fail-safe.

12. Instrumentation and other PCS components shall return automatically to accurate measurement within 15 seconds upon restoration of power after a power failure, and when transferred to standby power supply.

13. Provide surge protection for instruments and all other PCS components that could be damaged by electrical surges.

14. Field-mounted instruments and PCS components shall be suitable for installation in humid and corrosive service conditions. Field-mounted instrument enclosures, junction boxes, and appurtenances shall comply with NEMA 4X requirements, unless otherwise shown or specified.

15. Relays with interconnections to field devices shall be wired through terminal blocks. Terminals as part of the relay base are unacceptable.

16. Panel mounted instruments, switches, and other devices shall be selected and arranged to present a pleasing coordinated appearance. Front-of-panel-mounted devices shall be of the same manufacturer and model line.

17. All components furnished, including field-mounted and rear-of-panel instruments, shall be tagged with the item number and nomenclature as shown and the instrument index in the Contract Documents.

18. Ranges and scales specified in the Contract Documents shall be coordinated to suit equipment actually furnished. Range, scale, and set point values specified in other Sections of Division 40 are for initial setting and configuration. Coordinate specified values with actual equipment furnished to implement proper and stable process action as systems are placed in operation.

19. Field-mounted devices shall be treated with an anti-fungus spray. 20. Field-mounted devices shall be protected from exposure to freezing

temperatures.

B. Environmental Conditions: 1. PCS and its components shall be designed and constructed for continuous

operation under the following temperature and humidity conditions: a. Equipment and Devices Installed in Control Rooms:

1) Ambient Temperature: 60 degrees F to 80 degrees F normal range; and 40 degrees F to 105 degrees F occasional maximum extremes.

2) Relative Humidity: 80 percent, normal; 95 percent maximum. b. Equipment and devices installed at indoor locations (other than control

rooms) for digital processing equipment hardware, control panels, and instruments: 1) Ambient Temperature: 40 degrees F to 120 degrees F. 2) Relative Humidity: 98 percent maximum.

c. Equipment and Devices Installed Outdoors: 1) Ambient Temperature: -10 degrees F to 120 degrees F. 2) Relative Humidity: 100 percent maximum.

C. Refer to Sections 40 61 13 through 40 78 00 for product requirements for materials and equipment that are part of the PCS.


02270037.D001 7/31/15 10:18:37 AM 40 61 13-12

PART 3 — EXECUTION

3.1 PCS — GENERAL PROVISIONS FOR EXECUTION

A. Refer to Sections 40 61 13 through 40 78 00 for execution requirements for the PCS.



02270037.D001 7/31/15 10:18:37 AM 40 61 13-13

SECTION 40 61 21

PROCESS CONTROL SYSTEM FACTORY TESTING

PART 1— GENERAL

1.1 DESCRIPTION

A. Scope 1. CONTRACTOR shall coordinate with CONTROL SYSTEM SUPPLIER

and RADIO SYSTEM SUPPLIER to provide all labor, materials, equipment, and incidentals as specified and required for factory testing at the CONTROL SYSTEM SUPPLIER's facility to verify that system components function properly and comply with the functional and performance requirements of the Contract Documents.

2. Perform factory testing on the following types of equipment: a. Control Panels.

3. Perform factory testing on the process control systems for the following process equipment: a. Booster Pumps.

4. CONTRACTOR shall advise ENGINEER in writing of the scheduled dates for process control systems factory testing; submit such notice not less than 28 days prior to the scheduled start of factory testing. OWNER and ENGINEER will be present at factory testing facility during operational testing of the process control systems at the factory, either for individual units or for the integrated system. Presence of OWNER and ENGINEER during testing does not relieve CONTRACTOR from complying with the Contract Documents and shall does not indicate or imply acceptance of the equipment.

B. Related Sections:

1. 40 61 13, Process Control System General Provisions.

1.2 SUBMITTALS

A. Action Submittals: Submit the following:

1. Testing Plans: a. Submit factory test procedures in accordance with Section 40 61 13,

Process Control System General Provisions, for all equipment listed in Paragraph 1.1.A of this Section. Obtain ENGINEER's acceptance of testing plan not less than 28 days prior to scheduled start of factory test.

B. Informational Submittals: Submit the following:

1. Source Quality Control Submittals:

40 61 21 - Process Control System Factory Testing.doc

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a. Written results of factory testing for process control systems. Submit the complete factory test report within two weeks after completion of the factory test.

PART 2— PRODUCTS


A. Inspections Prior to Factory Testing: 1 Inspect each panel, console, and cabinet to verify compliance with the

Contract documents, and approved Shop Drawings and approved other CONTRACTOR submittals.

2. Inspection shall include, but not be limited to, the following: a. Nameplates and tags. b. Wire sizes and color coding. c. Terminal block contact ratings and numbers. d. Panel-mounted equipment and identification. e. External and internal panel layout. f. Proper wiring practices and grounding. g. Enclosure flatness, finish and color. h. NEMA rating and environmental control equipment.

3. Correct materials and equipment that do not comply with the Contract Documents and submittals approved by ENGINEER, and re-inspect until compliance is verified.

B. Factory Tests: 1. System Hardware Operational Testing:

a. Test each input/output device and component to verify operability. If panel or device being tested contains pneumatic systems, test the instruments associated with such systems to verify that calibration.

b. Test all system hardware components to verify proper operation of the equipment as stand-alone units and as a system. Tests shall include, but are not necessarily limited to, the following: 1) AC/DC power checks. 2) Power fail/restart tests. 3) Verify that radio, network switch, and fiber-optic converters are

powered by separate circuits. 4) Verify that quantity of circuits assigned to power field instruments

corresponds to approved Shop Drawings and approved other CONTRACTOR submittals.

c. Process Control System (PCS) and radio telemetry communications shall be tested to verify that communications between components and master and remote stations are operating correctly.

d. Criteria for Acceptance: System hardware operational testing shall acceptably demonstrate that specified and required equipment operations capabilities function properly.


02270037.D001 7/31/15 10:20:38 AM 40 61 21-2

e. Separately test each panel furnished under this Contract to verify that panel instruments and processors are perform and function properly in accordance with the Contract Documents. For the factory test required in this Section, simulate field sensors and field instruments using appropriate signal generators, switches, and jumper cables.

2. System Hardware Demonstration (Programming by OWNER) a. Factory test shall be performed jointly by the CONTRACTOR,

CONTROL SYSTEM SUPPLIER, ENGINEER, and OWNER. b. Preparation:

1) CONTRACTOR shall coordinate with OWNER and assemble the control system at the factory. Make the fully-assembled control system available to OWNER at the factory not less than two days prior to the scheduled start of the factory test.

2) OWNER will use the time between assembly for testing and the start of the factory test to upload the PLC logic and SCADA program, and verify that PLC logic and SCADA program are ready for the factory test.

3) Test system performance using a fully-integrated system, including all software and hardware. Prior to factory test, assemble entire control system, including all the peripheral devices and all interconnecting cables, at the factory test location. Apply simulated inputs. Signal generators shall be appropriately sized and calibrated for full range of use and shall have a power source to accommodate not less than a full day of testing.

4) Prior to the factory test, CONTROL SYSTEM SUPPLIER shall provide a process I/0 simulation panel consisting of the following: a) Toggle switches to simulate field or other input contacts. b) Indicating lights to simulate outputs from tested panels. c) Control relays to simulate motor control center coil inputs. d) Time relays to simulate position switches. e) Indications (in milliamps) to indicate every 4 to 20 ma-dc

output from tested panel. f) Potentiometers to simulate 4 to 20 ma-dc inputs to tested panel. g) Each device shall have nameplate with description and device's

process and instrumentation Drawings (P&ID) tag number. Nameplates shall be removable and interchangeable for multiple use of the panel during the test.

c. Factory Test: 1) CONTROL SYSTEM SUPPLIER shall perform the factory test,

during which the system equipment shall operate continuously without failure in accordance with the Contract Documents.

2) CONTROL SYSTEM SUPPLIER shall demonstrate via simulation of not less than five percent of total I/O quantity for both analog and discrete, as selected by ENGINEER. In addition, at the time of the factory test, OWNER or ENGINEER will randomly select additional I/0 to be simulated by CONTROL SYSTEM SUPPLIER in quantity not less than five percent of total I/O quantity.


02270037.D001 7/31/15 10:20:38 AM 40 61 21-3

3) Demonstrate that the monitoring and control wiring and instruments within the panel perform and function as intended.

4) Functional issues related to PLC programming, PCS programming or configuration, or HMI and OTT configuration by CONTROL SYSTEM SUPPLIER will be cause for a failed factory test.

5) When required, corrections to PLC programming, PCS programming or configuration, or HMI and OTT configuration will be by CONTROL SYSTEM SUPPLIER at no additional cost to OWNER.

3. Factory Test Acceptance Criteria: a. In addition to complying with Paragraph 2.1.B.1 of this Section,

failure or non-functioning of one or more communication links, failure of more than five percent of the total control functions, more than ten internal panel wiring discrepancies including I/O point cross-wirings, or more than ten I/0 point- or database-addressing errors will be unacceptable and constitutes factory test failure.

b. Do not ship the equipment from the factory until ENGINEER accepts the factory test results submittal.

c. Modifications, if any, to documentation as a result of the factory tests shall be completed before shipping the control system.

d. Should a factory test run fail to comply with the Contract Documents, necessary changes and corrections shall be made and the entire system retested until acceptable results are achieved.

e. Expenses and costs for OWNER and ENGINEER witnessing such retesting shall be paid by CONTRACTOR, including the following: 1) Transportation of OWNER and ENGINEER personnel to the

factory test location and return via commercial airline, and ground transportation to and from airports as required.

2) Overnight accommodations (two single occupancy rooms) in a hotel in reasonable proximity to the factory testing location. Room quality to be standard business class.

3) Ground transportation between the hotel and factory testing location 4) Meals for the duration of the testing. Meal allowance shall not be

less than U.S. Internal Revenue Service guidelines.

PART 3 — EXECUTION (NOT USED)



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SECTION 40 61 23

PROCESS CONTROL SYSTEM START-UP AND FIELD TESTING

PART 1 - GENERAL

1.1 SYSTEM CHECK-OUT AND START-UP RESPONSIBILITIES

A. CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish and install all equipment and coordinate all activities necessary to perform check-out and start-up of the equipment.

B. CONTRACTOR shall retain the services of the CONTROL SYSTEM SUPPLIER to supervise and/or perform check-out and start-up of all system components. As part of these services, the CONTROL SYSTEM SUPPLIER shall include for those equipment items not manufactured by him the services of an authorized manufacturers' representative to check the equipment installation and place the equipment in operation. The manufacturers' representative shall be thoroughly knowledgeable about the installation, operation and maintenance of the equipment.

1.2 SYSTEM CHECKOUT AND START-UP

A. CONTRACTOR, under the supervision of the CONTROL SYSTEM SUPPLIER and RADIO SYSTEM SUPPLIER, and other instrument suppliers as applicable, shall perform the following: 1. Check and approve the installation of all Process Control System (PCS)

components and all cable and wiring connections between the various system components prior to placing the various processes and equipment into operation.

2. Conduct a complete system checkout and adjustment, including calibration of all instruments, tuning of control loops, checking operation functions, and testing of final control actions. When there are future operational functions included in this work, they should be included in the system checkout. All problems encountered shall be promptly corrected to prevent any delays in start-up of the various unit processes.

3. PCS and radio telemetry communications shall be tested to verify that communications between components and master and remote stations are operating correctly.

B. CONTRACTOR shall provide all test equipment necessary to perform the testing during system checkout and start-up.

C. CONTRACTOR and CONTROL SYSTEM SUPPLIER shall be responsible for initial operation of monitoring and control system and shall make any required

40 61 23 - Process Control System Start-up and Field Testing.doc

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changes, adjustment or replacements for operation, monitoring and control of the various processes and equipment necessary to perform the functions intended.

D. CONTRACTOR shall furnish to the ENGINEER certified calibration reports for field instruments and devices specified in Section 40 70 05, Primary Sensors and Field Instruments, and panel mounted devices specified in Section 40 78 00, Panel-Mounted Instruments and Devices, as soon as calibration is completed.

E. CONTRACTOR shall furnish ENGINEER an installation inspection report certifying that all equipment has been installed correctly and is operating properly. The report shall be signed by authorized representatives of both CONTRACTOR and the CONTROL SYSTEM SUPPLIER.

1.3 INTEGRATED SYSTEM FIELD TEST

A. Following the PCS checkout and initial operation, CONTRACTOR, under the supervision of the CONTROL SYSTEM SUPPLIER, shall perform a complete system test to verify that all equipment is operating properly as a fully integrated system, and that the intended monitoring and control functions are fully implemented and operational, including radio communications between master and remote stations. Any defects or problems found during the test shall be corrected by CONTRACTOR and then retested to demonstrate proper operation.

B. Following demonstration of all system functions, the PCS including field sensors/transducers and instruments shall be running and fully operational for a continuous 48 hour period to be considered operational.

PART 2- PRODUCTS (NOT USED)

PART 3- EXECUTION (NOT USED)


40 61 23 - Process Control System Start-up and Field Testing.doc

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SECTION 40 61 26

PROCESS CONTROL SYSTEM TRAINING

PART 1 - GENERAL

1.1 REQUIREMENTS AND RESPONSIBILITIES

A. CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown, specified and required to perform and coordinate all required training at times acceptable to OWNER and ENGINEER.

B. CONTRACTOR shall retain the services of the CONTROL SYSTEM SUPPLIER to provide operation and maintenance training for all Process Control System (PCS) equipment as specified herein.

C. For equipment items not manufactured by the CONTROL SYSTEM SUPPLIER, the CONTROL SYSTEM SUPPLIER shall provide for on-site training by an authorized representative of the equipment manufacturer as part of the CONTROL SYSTEM SUPPLIER's services. The manufacturer's representative shall be fully knowledgeable in the operation and maintenance of the equipment.

D. CONTRACTOR shall be responsible for all costs, including cost oftravel, meals and lodging, if required, associated with training on-site, and shall provide all required materials, texts and required supplies.

E. All training shall be conducted in the normal eight-hour working days until conclusion of the training course.

1.2 SUBMITTALS

A. Within 90 days of the effective date of the Notice to Proceed, CONTRACTOR shall submit his plan for training conforming to the requirements of Section 01 79 23, Instruction of Operations and Maintenance Personnel.

1.3 ON-SITE TRAINING

A. Primary Sensors/Transducers and Field Instruments: 1.

Provide on-site operation and maintenance training by CONTROL SYSTEM SUPPLIER and the equipment manufacturer representatives prior to placing the equipment in continuous operation, conforming to the requirements of Section 01 79 23, Instruction of Operations and Maintenance Personnel. The services of equipment manufacturer's representatives shall be provided for a minimum of four hours for each type of instrument provided.

40 61 26 - Process Control System Training.doc

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2. Training shall accomplish the following: a. Provide instruction covering use and operation of the equipment to

perform the intended functions. b. Provide instruction covering procedures for routine, preventive and

troubleshooting maintenance including equipment calibration. c. Explain procedures for placing the equipment in and out of operation and

explain necessary actions and precautions to be taken regarding the overall plant monitoring and control system.

B. Control Panels: 1. During the first thirty (30) days of continuous operation of the control panels,

retain qualified representatives of the CONTROL SYSTEM SUPPLIER and equipment manufacturer to instruct on-site Owner personnel. The qualified representatives of the CONTROL SYSTEM SUPPLIER and equipment manufacturer shall provide, as a minimum, the following control panel training: a. Water Treatment Plant Master Telemetry Panel: Two (2) hours of

training. b. Benner Road Booster Station Remote Telemetry Panel: Two (2) hours of

training. c. Byers Road Water Tower Remote Telemetry Panel: Two (2) hours of

training. d. Richard Street Water Tower Remote Telemetry Panel: Two (2) hours of

training. 2. Operator and maintenance training shall accomplish the following:

a. Provide instruction covering the use and operation of the control panels and all items contained on or within the control panels.

b. Provide instruction covering procedures for routine, preventative, and troubleshooting maintenance including device calibration.

c. Explain procedures for placing the control panels in and out of operation.

C. PLC Training: 1. The CONTROL SYSTEM SUPPLIER shall provide a minimum of (4) hours of

training (maximum four students) that covers PLC as follows: a. Provide an overview of system hardware and software. b. Configuration, operation and programming processors. c. The emphasis shall be placed on how to perform set point changes, minor

programming changes, range changes, diagnostics and upkeep of documentation.

d. Instruction for hardware and software maintenance, trouble shooting and maintenance planning.

D. Training following two months of regular system operations: 1. The CONTROL SYSTEM SUPPLIER shall provide operation and

maintenance covering all system equipment provided. 2. The training shall be of the same format, content and duration as the training

described in Paragraph 1.3.A. and Paragraph 1.3.B., above.


02270037.D001 7/31/15 10:21:49 AM 40 61 26-2

PART 2- PRODUCTS (NOT USED)




02270037.D001 7/31/15 10:21:49 AM 40 61 26-3

SECTION 40 61 93

INPUT/OUTPUT SCHEDULE

PART 1 - GENERAL

1.1 SUMMARY

A. CONTRACTOR shall provide the field wiring for the input/output capacity as listed herein and as shown on the Drawings. The I/0 enclosures shall be provided by the CONTROL SYSTEM SUPPLIER. CONTRACTOR shall terminate input/output signals in the CONTROL SYSTEM SUPPLIER furnished I/0 enclosures as shown on the Drawings and as listed herein.

B. An input/output schedule for the Process Control System (PCS) is included at the end of this Section.

1.2 SUBMITTALS

A. Comply with the requirements of Section 40 6113.

PART 2- PRODUCTS

2.1 INPUT/OUTPUT SCHEDULE

A. Column Headings: The following column headings identify individual I/O point characteristics:

1. CP: Name of panel or enclosure containing the I/0 module.

2. DESCRIPTION 1/DESCRIPTION Functional description of 110 point. 2:

3. I/O TYPE: I/O module type a. DI: isolated discrete input, 120 VAC. b. DO: isolated discrete output, 120 VAC. c. Al: isolated analog output, 4-20 mA DC types. d. AO: isolated analog output, 4-20 mA DC types.

4. RANGE: Analog signal range in engineering units.

5. EQUIP TAG: Equipment Tag number

6. TAG: Signal Tag number

7. DWG NO.: Con-esponding P&ID.

8. MONITOR/CNTRL/ Signal Type. MONITOR W/ACTION

40 61 93 - Input Output Schedule.docx

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40 61 93 - Input Output Schedule.docx

02270037.D001 7/31/15 10:22:10 AM 40 61 93-2

BNR-BPS-RTU

Index Dwg

# Equip Tag

Tag DESCRIPTION 1 DESCRIPTION 2 I/0

Type Range

Monitor/ CNTRL/

Monitor w/ Action CP

1 -3 YIU-B000 AUTOMATIC TRANSFER

SWITCH SYSTEM ON

UTILITY DI N/A MONITOR BNR-BPS-RTU

2 -3 YIG-B000 AUTOMATIC TRANSFER

SWITCH SYSTEM ON GENERATOR

DI N/A MONITOR BNR-BPS-RTU

3 -3 UAF-B000 AUTOMATIC TRANSFER

SWITCH ATS FAILURE DI N/A MONITOR BNR-BPS-RTU

4 -3 LAHH-B001 GENERATOR FUEL TANK LEAK

ALARM DI N/A MONITOR BNR-BPS-RTU

5 -3 UAS-B001 GENERATOR EMERGENCY

STOP DI N/A MONITOR BNR-BPS-RTU

6 -3 YIR-B001 GENERATOR RUNNING DI N/A MONITOR BNR-BPS-RTU

7 -3 UAH-B001 GENERATOR COMMON

WARNING ALARM DI N/A MONITOR BNR-BPS-RTU

8 -3 UAHH-B001 GENERATOR LAJNIMUIN

SHUTDOWN Al A RNA

DI N/A MONITOR BNR-BPS-RTU

9 -3 LAL-B001 GENERATOR FUEL TANK LEVEL

LOW DI N/A MONITOR BNR-BPS-RTU

10 -3 FI-B004 BOOSTER PUMP

(RECYCLE) FLOW Al

0 -2,000

GPM MONITOR BNR-BPS-RTU

11 -3 PI-B005 BOOSTER PUMP

(RECYCLE) SYSTEM

PRESSURE Al 0 - 200 PSI MONITOR BNR-BPS-RTU

12 -3 YIR-B010 BOOSTER PUMP NO. 1 RUNNING DI N/A MONITOR BNR-BPS-RTU

13 -3 YIF-B010 BOOSTER PUMP NO. 1 COMMON FAULT DI N/A MONITOR BNR-BPS-RTU

14 -3 SC-B010 BOOSTER PUMP NO. 1 SPEED CONTROL AO 0- 100% CNTRL BNR-BPS-RTU

15 -3 SI-B010 BOOSTER PUMP NO. 1 SPEED FEEDBACK Al 0- 100% MONITOR BNR-BPS-RTU

16 -3 II-B010 BOOSTER PUMP NO. 1 AMPS Al MONITOR BNR-BPS-RTU

17 -3 El-B010 BOOSTER PUMP NO. 1 VOLTS Al MONITOR BNR-BPS-RTU

00621003 DB01

Page 1 of 5

I/O SIGNAL LIST

BNR-BPS-RTU

Index Dwg

# Equip Tag


Type Range

Monithr/ CNTRL/


18 -3 TI-B010 BOOSTER PUMP NO. 1 TEMP Al MONITOR BNR-BPS-RTU

19 -3 YIB-B010 BOOSTER PUMP NO. 1 IN PLC DI N/A MONITOR BNR-BPS-RTU



22 -3 SC-B020 BOOSTER PUMP NO. 2 SPEED CONTROL AO 0 -100% CNTRL BNR-BPS-RTU








30 -3 SC-B030 BOOSTER PUMP NO. 3 SPEED CONTROL AO 0- 100% CNTRL BNR-BPS-RTU





00621003 DB01

Page 2 of 5

I/O SIGNAL LIST

BNR-BPS-RTU

Index Dwg

# Equip Tag


Type Range

Monitor/ CNTRL/



36 -3 YIR-B040 BOOSTER PUMP NO. 4

(FUTURE) RUNNING DI N/A MONITOR BNR-BPS-RTU

37 -3 YIF-B040 BOOSTER PUMP NO. 4

(FUTURE) COMMON FAULT DI N/A MONITOR BNR-BPS-RTU

38 -3 SC-B040 BOOSTER PUMP NO. 4

(FUTURE) SPEED CONTROL AO 0 - 100% CNTRL BNR-BPS-RTU

39 -3 SI-B040 BOOSTER PUMP NO. 4

(FUTURE) SPEED FEEDBACK Al 0 - 100% MONITOR BNR-BPS-RTU

40 -3 II-B040 BOOSTER PUMP NO. 4

(FUTURE) AMPS Al MONITOR BNR-BPS-RTU

41 -3 El-B040 BOOSTER PUMP NO. 4

(FUTURE) VOLTS Al MONITOR BNR-BPS-RTU

42 -3 TI-B040 BOOSTER PUMP NO. 4

(FUTURE) TEMP Al MONITOR BNR-BPS-RTU

43 -3 YIB-B040 BOOSTER PUMP NO. 4

(FUTURE) IN PLC DI N/A MONITOR BNR-BPS-RTU

44 -3 PCV-1 PB-B014 PUMP CONTROL VALVE

NO. 1 START/STOP DO N/A CNTRL BNR-BPS-RTU

45 -3 PCV-1 Y10-B014 PUMP CONTROL VALVE

NO. 1 OPENED DI N/A MONITOR BNR-BPS-RTU

46 -3 PCV-1 YIC-B014 PUMP CONTROL VALVE

NO. 1 CLOSED DI N/A MONITOR BNR-BPS-RTU

47 -3 PCV-1 YIB-B014A PUMP CONTROL VALVE

NO. 1 LCP IN REMOTE DI N/A MONITOR BNR-BPS-RTU

48 -3 PCV-1 YIB-B014B PUMP CONTROL VALVE

NO. 1 IN REMOTE DI N/A MONITOR BNR-BPS-RTU

49 -3 PCV-1 YIF-B014 PUMP CONTROL VALVE

NO. 1 COMMON FAULT DI N/A MONITOR BNR-BPS-RTU





00621003 DB01

Page 3 of 5

I/O SIGNAL LIST

BNR-BPS-RTU

Index Dwg

# Equip Tag


Type Range

Monitor/ CNTRL/






















62 -3 PB-B044 PUMP CONTROL VALVE

NO. 4 (FUTURE) START/STOP DO N/A CNTRL BNR-BPS-RTU

63 -3 Y10-B044 PUMP CONTROL VALVE

NO. 4 (FUTURE) OPENED DI N/A MONITOR BNR-BPS-RTU

64 -3 YIC-B044 PUMP CONTROL VALVE

NO. 4 (FUTURE) CLOSED DI N/A MONITOR BNR-BPS-RTU

65 -3 YIB-B044A PUMP CONTROL VALVE

NO. 4 (FUTURE) LCP IN REMOTE DI N/A MONITOR BNR-BPS-RTU

66 -3 YIB-B044B PUMP CONTROL VALVE

NO. 4 (FUTURE) IN REMOTE DI N/A MONITOR BNR-BPS-RTU

67 -3 YIF-B044 PUMP CONTROL VALVE

NO. 4 (FUTURE) COMMON FAULT DI N/A MONITOR BNR-BPS-RTU

68 -3 LAH-B007 SUMP LEVEL HIGH DI N/A MONITOR BNR-BPS-RTU

00621003 DB01

Page 4 of 5

I/O SIGNAL LIST

BNR-BPS-RTU

Index Dwg

# Equip Tag


Type Range

Monitor/ CNTRL/


69 1-3 LAH-B009 SANITARY HOLDING TANK LEVEL HIGH DI N/A MONITOR BNR-BPS-RTU

70 1-3 Y10-B002 ENTRANCE GATE OPENED DI N/A MONITOR BNR-BPS-RTU

71 1-3 YIC-B002 ENTRANCE GATE CLOSED DI N/A MONITOR BNR-BPS-RTU

00621003 DB01

Page 5 of 5 I/O SIGNAL LIST

SECTION 40 61 96

PROCESS CONTROL DESCRIPTIONS

PART 1 - GENERAL

1.1 DESCRIPTION

A. Definition: 1.

The purpose of this document is to describe the proposed control philosophy and control system approach for the Benner Road Pump Station and Water Main Improvements in the city of Miamisburg, Ohio. This document describes the proposed control system, including monitoring requirements, control capabilities and general control system and operator interface computer station (otherwise referred to as a Human Machine Interface, or HMI) layout.

B. Scope: 1. The CONTROL SYSTEM SUPPLIER shall furnish control strategy

diagrams, configuration sheets and control strategy descriptions as shown, specified and required to configure the system complete and operational.

2. The CONTROL SYSTEM SUPPLIER shall perform all programming, configuration and tuning of the control system.

3. The Process Control System (PCS) shall monitor and control the systems contained within the facility in accordance with this specification section and the manufacturer recommendations. The control descriptions and instrumentation drawings describe the required monitoring and control, which may include multiple locations of control including at the equipment, at RTLT panels, and at HMI. The CONTROL SYSTEM SUPPLIER will be responsible for the programming and configuration of the PLC, HMI, and network hardware. The CONTROL SYSTEM SUPPLIER HMI programming is to provide graphical control of equipment from the locations shown in accordance with OWNER preferences.

C. Related Sections: 1. Section 40 61 13, Process Control System General Provisions. 2. Section 40 61 21, Process Control System Factory Testing. 3. Section 40 61 23, Process Control System Start-up and Field Testing 4. Section 40 61 26, Process Control System Training 5. Section 40 64 00, Programmable Logic Controllers

D. This Section describes all of the anticipated control programming. The control strategies are generally divided process area.

1.2 GENERAL CONTROL PHILOSOPHY:

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A. Control System Description: 1. The control system will consist of Human Machine Interfaces (HMIs),

Programmable Logic Controllers (PLCs), Remote Telemetry Units (RTUs), and field devices. The Controllers will be configured and programmed to control all systems either manually or automatically, based on monitored data, commands and set points entered by operators at the HMIs. For maintenance mode only, control of equipment will be possible from local control stations or control panels located at or near the equipment.

2. The control strategies are written descriptions of process control for the unit processes and mechanical or electrical equipment controls required for safe operation. Control strategies shall reside in the memory of the designated processor.

B. Local Control Mode: 1. All equipment will have local manual control capability at or near the

equipment. Equipment that can also be controlled remotely by the PLC will have a LOCAL-OFF-REMOTE selector switch at that piece of equipment to select control location. If the selector switch is in the LOCAL position, the local manual control will be enabled and the remote control and PLC control will be disabled.

C. Remote Control Mode: 1. When the LOCAL-OFF-REMOTE selector switch for the equipment that can

be controlled remotely is in the REMOTE position, the remote control and PLC control will be enabled and the local manual control (except for stop push buttons) will be disabled. Where multiple remote control locations are available such as OTT and HMI, both controls are available simultaneously with no priority given to one or the other. The OITs are intended for use in maintenance.

2. In some cases, there is more than one level of remote control. In the case of a VFD driven pump or blower, for example, local control is provided by a Local Control Station (LCS) at or near the piece of equipment as the VFD is usually remote from the equipment. The remotely located VFD then acts as a first layer of remote control. The OITs and HMIs, together, form the second layer of remote control. To separate the two layers of remote control, a switch, labeled VFD-PLC, shall be provided on the panel containing the VFD. a. When the LOCAL-OFF-REMOTE switch on the LCS is in LOCAL, the

equipment shall be controlled via START and STOP pushbuttons on the LCS

b. When the LOCAL-OFF-REMOTE switch on the LCS is in REMOTE and the VFD-PLC switch at the VFD is in VFD, start/stop and speed control will be manually adjusted by the operator at the VFD.

c. When the LOCAL-OFF-REMOTE switch on the LCS is in the REMOTE mode and the VFD-PLC switch at the VFD is in the PLC mode, the PLC will be allowed to control the equipment based on


02270037.D001 7/31/15 10:22:58 AM 40 61 96-2

control values entered by the operator. The PLC will control the equipment in either a PLC MANUAL or a PLC AUTO mode of operation, as selected by the operator at the HMI. 1) PLC MANUAL Control: The PLC MANUAL mode of control

requires operator action at the HMI to change the operating status of the piece of equipment.

2) PLC AUTO Control: PLC AUTO control allows the PLC to control the equipment based on operator-entered set points and measured values.

3. Control Modes: a. Remote Manual control: It shall be possible for the Operator to

interrupt any sequence, loop, or automatic operation and operate the same manually through the operator workstation.

b. Output Verification: This control function shall verify that the equipment has responded to the digital commands before proceeding to the next step during automatic operation. If any discrepancy is detected, an alarm shall be annunciated.

c. System Initialization Routine: Each processor shall have an initialization routine to initialize all system variables.

D. Protective Interlocks: 1. Equipment protective, hardwired interlocks shall remain in effect in all

control modes.

E. Control System Configuration: 1. The PLC and HMIs will be located as shown on the configuration diagram

and building layout drawings. 2. At each HMI, graphic displays will provide detailed, user-friendly

information on all equipment, and will allow the operator to initiate process changes or respond to alarm conditions as shown on the drawings with this description.

3. The information contained within each PLC connected to the network shall be fully available on the control system network for viewing on the HMIs within the control room. The monitoring and control functions shown on the drawings represent the minimum required information to be programmed into the HMI screens.

4. Each PLC shall be programmed to be a standalone unit that will control the equipment connected to it, even if the communication between the PLC and the HMI is severed. In this case, the PLC shall use the previously entered set points to control the equipment.

5. All set points, tuning parameters and engineering scales shall be documented for each control point and each control strategy on configuration sheets or similar documentation. These configuration sheets with initial data shall be submitted for review, shall be updated before the factory test and available at the factory test, and shall be updated during startup and commissioning. The


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record documents shall be submitted showing the final version of the configuration sheets

F. Process Control Functions: 1. Process control function shall be structured to permit the realization of all

control strategy requirements. In addition, each control function shall be designed so that non-disruptive (bumpless and balance free) transfers are obtained during operating mode changeover and initialization. Where applicable, user changeable parameters shall be automatically defaulted to a preset value if a specific value is not given during system operation.

2. The P&IDs represent the required process monitoring and control. The required control for the system is a combination of the representation on the P&IDs and the requirements specified herein. The P&IDs do not show all the required internal diagnostic indications for the systems. In addition to the indications shown on the P&IDs, the following, at a minimum shall be provided, including internal diagnostic functions, indications, analog signal conversions and discrete signal verifications: a. Indication of bad quality on any hard wired input/output point (such as

zero milliamps on a 4 to 20 mADC circuit). Bad quality points shall be excluded from average calculations.

b. Individual PLC fault indications. (controller fault) c. Indication of a communications failure. d. For all motor start and stop commands check for run feedback after

adjustable time delay (0 to 30 seconds). Provide a "FAIL TO START" and "FAIL TO STOP" alarm if unit fails to run or stop. Provide validation of equipment running using process monitoring conditions such as PSH, FSH, or PSL instead of starter contact. Use the bad start or stop bit to remove the run command from the control logic.

e. For all motorized valve and gate open and close commands check for open or close limit switch feedback after an adjustable time delay (0 to 360 seconds). Provide a "FAIL TO OPEN" and "FAIL TO CLOSE" alarm if valve or gate fails to open or close. Each timer shall be adjusted during startup based on valve and gate performance.

f. For all modulating valve and gate position control commands check for a deviation between command and feedback after an adjustable time delay (0 to 360 seconds). Provide a "FAIL TO MOVE" alarm if valve or gate fails to move to + 5% of the commanded position. Each timer shall be adjusted during startup based on valve and gate performance.

g. Cumulative runtime indicators shall be provided for all equipment. h. Adjustable startup and shutdown delay timers shall be provided to allow

normal startup and shutdown of equipment without alarms or bypassing of hardware safety interlocks.

i. Controller fault- individual controller fault indication. j. PCS Network communication failure - Indication of communication

failure at each process network node or processor.


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k. Track and hold- for analog control loops, when control of field equipment is not in "remote mode" the associated PID controller output shall track the position feedback.

1. Analog alarms: for all analog signals, provide the following alarm indications. These settings shall be adjustable based on security login. 1) High-high 2) High 3) Low 4) Low-low 5) High rate of change, low rate of change.

3. If any equipment faults or shuts down through an interlock, the cause of the alarm/shutdown must be corrected and the alarm must be acknowledged in the HMI prior to restart.

4. All equipment shall be controlled independently of each other when operated in manual unless otherwise indicated.

5. Each control function shall be implemented using the programmable hardware in the designated processor. No functions shall be developed using hardwired relay logic.

6. The following shall be provided in addition to the indications above. a. ANALOG DATA SCALING: This control function shall scale all

analog inputs to a common span and shall normalize the digital representation of each analog input to a percent of the operating span. The processed value shall be expressed as a binary number that specifies the analog input's position on a straight line lying between zero and full scale as defined for a given input by the zero and span values in the data base.

b. AMPLITUDE LIMIT CHECK: This control function shall perform dual level, high/low amplitude limit checking and shall identify a limit violation every time a measured or virtual variable goes out-of-limits and returns back into limits. The control function shall determine the time at which each limit excursion occurred. A deadband shall be provided on each limit and shall be expressed as a percentage of span or in engineering units. Low and high limiting default values shall be set-up for each measured or calculated variables used in the process control loops.

c. ENGINEERING UNIT CONVERSION: This control function shall convert scaled analog data to engineering units by means of the following equation:

Y = (H - L) (D/DH) + L

where:

Y = value in engineering units

H = high value of span, expressed in engineering units

L = low value of span, expressed in engineering units

D = digitized scaled input value in counts 40 61 96 - Process Control Descriptions.doc

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DH = full scale digitized value in counts

7. All equipment shall be controlled independently of each other when operated in manual unless otherwise indicated.

G. Hardware: CONTROL SYSTEM SUPPLIER shall provide all the hardware, as shown, specified, or required to implement the control strategies as described.

H. Configuration: All set points, tuning parameters, and engineering scales shall be documented for each control point and each control strategy on configuration sheets or similar documents. These documents shall be updated during Factory Testing and finally during start-up.

I. Control Strategy Displays: Control strategy displays shall be submitted for review. Displays shall clearly show initial conditions, start, and progression of the control strategies. Each control strategy shall be displayed in a minimum number of displays for ease of monitoring by the Operator.

J. Plant Power Failure: Plant equipment controlled by the control system shall be programmed to automatically reset upon failure. The reset and restart sequence shall be enabled through the PCS. When power is restored select process equipment as approved by the ENGINEER shall be permitted to restart.

K. Restart: Equipment and motors that can safely be restarted shall be automatically restarted after power failure by the control system in an orderly time delayed sequence approved by the ENGINEER. Equipment that requires Operator intervention shall be prompted for restart following power restoration.

L. All relays, tuning parameters, scales, configuration values, mathematical constants, equations, and set points given in the control strategies are adjustable over a wide range. The values given are initial and may change during Shop Drawing review and may have to be readjusted during start-up.

1.3 COORDINATION WORKSHOPS

A. CONTROL SYSTEM SUPPLIER shall attend programming workshops with OWNER. The content of these workshops shall include PLC and HMI programming, including documentation and security. Prior to the development of the control strategies these workshops shall be scheduled and completed.

1.4 SUBMITTALS A. The control strategies are written descriptions of the basic configuration and/or

programming required to implement regulatory and sequential control of the unit processes as shown on the P&IDs. They do not in all cases describe the process characteristics fully. Finalizing and tuning of strategies, as required, by process characteristics shall be accomplished during start-up. Control strategies shall fully reside in the memory of the designated PLC. The process inputs/outputs referred


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to in the Control Strategies are shown on the P&IDs.

B. CONTROL SYSTEM SUPPLIER shall furnish control strategy diagrams, configuration sheets and control strategy descriptions as shown, specified and required to configure a complete and operational system. They shall incorporate revisions to the Contract P&IDs, these control descriptions, the 110 listing, interlocks, alarms, reporting requirements and manufacturer equipment requirements. 1. Shop drawing review. 2. Factory test. 3. Following system startup and commissioning.

PART 2 PRODUCTS

2.1 PERFORMANCE:

A. Purpose of the Control Descriptions: 1. The following descriptions explain the proposed monitoring and control

scheme for each piece of equipment in each process area. 2. Equipment that is just monitored will be indicated as "Just monitoring, no

control."

B. Update digital inputs and analog inputs in the processor controller within 1 second of a change of state for digital inputs or exceeding the exception deadband for analog inputs. 1. The display response time is the elapsed time from the instant the display

request is made by the operator, to the instant the display is completely shown on the operator workstation. Meet the following display response times: a. For graphic displays average 1 second with a maximum of 2 seconds for

static and dynamic data fields. Update dynamic fields every 2 seconds. b. For real-time trend displays average 2 seconds with a maximum of 3

seconds. c. Average 1.5 seconds with a maximum of 3 seconds for other displays

which do not require access to historical data. d. For historical data displays, do not exceed 10 seconds to retrieve and

display data. 2. The operator workstation response time is the elapsed time from the instant

an operator request has been made and the instant the request is executed at the processor. Average 1 second with a maximum of 2 seconds for control related requests including, but not limited to, start/stop, open/close, setpoint changes, and control strategy auto/manual status changes.

3. The report request time is the elapsed time from the instant a report request is made to the instant the printing of the report begins. Do not exceed 30 seconds.


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4. Accept data entry at 60 words per minute typing speed. 5. Reload the system software for entire system within 1 hour. 6. Demonstrate performance at Factory Testing and Field Testing. 7. Meet a system availability of 99.7 percent over 90 consecutive days.

PART 3 EXECUTION

3.1 BOOSTER PUMPING

A. General:

1. The Booster Pumps consist of three variable speed pumps and one future pump located inside the Booster Pump Station.

B. Local Control:

1. When the LOCAL-OFF-REMOTE selector switch on the pump control valve local control panel (LCP) is in the LOCAL position, commands via control panel touch screen on the LCP shall control the pump. a. START command via control panel touch screen shall initiate the

Booster Pump Start Sequence. b. STOP command via control panel touch screen shall initiate the

Booster Pump Stop Sequence. c. Operation of the EMERGENCY STOP pushbutton on the LCP

shall de-energize the pump. d. Speed control shall be from the drive keypad.

2. When the LOCAL-OFF-REMOTE selector switch is in the OFF position, the pump shall not operate.

C. Remote Control: 1. When the LOCAL-OFF-REMOTE selector switch on the LCP is in the

REMOTE position, a VFD-PLC selector switch on the VFD drive shall determine further control. If the VFD-PLC selector switch is in the VFD position: a. Drive speed control shall be from the drive keypad.

2. When the VFD-PLC selector switch is in the PLC position, the pump shall start/stop in an automatic mode and vary speed in either a manual or automatic mode based on operator inputs at the OIT/HMI. Each pump shall have an Auto/Manual selection for speed control on the OIT/HMI. a. When the pump is selected for manual speed control from the

OIT/HMI, the pump speed shall be controlled based on an operator entered speed setpoint at the OIT/HMI.

b. When the pump is selected for automatic speed control from the OIT/HMI, the pump speed shall be automatically adjusted by the SCADA system to maintain an operator-entered level setpoint in the Byers Rd. tank or to maintain an operator-entered pressure


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setpoint at the booster pumps discharge header. Selection of level or pressure control shall be at the OIT/HMI.

c. When the pump is selected for remote start/stop control from the OIT/HMI, the pump shall automatically start and stop based on Lead or Lag designation. Each pump shall be designated as Lead, Lag, or Standby from the HMI. Designations shall be automatically rotated to distribute operation evenly amongst the pumps. The Lead pump shall always run first when called to run in the automatic mode. The Lag pump shall start when the Lead pump has been running at an operator adjustable full speed setpoint for five minutes and the automatic speed control is calling for more pumping capacity. The Lag pump shall stop when the pumps are running at an operator adjustable minimum speed setpoint for five minutes and the automatic speed control is calling for less pumping capacity. When Lead and Lag pumps are running, they shall run at the same speed.

1) If the Lead pump should fail, the Lag pump shall operate in place of the failed Lead pump, and the Standby pump shall operate as Lag.

2) If the Lag pump should fail, the Standby pump shall operate in place of the Lag pump.

D. Interlocks: 1. Drive shall shutdown upon opening of motor winding thermal switch.

3.2 BOOSTER PUMP CONTROL VALVE

A. General: 1. Each Booster Pump has an electric control valve on its discharge line.

B. Local Control: 1. When the LOCAL-OFF-REMOTE selector switch on the Booster Pump

control valve actuator is in the LOCAL position, OPEN-CLOSE-STOP pushbuttons on the actuator shall control the valve.

2. When the LOCAL-OFF-REMOTE selector switch on the Booster Pump control valve actuator is in the OFF position, the valve shall not operate.

C. Remote Control: 1. When the LOCAL-OFF-REMOTE selector switch on the Booster Pump

control valve actuator is in the REMOTE position, OPEN-CLOSE control of the valve shall be from the control valve local control panel in either local or remote mode as determined by the position of the LOCAL-OFF-REMOTE selector switch on the Booster Pump control valve local control panel. a. When the LOCAL-OFF-REMOTE selector switch on the Booster

Pump control valve local control panel is in the LOCAL position,


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1) OPEN-CLOSE commands via control panel touch screen shall control the valve.

2) The valve shall open/close as part of the Booster Pump Start Sequence upon operation of the START command via control panel touch screen.

3) The valve shall open/close as part of the Booster Pump Stop Sequence upon operation of the STOP command via control panel touch screen.

b. When the LOCAL-OFF-REMOTE selector switch on the Booster Pump control valve local control panel is in the OFF position, the valve shall not operate.

c. When the LOCAL-OFF-REMOTE selector switch on the Booster Pump control valve local control panel is in the REMOTE position, the valve shall open and close in accordance with the Booster Pump logic in Section 40 05 53.

D. Interlocks: a. Valves shall only be allowed to open/close via manual control panel touch

screen commands when the associated pump is not running.



02270037.D001 7/31/15 10:22:58 AM 40 61 96-10

SECTION 40 64 00

PROGRAMMABLE LOGIC CONTROLLERS

PART 1- GENERAL

1.1 DESCRIPTION

A. CONTRACTOR shall coordinate with CONTROL SYSTEM SUPPLIER to furnish all labor, materials, and components, and shall provide all design, assembly, testing, and start-up services required to provide a complete and operational programmable controller (PLC) system as specified and shown on the Drawings. The system includes, but is not necessarily limited to the following: 1. PLC processors. 2. PLC 110 modules, chassis, and power supplies. 3. Operator Interface Terminal (OTT) for interfacing with PLC. 4. PLC communications systems including, but not limited to, between

processors, and to OITs and HMI computers. 5. PLC system detailed design, assembly, installation, testing, and start-up

services. 6. Coordination with the RADIO SYSTEM SUPPLIER to ensure proper

interface and communications between equipment specified herein and Telemetry System equipment specified in Section 40 66 53, Multiple Address Radio Equipment.

B. The PLC system configuration shall be as shown on the Drawings and specified herein. The PLC system configuration was developed using Allen Bradley CompactLogix processors and 1769 input/output modules as the basis of design. Some variations in the configuration will be considered provided the physical and functional constraints as intended for the various system components are met.

C. The Process and Instrumentation Diagrams (P&ID's) and the specifications of this Section and the other Division 40 Sections generally illustrate and describe the overall PLC System requirements.

D. All equipment shall be constructed specifically for the demanding requirements of real-time process management and control on a continuous basis for use in a municipal water treatment plant.

1.2 SUBMITTALS

A. Comply with the requirements of Section 40 61 13, Process Control System General Provisions.


40 64 00 - Programmable Logic Controllers.doc

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1.4 EQUIPMENT DELIVERY, HANDLING, AND STORAGE.

A. Comply with the requirements of 40 61 13, Process Control System General Provisions.

PART 2- PRODUCTS

2.1 PLC SYSTEM GENERAL REQUIREMENTS

A. All materials and equipment furnished shall be new, free from defects, and of first quality, produced by manufacturers who have been regularly engaged in the manufacture of these products.

B. All materials furnished under this Contract shall be determined safe by either Underwriters Laboratories, Inc., or Factory Mutual and all material shall be labeled, certified, or listed by the testing agency.

C. Provide PLC processors, communication modules, local and remote I/O components, and other hardware and system components required for a complete functioning PLC System to meet the intent of the configuration drawing and as listed in the PLC System 1/0 Schedule at the end of this section. The PLC shall be configured to perform the functions shown on the Contract Drawings and specified herein.

D. The PLC shall be designed, constructed and tested in conformance to NEMA Standard ICS 3-304 for programmable controllers, and shall be suitable for use under the following environmental conditions: 1. Operating Temperature: 32° to 140°F. 2. Relative Humidity: 5% to 95% non-condensing. 3. Shock: 30 G peak acceleration for 1 lms duration. 4. Vibration: 10 to 500 Hz, 2.0g maximum peak acceleration.

E. The PLC shall be capable of being programmed in both an off-line (program) mode and an on-line (run) mode by means of a portable personal computer based laptop programming unit connected to the PLC processor installed in the system I/0 chassis and/or connected to the processor via the PLC System Ethernet Communication Link at a remote location. On-line data and program logic changes shall not necessitate halting the processor.

F. The PLC shall be a complete system of modular design consisting of the following major components: 1. PLC (CPU) processor modules.


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2. Discrete and Analog 110 modules of the types and quantities described in the Input/Output list at the end of this Section.

3. Chassis for housing, distributing power to, and providing digital interfacing of the CPU and I/O modules.

4. 120 VAC system power supply for providing DC operating power to the chassis, processor, and I/O modules.

5. Communications to distributed I/0 racks and to the HMI. 6. Miscellaneous communications hardware and wiring components necessary

for a complete functioning PLC system.

G. All system modules shall be designed for easy removal from and replacement in the chassis. The PLC shall be designed to allow removal and insertion of any module under power without disruption to the system. All discrete and analog I/0 modules shall be designed to permit module removal and re-installation without disturbing or disconnecting any field wiring terminations.

H. Electronic keying shall be used to prevent insertion of an I/0 module into the wrong chassis slot, once the slot assignments and module layouts are finalized.

I. The PLC editor shall be IEC-1131 compliant.

2.2 APPLICATION PROCESSOR (CPU)

A. Type: Microprocessor based, industrial CPU with high quantities of I/0 available.

B. Processor Memory: 1 Megabyte static RAM.

C. Non-Volatile Memory: 1 gigabyte Secure Digital non-volatile memory.

D. Program Scan Rate: less than lms typical.

E. Diagnostics: 1. Standard, self-diagnostic routines shall be provided to determine proper

hardware and software operation. 2. Diagnostic LED's shall be provided on the processor front panel to indicate

the following: a. Processor running. b. Processor fault. c. Battery low. d. Forced I/O. e. Communications active. f. Communications error.

F. System Communications: The CPU shall be equipped with built-in Ethernet and USB port(s) for networking and programming.

G. Instruction Set:


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1. The PLC shall be equipped with the following instructions as a minimum: a. Ladder and Function Block programming. b. Ladder-logic or relay-type logic Functions: Normally open contacts,

normally closed contacts, and output coils. c. Timers: On delay, off delay, and retentive. d. Counters: Up, down. e. Math Functions Including Integer and Floating Point: Add, subtract,

multiply, divide, and square root. f. Data Transfer Instructions: Bit, word, and file. g. Logical Instructions: AND, NOT, OR, XOR. h. Compare Instructions: Equal to, greater than, less than. i. Control: Proportional - Integral - Derivative control instruction. j. Advanced instruction set including file handling, sequencer, diagnostic,

shift register, immediate I/O, and program control instructions. 2. The PLC shall support branching functions to allow any combination of series

or parallel instructions. 3. The PLC shall support the use of subroutines where appropriate.

H. Clock: Battery-backed clock with a typical variation of ± 20 seconds per month.

I. Manufacturer and Model: 1. Allen Bradley 1769-L30ER CompactLogix 5370 processor. 2. Or equal.

2.3 POWER SUPPLY

A. Each PLC processor with 110 shall include a separate power supply. The power supply shall be mounted alongside the I/0.

B. Input Voltage: 120 VAC, 60 Hz.

C. Output Current: Coordinate Power Supply output with equipment provided. As a minimum, provide 4 amps at 5 VDC.

D. Provide all cabling as required.

E. Manufacturer and Model: 1. Allen Bradley 1769-PA4. 2. Or equal.

2.4 PLC 110 MODULES

A. Available Types: The types of I/0 modules available for use with the PLC system shall be as specified and as identified in the input/output list. 1. Sixteen point discrete input modules which accept an input of 115 VAC, 60

Hz. The discrete input modules shall be Allen Bradley Model 1769-IA16, or equal.


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2. Sixteen point relay output modules. The isolated relay output modules shall be Allen Bradley Model 1769-0W16, or equal.

3. Four point isolated analog input modules (16 bit resolution) which accept an input of 4-20 mA DC. The analog input modules shall be Allen Bradley Model 1769-IF41, or equal.

4. Four point isolated analog current output modules (16 bit resolution) which produce an output of 4-20 mA DC. Analog output modules shall allow selectable output response to faults of minimum, maximum, or last output value. The analog output modules shall be Allen Bradley Model 1769-0F4CI, or equal.

B. Required Features: The I/0 modules and system hardware supplied shall incorporate the following design and construction features and comply with the following requirements: 1. Noise immunity and filtering. 2. IEEE surge-withstand rating to ANSI/IEEE C37.90 (formerly IEEE 472). 3. Optical isolation for all inputs and outputs to provide controller logic

protection. 4. Any card, any slot, plug-in packaging, with locking bars and/or screws to hold

I/0 modules in place. 5. 300 volt, screw type, 110 wiring terminal arms sized to accommodate a

minimum of two #14 AWG wires per terminal. Wiring design shall allow 110 module removal and replacement without disturbing 110 wiring connections.

6. Front-of-module LED Status indicators for each individual input and output point to indicate when power is applied at I/0 terminals.

7. Where required and recommended by the manufacturer, external transient suppressors shall be provided for installation across the output loads.

8. Scaling to engineering units for analog modules. 9. Provide required connectors with each I/O module.

C. For each PLC, provide installed I/0 capacity of the types and quantities as identified in the Input/Output Schedule, plus an additional 25% spare capacity for each type of I/O. All I/O, including future and spare, shall be wired to fused terminal blocks prior to interconnection with other devices. Fused terminal blocks shall have blown fuse indication.

D. Arrange I/0 Modules as follows: 1. Left most module group shall be digital input modules. 2. Modules to the right of the digital input module group shall be digital output

modules. 3. Right most module group shall be analog output modules. 4. Modules to the left of the analog output module group shall be analog input

modules.

E. I/0 points shall be arranged (per group of modules) in alphabetical order with the 25% spare I/0 at the end of each module.


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2.5 OPERATOR INTERFACE TERMINAL (OIT)

A. General: The OIT shall provide a means of communicating with the local PLC. The OIT shall continue to function in the event of a failure of the Fiber Optic Backbone for the PLC network. Provide an OIT where indicated on the Drawings and connect to the local PLC.

B. The OIT shall meet the following requirements: 1. Display Screen Resolution: 1024 X 768 pixels, 256k colors minimum. 2. Display type: 10" Color Active Matrix Thin Film Transistor. 3. Memory: 512 MB nonvolatile memory and 512 MB of random-access

memory minimum. 4. Storage Memory: 1 Secure Digital high-capacity (SDHC) slot. 5. Supply Voltage: 120 VAC. 6. Communications:

a. Ethernet/IP. b. RS-232 Serial. c. ControlNet. d. Physically connect only the communications methods as shown on

Drawings. 7. Mounting: Unit shall be mounted on the front face of enclosure, as

indicated on the Drawings. Provide sun/light shield apparatus for a clear, unobstructed view of entire OIT display as required.

8. Provide 12 protective overlays for screen. 9. NEMA 12 enclosure and display minimum.

C. Operating System and Application Software: 1. Windows CE 6.0 operating system. 2. FactoryTalk View ME software, version 6.0 or later. 3. Provide all drivers and cards needed for communications to the PLCs. 4. Manufacturer and Model:

a. Model Panel View Plus 6 Bulletin 2711P, as manufactured by Allen- Bradley.

b. Or equal.

2.6 WIRING ACCESSORIES

A. Provide wiring accessories including but not limited to connectors, taps, terminator lugs, and screw clamp blocks as recommended by the manufacturer for a complete PLC system installation.

2.7 UNINTERRUPTIBLE POWER SUPPLY

A. A backup power unit shall be provided for each panel housing a PLC or for each network rack enclosure.

B. Backup power unit shall be self-contained, and shall fit inside the PLC or network rack enclosure.


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C. Backup power unit shall be as specified in Section 40 78 00, Panel Mounted Instruments and Devices.

2.8 INPUT/OUTPUT SCHEDULE

A. An Input/Output (I/O) schedule for the programmable controller system is included at the end of this section. CONTRACTOR shall provide the input/output capacity necessary to facilitate the system functional requirements as specified and shown on the Drawings.

2.9 SPARE PARTS AND EXPENDABLE MATERIALS

A. The following spare parts and expendable materials shall be provided as a minimum, for the PLC System: 1. One (1) of each type 110 module for each ten or fraction thereof used in the

system. 2. One of each type of the following modules used in the system:

a. Processor modules. b. Communications modules. c. Any other type of special function modules.

3. One (1) replacement power supply and interconnecting cable for each type used in the system.

4. Ten (10) percent of total quantity of each type of fuse used in the system. 5. Ten (10) percent of total quantity of each type of lamp used in the system.

B. All spare parts shall be individually packaged for protection against impact, moisture, and dirt. Each package shall be clearly labeled as to its contents with a description and part number.

C. All spare parts shall become the property of the OWNER. The CONTRACTOR shall maintain the spare parts inventory as listed above, and replace, at no additional cost, all spare parts consumed during the one-year warranty period.

2.10 MANAGED RACK-MOUNT ETHERNET SWITCH — TYPE "A"

A. General Switch Information: 1. Provide a managed, rack-mount Ethernet switch for segment connection of

the network backbone to the area servers, operator workstations, and other related network devices, as shown on the Drawings.

B. Required Features: 1. 10/100/1000Base-TX (auto-sensing). 2. Minimum of twenty four (24) RJ-45 ports. 3. Per-port Status Indicators:

a. Link Integrity. b. Disabled. c. Activity.


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d. Speed. e. Full/Half Duplex.

4. Minimum of (2) Gigabit Ethernet uplinks. 5. Network Management Interface:

a. 10/100 Mbps Ethernet (RJ-45). 6. Flash Memory: Minimum 128 MB. 7. DRAM: Minimum 512 MB. 8. Forwarding Bandwidth: Minimum 108 Gbps. 9. Forwarding Mode: Store-and-Forward. 10. Power over Ethernet.

C. Operating Conditions: 1. Power Supply: AC Power Supply. 2. Power Requirements: 120 VAC, 60 Hz. 3. Operating Temperature: 23 to 113 degrees Fahrenheit 4. Relative Humidity: 10 to 95 percent noncondensing. 5. Mounting: 19 inch rack mount kit.

D. Performance Features: 1. Support spanning tree protocol. 2. Configurable for multiple VLANs. 3. Switch Management:

a. Support Simple Network Management Protocol (SNMP). b. Bridging Management Information Base. c. Remote Monitoring (RMON) control.

4. Comply to IEEE 802.3x Full-Duplex on 10Base-T, 100Base-TX, and 1000BASE-T ports.

5. Provide a range of security features to limit network access and mitigate threats.

6. Units shall be stackable for expansion as needed.

E. Product Manufacturer and Model 1. Cisco Systems, Inc., Catalyst 2960-X Series. 2. Or equal.

2.11 UNMANAGED INDUSTRIAL ETHERNET SWITCH — TYPE "B"

A. General Switch Information: 1. Industrial Ethernet Rail Switch, store-and-forward switching mode, Ethernet

(10 Mb/s) and Fast-Ethernet (100 Mb/s). 2. Port Type and Quantity: Eight 10/100BASE-TX, RJ45 sockets, auto-

crossing, auto-negotiation, auto-polarity.

B. Operating Conditions: 1. Power Supply: 1 plug-in terminal block, 3-pin. 2. Operating Voltage: 24 VDC. 3. Operating Temperature: 0 to 60 degrees Celsius.


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4. Relative Humidity: 5 to 95 percent noncondensing. 5. Mounting: DIN Rail.

C. Manufacturer and Model: 1. Stratix 2000 unmanaged switches as manufactured by Allen Bradley. 2. Or equal.

PART 3- EXECUTION

3.1 INSTALLATION REQUIREMENTS

A. General: 1. Install all equipment and components in accordance with the Drawings,

approved Shop Drawings, and installation instructions furnished by the manufacturer.

2. Do not begin installation of system hardware and panels until building construction is completed and major equipment has been installed.

3. Maintain areas where instruments, control panels, and enclosures are being or have been installed, dust free and within the environmental conditions specified for the equipment.

4. Inspect each instrument, panel and other items for damage and defects before installation. Replace deficient items.

5. The PLC and I/0 racks shall be installed such that all LED indicators and switches are readily visible with the panel door open and such that repair and/or replacement of any PLC component can be accomplished without disconnecting any wiring or removing any other components.

6. Comply with the other specific installation, start-up, and testing requirements as specified in the other Division 40 Sections.



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SECTION 40 66 53

MULTIPLE ADDRESS RADIO EQUIPMENT

PART 1 - GENERAL

1.1 DESCRIPTION

A. Scope of work: 1. RADIO SYSTEM SUPPLIER shall provide all labor, materials, equipment

and incidentals as shown, specified and required to furnish, install, configure, test, start-up and place in satisfactory operation the City of Miamisburg Telemetry System. The telemetry system shall be completely compatible and interoperable with the Water Treatment Plant Process Control System (PCS).

2. In order to centralize responsibility, it is required that all equipment provided under this Section be furnished by a single supplier as specified in Article 1.2, below. RADIO SYSTEM SUPPLIER shall guarantee and be the source of information on all equipment furnished regardless of the manufacturing and supply source of the equipment.

3. Electrical Work: All equipment, materials, and appurtenances, as well as all signal and power wiring and cable runs and interconnections, shall be in strict accordance with the requirements of Division 26, Electrical, unless specified otherwise herein.

4. RADIO SYSTEM SUPPLIER shall coordinate the radio system configuration, hardware, and interconnection with the physical radio propagation study performed by J&K Communications, Inc. during the week of July 13, 2015.

5. Specific Information is provided below: a. Master Telemetry Unit (MTLT): Master Site located at the Water

Treatment Plant, 302 South Riverview Avenue, Miamisburg, OH 45342. Provide one new radio to communicate with the remote sites listed below, and for installation in the Master Telemetry Panel, as shown on the Drawings. Antenna shall be mounted at the height and location as required per the physical propagation study. Master Site shall store the combined polled data from each remote Site and communicate this data to the plant PCS. Complete Telemetry System monitoring and debugging shall be capable from this Site without requiring visits to each remote Site.

b. Remote Telemetry Unit (RTU): Remote Site located at Benner Road Booster Station, 475 Benner Road, Miamisburg, OH 45342. Provide one new radio to communicate with the MTU at the Water Treatment Plant, and for installation in the Remote Telemetry Panel, as shown on the Drawings. Antenna shall be mounted at the height and location as required per the physical propagation study. RTU shall receive the signals from the field, transmit the signals to the MTU, and receive set points and commands from the MTU.

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40 66 53-1

c. RTU: Remote Site located at Byers Road Water Tower, 779 Byers Road, Miamisburg, OH 45342. Provide one new radio to communicate with the MTU at the Water Treatment Plant, and for installation in the new Remote Telemetry Panel, as shown on the Drawings. Antenna shall be mounted at the height and location as required per the physical propagation study. RTLT shall receive the signals from the field, transmit the signals to the MTU, and receive set points and commands from the MTU.

d. RTU: Remote Site located at Richard Street Water Tower, 1400 Richard Street, Miamisburg, OH 45342. Provide one new radio to communicate with the MTU at the Water Treatment Plant, and for installation in the new Remote Telemetry Panel, as shown on the Drawings. Antenna shall be mounted at the height and location as required per the physical propagation study. RTU shall receive the signals from the field, transmit the signals to the MTU, and receive set points and commands from the MTU.

6. RADIO SYSTEM SUPPLIER shall be responsible for all installation and wiring details required for the radio telemetry equipment only. CONTROL SYSTEM SUPPLIER shall provide Master and Remote Telemetry Panels and related appurtenances not covered within the scope of the RADIO SYSTEM SUPPLIER. CONTRACTOR shall be responsible for all other installation details and power and field signal wiring to and from the Master and Remote Telemetry Panels as specified herein, and in related Sections of Division 40.

7. Telemetry system radios, accessories, installation and any modifications to the proposed design necessary for successful communications shall be covered under cash allowance specified in Section 01 21 00, Allowances.


A. All telemetry equipment shall be installed by personnel with at least five years experience in the installation of such equipment. Antenna installation shall be performed by personnel with a minimum of two years experience with antenna installation.

B. All equipment provided under this Section shall be furnished by a single supplier who shall assume responsibility for providing a complete fully functional and integrated telemetry system.

C. Conform to OSHA requirements during antenna installation at each site.

D. The radio system supplier shall be: 1. J&K Communications, Inc.

222 South Tower View Drive Columbia City, 1N 46725. (260) 244-7975


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1.3 SUBMITTALS

A. Comply with the requirements of Section 40 61 13, Process Control Systems General Provisions.

1.4 PRODUCT DELIVERY, STORAGE AND HANDLING

A. All equipment shall be stored in accordance with the manufacturers' recommendations prior to installation.

1.5 GENERAL COMMUNICATION FUNCTIONAL REQUIREMENTS

A. Each radio shall support the establishment of a data communication network utilizing non-licensed radio.

B. The telemetry system shall be capable of bidirectional transfer of data between the MTh located at the Water Treatment Plant and the RTUs located at the remote Sites specified herein.

1.6 RADIO NETWORK FUNCTIONAL REQUIREMENTS

A. The Telemetry System service area shall not be required to be direct line of sight radio paths to all remote sites from the plant site. The radio network shall provide data routing between radios to establish repeater routes, overcoming local terrain. Contractor shall submit a radio architecture connectivity diagram as part of the Shop Drawing submittals. The connectivity diagram must show the paths available for transmission of communications for each remote site.

B. It shall be possible to interface any radio in the network directly from a computer anywhere within the telemetry network, directly over the radio network. All radio communication shall be encrypted. The computer interface shall be provided under this Section and shall be supplied with the radio software specified in Article 2.4, below, from the radio manufacturer.

PART 2- PRODUCTS

2.1 SPREAD SPECTRUM RADIOS

A. The 900 MHz Spread Spectrum radios shall operate under FCC, Part 15 rules for unlicensed radio operation in the 902 MHz to 928 MHz band. The radio shall utilize the frequency-hopping technique to accomplish these functions, using FCC-assigned channels.

B. Radio shall contain an Ethernet (IEEE 802.3) interface for connection to other equipment.


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40 66 53-3

C. Manufacturers: Provide one of the following: 1. GE MDS. 2. Or Equal.

2.2 ANTENNAS

A. Directional remote mount antennas and ground impulse suppressors shall be furnished for each Site as required.

B. Antenna mounting at each Site shall be determined by RADIO SYSTEM SUPPLIER at the time of installation, based on the field propagation study of the terrain.

2.3 ANTENNA TRANSMISSION CABLE AND ACCESSORIES

A. The transmission cable connecting the radio antenna port with the antenna shall be the low-loss foam-dielectric coaxial type. A single continuous piece of coaxial cable shall be furnished for each radio. For coax runs exceeding 100 feet in length, furnish 7/8-inch diameter cable (Andrew LDF5-50A, or equal), minimum.

B. Provide one 3-foot section of superflexible transmission cable for coax interconnection at the radio antenna port (one for each radio). Provide standard Type N connectors at each end, which will mate with the radio and the transmission cable.

C. Furnish two Type N connectors for terminating both ends of each transmission cable.

D. Coaxial cable grounding kit shall be furnished. Furnish Andrew, or equal. Furnish two kits for each radio.

E. One in-line coaxial cable surge protector shall be furnished for each cable. Furnish Polyphaser, or equal, with Type N connector mating.

F. Provide Andrew coaxial cable hanger kits and clamping hardware. Adequate kits shall be installed to anchor the cables at three foot intervals on the vertical antenna mast/tower.

G. All outdoor coaxial connectors shall be wrapped with two layers of Scotch Super 88 UV resistant tape or equal, and then coated with two layers of Scotch-Kote or equal.

2.4 RADIO CONFIGURATION AND DIAGNOSTICS SOFTWARE

A. A radio configuration and diagnostics system shall be furnished with the radio system. This system shall be manufactured by the radio manufacturer. The


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system shall provide configuration capabilities to set up and modify, if necessary, the operating parameters of each radio, and provide diagnostic features to test system performance. The system shall include a centralized RTS Interface Computer.

B. Specific requirements of the configuration and diagnostics system shall include the following: 1. Read all Remote Radio Tables for: Status, node, frequency interference

history, and RF signal strength. 2 Write any or all (user selectable) acquired data to hard disk storage for later

access. 3. Configure (over the air) all configurable radio parameters. 4. Provide user-programming of radio diagnostic functions.

2.5 RADIO ANTENNA MASTS OR POLES

A. All antennas shall be mounted on antenna masts or poles. RADIO SYSTEM SUPPLIER shall determine mast or pole height based on field conditions and the results of the field propagation study. RADIO SYSTEM SUPPLIER shall make every effort to mount the antennas at the minimum allowable height so as to minimize the impact of the antenna on the surrounding environment. Location and height of the antenna shall be such that a 99% communications rate with the radio at the Water Treatment Plant Master Site shall be guaranteed year round with a 15-year design goal. Final locations and height of antenna pole or masts shall be approved by OWNER prior to installation.

B. Material of Construction: 1. Masts: Provide masts for applications with less than 10 foot antenna

mounting heights above building structure and can be rigidly supported from the building structure. Masts shall be constructed of minimum 2" rigid, heavy walled aluminum pipe, or of minimum 2" heavy walled fiberglass pipe as required for structural integrity in outdoor applications.

2. Poles: Provide poles for applications where antenna height exceeds the requirements of Paragraph 1, above. Antenna pole shall be constructed of fiberglass or similar composite and be equivalent in strength to ANSI Class 4 wood poles, or better. Antenna pole shall be capable of supporting the antenna load at wind speeds up to 100 mph. Antenna pole shall be buried vertically at least six feet and set in concrete using a concrete form as recommended by the pole manufacturer.

3. Mounting Hardware and Fasteners: Mounting Hardware and Fasteners shall be stainless steel, unless otherwise noted on the Drawings or in the Specifications.

2.6 SPARES

A. Provide the following spare equipment:


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40 66 53-5

1. Minimum of one spare for every five of each radio type provided with the system. The radios shall be suitable for installation at any of the telemetry Sites in the system. For each spare radio provide communication cables.

2. Minimum of one spare for every antennas of each type provided with the radio system.

B. The spare parts shall be packed in sturdy containers with clear indelible identification markings and shall be stored in a dry, warm location until transferred to the OWNER at the conclusion of the Project.

PART 3- EXECUTION

3.1 TELEMETRY SYSTEM INSTALLATION

A. RADIO SYSTEM SUPPLIER is responsible for the installation of all radio equipment.

3.2 TELEMETRY SYSTEM CONFIGURATION/PROGRAMMING

A. Telemetry System shall be configured and programmed according to requirements set forth in this Section.

3.3 TELEMETRY SYSTEM FIELD TESTING

A. Telemetry System shall be field tested in accordance with requirements set forth in Section 40 61 23, Process Control System Start-up and Field Testing.

3.4 TELEMETRY SYSTEM TRAINING

A. Telemetry System training shall be provided in accordance with the requirements set forth in Section 40 61 26, Process Control System Training.



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40 66 53-6

SECTION 40 67 17

PROCESS CONTROL PANELS AND ENCLOSURES

PART 1 - GENERAL

1.1 DESCRIPTION

A. Scope of Work: 1. CONTROL SYSTEM SUPPLIER shall furnish, install, test, and place into

satisfactory operation the control panels, enclosures, and panel devices as shown on the Drawings and specified herein.

2. Operational and functional requirements for the various panels are shown in control schematics, pneumatic diagrams, and/or functional instrumentation diagrams on the Instrumentation (I) drawings and Electrical (E) drawings.

3. The Drawings and Specifications illustrate and specify functional and general construction requirements of the panel components and do not necessarily show or specify all components, wiring, piping, and accessories required to make a completely integrated system. CONTRACTOR shall provide all piping, wiring, accessories, and labor required for a complete, workable, and integrated system.

4. Process system equipment control panels which are to be furnished as part of a "packaged" system by the various system equipment vendors, are identified by asterisks (*) on the Instrumentation (I) drawings. Operational and functional requirements for these panels are specified in the various Division 40, 43, and 46 Sections and are shown on the Process and Instrumentation Diagrams.


A. Standards, Codes and Regulations: 1. Construction of panels and the installation and interconnection of all equipment

and devices mounted within shall comply with applicable provisions of the following standards, codes, and regulations: a. National Electrical Code (NEC). b. National Electrical Manufacturer's Association (NEMA) Standards. c. Institute of Electrical and Electronics Engineers, Inc (IEEE). d. Local and State Building Code. e. Operational Safety and Health Administration (OSHA) Regulations. f. American Society for Testing and Materials (ASTM). g. Where any conflict arises between codes or standards, the more stringent

requirement shall apply. 2. All electrical materials and equipment shall be new and shall bear the label of

the Underwriters Laboratory (UL), Inc., Factory Mutual (FM) or equivalent where standards have been established and label service regularly applies.

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B. Acceptable Manufacturers: 1. Furnish panel instruments and devices by the named manufacturers or equal

equipment by other manufacturers. 2. The named manufacturers have been specified to establish the standard of

quality and performance of the equipment to be supplied. 3. Obtain all instruments or devices of a given type from the same manufacturer.

C. General Design Requirements: 1. Comply with the requirements of Section 40 61 13, Process Control System

General Provisions.

D. Factory Assembly and Testing: 1. Fully assemble and test each enclosure and panel at the factory prior to shipment,

demonstrating that all specified functions are performed. 2. Comply with the requirements of Section 40 61 21, Process Control System

Factory Testing.

1.3 SUBMITTALS

A. Comply with the requirements of Section 40 6113, Process Control System General Provisions.



PART 2- PRODUCTS

2.1 GENERAL CONSTRUCTION REQUIREMENTS

A. Provide all electrical and/or pneumatic components and devices, support hardware, fasteners, interconnecting wiring and/or piping required to make the control panels complete and operational units. Provide bulkhead fittings for ail air piping and tubing penetrating control enclosures.

B. Locate and install all devices and components so that connections can be easily made and so that there is ample room for servicing each item.

C. Components for installation on panel exterior shall be located as shown on the Drawings. Layouts shall be submitted for approval as per Section 40 6113, Process Control System General Provisions. All exterior panel mounted instruments shall have a NEMA rating equal to the enclosure. For devices that cannot be obtained with a NEMA rating equal to the enclosure, mount the device behind a transparent


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viewing window as specified below. The window shall maintain the NEMA rating of the enclosure.

D. Where permitted by location and layout as shown on the Drawings, all panels and enclosures shall have full height rear access doors. Where rear doors are not possible, panels shall have full height front access doors.

E. Adequately support and restrain all devices and components mounted on or within the panel to prevent any movement.

F. Provide subpanels for installation of all internally mounted components. All free standing control panels shall include full height rear and side subpanels, where enclosure layout permits. All wall mounted, frame mounted, and floor mounted enclosures shall include full height rear subpanels.

G. Provide mounting strips for installation of all relays and other components where mounting strips are practical.

H. All wiring to panel connections from field instruments, devices, and other panels shall be terminated at master numbered terminal strips, unless otherwise specified.

I. Provide the following convenience accessories listed below inside of each free- standing control panel. The accessories are shown as the "utility circuit" on the Contract Drawings and shall have their own circuit breaker and separate power feed. 1. At least one 120 VAC, 15A duplex, grounding type receptacle. 2. One or more 120 VAC fluorescent light fixtures with minimum 40 watt lamp

and protective plastic shield, as required to span across a minimum oftwo-thirds of the panel width. Fluorescent open shall activate upon opening the enclosure door.

J. The bottom 12 inches of free standing panels shall be free of all devices, including terminal strips, to provide ease of installation and testing.

K. Front panel indication and control devices shall be mounted within a range of 42 to 68 inches above the operating floor. No indication or control devices shall be mounted less than 36 inches above the operating floor level unless otherwise specified or shown on the Drawings.

2.2 IDENTIFICATION

A. Provide laminated plastic nameplates and legend plates for identification of panels, enclosures, and components mounted thereon as follows: 1. Nameplates shall be of 3/32 thick laminated phenolic type with white matte

finish and black letter engraving. 2. Panel identification nameplates to have 1/2-inch high letter engravings.


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3. Panel mounted component identification (i.e. control devices, indicating lights, selector switches, etc.) nameplates and legend plates to have 1/4 inch high letter engravings, unless otherwise noted on the Drawings.

4. Nameplates shall be attached to the panel face with two stainless steel self-tapping screws and self-backed adhesive.

5. Nameplate engravings shall include the descriptive title indicated on the Drawings and Specifications.

B. Tag all panel mounted instruments in accordance with Section 40 70 05, Primary Sensors and Field Instruments, Paragraph 2.0.1.

C. Tag all electrical components and devices mounted within control panel enclosures with engraved nameplates as specified in Paragraph A. above. Tag all door-mounted devices on the rear of the door with engraved nameplates as specified in Paragraph A above. All interior panel nameplates shall be attached with self-backed adhesive.

D. Tag all pneumatic lines with plastic tags. Paper tags are not acceptable.

E. Numerically code terminals on terminal strips.

F. Numerically code wiring as required by applicable standards. Wires shall be identified at each end with permanent alphanumeric codes as specified below. All wiring not de-energized by the panel disconnect or circuit breaker shall be orange wire.

G. For all panels containing wiring not de-energized by the panel disconnect or circuit breaker, provide a warning nameplate on the front of the panel stating "WARNING ORANGE WIRING NOT DE-ENERGIZED BY PANEL DISCONNECT". The nameplate shall be amber with black, 1/4- inch high letter engravings and shall be attached to the panel face with stainless steel screws and adhesive.

2.3 PANELS AND ENCLOSURES

A. General: 1. Panels and enclosures shall meet the NEMA requirements for the type specified

and/or as shown on the Drawings. 2. Sizes shown on the Drawings are estimates. CONTROL SYS tEM SUPPLIER

shall furnish enclosures of the size required to house all equipment, instruments, front panel mounted devices, power supplies, power distribution panels, wiring, tubing, and other components installed in the enclosures.

B. Construction Features: 1. All control panels shall be fabricated in accordance with the NEMA ratings

specified and/or as shown on the Drawings.


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a. Provide lifting eye bolts to facilitate handling of the enclosures, where enclosure size requires. Bolt lifting eyes directly to the enclosure structural members.

b. Continuously weld all exterior seams and grind smooth. Surface grind complete removal of corrosion, burrs, sharp edges, and mill scale.

c. Reinforce sheet steel with steel angles where necessary to adequately support equipment and ensure rigidity and to preclude resonant vibrations.

d. Panel shall be flat within 1/16-inch over a 24-inch by 24-inch area, or flat within 1/8-inch for a larger surface. Flatness shall be checked by using a 72-inch long straight edge. Out-of-flatness shall be gradual, in one direction only, and shall not consist of obvious depressions or a series of wavy sections.

e. Use pan type construction for doors. Door widths shall not exceed 36 inches.

f. Mount doors with full-length heavy-duty piano hinge with stainless steel hinge pins.

g. Provide oil resistant gasket completely around each door or opening. h. Use stainless steel fasteners throughout. i. Provide interior mounting panels and shelves constructed of minimum 12-

gauge steel with a white enamel finish. All free-standing control panels shall include full height rear and side subpanels where enclosure layout permits. All wall mounted, frame mounted, and floor mounted enclosures shall include full height rear subpanels.

j. Provide steel print pocket with white enamel finish. k. Provide enclosure mounting supports and/or bases as required for floor,

frame, or wall mounting and for free standing enclosures. 1. All panels outside of control rooms shall have solid bottoms. m. Provide all holes and cutouts for installation of conduit and equipment.

Cable and piping shall enter the enclosure through the bottom unless otherwise noted. All conduit and piping openings and all conduits shall be sealed watertight.

2. Control panels located in control or electrical room areas shall be NEMA 12 rated unless otherwise noted on the Drawings. a. Fabricate enclosures using minimum 14-gauge steel for wall or frame

mounted enclosures and minimum 12 gauge for floor mounted and free standing enclosures. Steel shall be free of pitting and surface blemishes.

b. For floor mounted enclosures, provide minimum 12 gauge steel floor stand kits bolted to the bottom of the enclosure and sealed and gasketed to maintain NEMA 12 rating. Floor stand heights shall be coordinated with enclosure sizes and base pads so as to comply with the general indication and control device mounting height requirements as specified herein and/or as shown on the drawings. Floor stands shall be mounted on base pads using anchor bolts and/or expansion anchors as specified in Paragraph 3.g below.

c. Free-standing enclosures shall be constructed with an integral fully enclosed solid bottom section at least 6 inches in height from the bottom of


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the enclosure to the bottom edge of the enclosure door opening. Free-standing enclosures shall be mounted on base pads as specified in Part 3 below.

d. Provide handle-operated, oil-tight, key-lockable three-point stainless steel latching system with rollers on latch-rods for easy door closing.

e. Completely clean all interior and exterior surfaces so they are free of corrosive residue, oil, grease, and dirt. Zinc phosphatize for corrosion protection.

f. One coat of primer shall be applied to all interior and exterior surfaces immediately after corrosion protection has been applied. Exterior surfaces shall then be given sufficient coats of primer surfacer, applied with sanding and cleaning between coats, until a Grade 1 finish can be produced on the finish coat.

g. All interior surfaces shall be painted with 2 coats of semi-gloss white enamel.

h. All exterior surfaces shall be painted with a minimum of 3 finish coats of enamel to ultimately produce a Grade 1 finish (super smooth; completely free of imperfections). Color to be selected by Engineer from complete selection of standard and custom color charts furnished by the manufacturer.

i. Primer and finish paint shall be compatible and shall be a low VOC, high solids polyurethane enamel as manufactured by Sherwin Williams, or equal. Provide one extra quart of touch-up paint for each exterior finish color.

3. All control panels located outside, or located in corrosive areas shall be NEMA 4X rated stainless steel. a. Panels shall be Type 304 stainless steel construction with a minimum

thickness of 12-gauge for all surfaces (except those areas requiring reinforcement) having a smooth brushed finish.

b. Provide stainless steel fast-operating clamp assemblies on three sides of each door.

c. Provide a rolled lip around three sides of door and along top of enclosure. d. Provide a hasp and staple for padlocking. Provide padlock for each

enclosure, all keyed alike. e. Provide custom fabricated sun shields for all outdoor panels as shown on

the Drawings. 1) Sun shields shall be fabricated from minimum 10 gauge aluminum,

and shall be designed, fabricated, installed and supported to fully cover and shade the top, sides and back of the enclosure, and to partially shade the front panel of the enclosure, from direct exposure to sunlight from sunrise to sunset.

2) Sun shields shall not be attached directly to the enclosure by drilling holes through, or welding studs to, the enclosure surfaces, and shall be designed and mounted to provide a minimum 1 inch air gap all around the enclosure for air circulation and heat dissipation.


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3) The top section of all sun shields shall be sloped at a minimum angle of 5 degrees from horizontal. For wall-mounted enclosures, the top section shall slope downward away from the wall and towards the front of the enclosure. For free standing, floor mounted and frame mounted enclosures the top section shall slope downward towards the backside of the enclosure.

4) The front edge of the top section of all sun shields shall incorporate a narrow and more steeply sloped drip shield segment which sheds water away from the front of the enclosure and prevents it from dripping and/or running directly onto the front panel of the enclo-sures.

5) All seam welds used in sun shield fabrication shall be continuous and shall be ground smooth.

6) All exposed corners, edges and projections shall be smooth rounded or chamfered to prevent injury.

7) CONTROL SYSTEM SUPPLIER shall submit detailed sun shield fabrication and support drawings with the enclosure shop drawings for review and approval.

f. Provide a clear plastic, NEMA 4X, gasketed, lockable, hinged door to encompass all non-NEMA 4X front of panel instruments.

g. For floor mounted enclosures, provide 304 stainless steel floor stand kits bolted to the bottom of the enclosure and sealed and gasketed to maintain NEMA 4X rating. Floor stand heights shall be coordinated with enclosure sizes and base pads so as to comply with the general indication and control device mounting height requirements as specified herein and/or as shown on the Drawings. Floor stands shall be mounted on base pads using anchor bolts and/or expansion anchors as specified below.

h. Free standing enclosures shall be constructed with an integral fully enclosed solid bottom section at least 6 inches in height from the bottom of the enclosure to the bottom edge of the enclosure door opening. Free-standing enclosures shall be mounted on base pads as specified below.

2.4 ELECTRICAL SYSTEMS

A. Control of Environment (refer to Section 40 61 13, Process Control System General Provisions for ambient temperature design criteria): 1. Outdoor Panels:

a. Provide adequately sized automatically controlled heaters to maintain temperature inside each enclosure above the minimum required for component operation and to prevent/control interior condensation.

b. Provide automatically controlled closed loop heat exchangers or closed loop air conditioners with filtered air louvers if required to maintain temperature inside each enclosure below the maximum operating temperature rating of the components inside the enclosure. Panel cooling components shall maintain the NEMA rating of the enclosure.


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c. Provide internal corrosion inhibitor devices, Hoffman HCI Series or equal, for corrosion control inside of each enclosure.

2. Indoor Panels: a. Provide adequately sized automatically controlled heaters to maintain

temperature approximately 10°F above ambient for condensation prevention inside panels.

b. Provide automatically controlled closed loop heat exchangers or closed loop air conditioners with filtered air louvers if required to maintain temperature inside each enclosure below the maximum operating temperature rating of the components inside the enclosure. Panel cooling components shall maintain the NEMA rating of the enclosure.

c. Provide internal corrosion inhibitor devices, Hoffman HCI Series or equal, for corrosion control inside of each enclosure.

3. Panel heaters shall be thermostatically controlled, fan-driven heaters, with all components mounted in anodized aluminum housing for sub-panel mounting. The heaters shall be powered from 115 VAC from a dedicated circuit breaker and shall be Hoffman Bulletin D-85, or equal.

4. Heat exchangers and air conditioners shall be of a dual loop design to isolate panel interior air from exterior air. The units shall be thermostatically controlled and shall be powered from 115 VAC from a dedicated circuit breaker. The units shall be Hoffman Bulletin D-85, or equal.

B. Power Source and Internal Power Distribution: 1. General: Control panel power supply source type, voltage, number of circuits

and circuit ratings shall be as shown on the Electrical Drawings. 2. The panels and enclosures shall be provided with internal 120 VAC DIN rail

mounted circuit breakers sized as required to distribute power to the panel components. Provide quantity of circuits as shown on the Drawings or as required. Circuit breakers shall be Allen Bradley Bulletin 1492-CB, 1492-GH, or equal. Each panel and enclosure shall contain two spare circuit breakers minimum. Provide a durable legend mounted near the circuit breakers in each panel which lists the circuit breaker numbers and functional descriptions.

3. Provide DC power supplies of quantities and sizes as required for powering DC signal and control loops.

4. Provide surge suppressors on all power sources as required to protect against damage from electrical surges.

C. Electrical Wiring and Accessories: 1. Unless otherwise specified, internal wiring shall be Type THHN stranded

copper wire with thermoplastic insulation rated for 600 V at 85°C for single conductors, color coded and labeled with wire identification.

2. For DC signal wiring, use No. 16 minimum AWG twisted pairs with overall shield.

3. For AC power wiring, use No. 12 minimum AWG. For AC signal and control wiring, use No. 14 minimum AWG. For wiring carrying more than 15 amps, use sizes required by NEC and IEEE standards.


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4. Install wiring runs in wire troughs along horizontal or vertical routes to present a neat appearance. Angled runs are not acceptable.

5. Separate and shield DC signal wiring from power and control wiring by a minimum of 4 inches, using separate wire troughs.

6. Where possible or practical in the panels and enclosures, route the low voltage DC signal wiring along the right portion of the enclosure subpanel(s) and route the AC power and control wiring to the left portion of the subpanel(s), with the incoming power and distribution circuit breakers located to the upper left.

7. Group or bundle parallel runs of wire using covered troughs. Maximum bundle size to be 1 inch. Troughs shall have 40 ')/0 spare capacity.

8. Adequately support and restrain all wiring runs to prevent sagging or other movement.

9. Terminal Blocks: a. Terminate field wiring and internal panel wiring not associated with PLC

I/0 interface modules at 600 V barrier type terminal blocks, Phoenix Contact UK 5N, Allen-Bradley 1492-W4 or equal.

b. Terminal blocks shall be tubular screw type with pressure plate capable of accepting #30-410 wires and shall be mounted on DIN rail. DIN rail by terminal block manufacturer or equal.

c. End anchors shall be provided on both ends of all terminal strips to firmly anchor the terminal blocks to the mounting rail and insulating end barriers shall be provided on one end of the terminal strip as necessary. End anchors by terminal block manufacturer or equal.

d. No more than two wires shall be terminated at any single screw. Provide jumpers as required to join adjacent terminal blocks for additional wiring connection points.

e. All terminal blocks shall be labeled with permanently affixed numeric identifiers on each block. Identifiers shall be self-stick plastic tape strips with permanent, machine printed numbers.

f. Provide a separate terminal block for landing each analog signal cable shield.

g. Provide separate terminal strips for DC signal and AC power wiring. h. Provide spare terminal blocks equal in number to 20 4)/0 of the terminals

used for each type of wiring (i.e., DC signal and AC power). 10. Panel Front Face Port Interface:

a. Equip Control Panels containing an Ethernet switch with a RJ-45 port and 120 VAC (rated at least 3 amps) 3 wire outlet interface for panel mounting. Interface module shall have a dust cover with securing latch, for protection against dust and splashing water. Installation shall maintain the NEMA rating of the panel.

b. Include External 120 VAC outlet in panel power distribution wiring. c. Provide Ethernet cable internally from the RJ-45 interface to the Ethernet

switch. d. Manufacturer and Model: Phoenix Contact HEAVYCON 5600573 or

equal. 11. Wire Markers:


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a. All panel wires and field wires shall have an alphanumeric identification tag at each point of termination.

b. Where practical, wire numbers shall be unique and continuous. Where wire numbers change, the appropriate drawings shall include both wire numbers, clearly indicated, at the point of transition.

c. Each wire number shall be solid, machine printed, and not pieced from other single and/or double-digit tags.

d. Wire markers shall be heat, oil, water, and solvent resistant, vinyl, self-laminating, self-adhesive, wrap type labels as manufactured by the W.H. Brady Co. or equal.

e. All wire labels shall be clearly visible and not hidden by wire duct or other components in the enclosures.

12. All wiring shall be installed such that if wires are removed from any one device, power will not be disrupted to any other device.

13. All alarms generated external to the panel, spare alarm, and repeat contacts shall be wired out to terminal blocks.

14. Use separate, isolated 5/16-inch diameter copper grounding studs or 1/4 inch thick drilled and tapped copper bus bars for instrument signal cable shield grounding connections and instrument power/equipment grounding system. Shield grounds shall be completely isolated from the enclosure instrument power/equipment grounds.

15. Where wires pass through panel walls, provide suitable bushings to prevent cutting or abrading of insulation.

16. When DC power and/or low voltage AC power is required, provide and install the necessary power supplies and transformers in the panel.

17. Provide circuit breakers to protect each circuit, with no more than six instru-ments on a single circuit.

18. Provide surge suppressors on field signal wiring as required to protect against damage from electrical surges.

19. All spare field wires within each panel or enclosure shall be coiled, and each coil shall be labeled with the wire destination. Neatly arrange spare wire coils in the bottom of the enclosure.

20. Provide complete wiring diagram showing "as built" circuitry. Diagram shall be enclosed in transparent plastic and placed in easily accessible pocket built into panel door.

2.5 CONTROL PANEL SCHEDULE

A. Information specific to the various control panels furnished as part of the Instrumentation and Control System is listed in the schedule at the end of this Section. Information has been included for panels furnished under other Sections and notations have been made in the schedule accordingly.

B. Every effort has been made to include specific information on control panels, however, some panels may have been inadvertently omitted. If information for any


02270037.D001 7/31/15 10:24:58 AM 40 67 17-10

panel has not been included in the schedule below, CONTROL SYSTEM SUPPLIER shall verify requirements with the ENGINEER.

Panel/Enclosure Identification

Description Location Mounting Rating Spec.

Section

WTF-MTU Water Treatment Plant

Master Telemetry Panel

Water Treatment

Facili ty

Free Standing

NEMA 12

40 67 17

BNR-BPS-RTU Benner Road Booster Pump Station Remote

Telemetry Panel

Benner Road Booster Station

Free Standing

NEMA 12

40 67 17

RCH-TWR-RTU Richard Street Water

Tower Remote Telemetry Panel

Richard Street Water Tower

Wall Mount

NEMA 4X

40 67 17

BYR-TWR-RTU Byers Road Water

Tower Remote Telemetry Panel

Byers Road Water Tower

Wall Mount

NEMA 4X

40 67 17

PART 3- EXECUTION

3.1 INSTALLATION

A. Install equipment in conformance with NEC.

B. Unless otherwise noted, install indoor free standing and floor mounted panels on 4- inch gout pad. Lay gout after panel sills have been securely fastened down. Extend pad 4 inches beyond outside dimensions of base, all sides, solid, and face-to-face.

C. Unless otherwise noted, install outdoor free standing and floor mounted panels and sun shields on a reinforced concrete pedestal: 1. Minimum Thickness: 8 inches with No. 4 steel reinforcing bars at 12 inches on

centers, each way. 2. Minimum Size: 12 inches larger than outer dimensions of base, each side. 3. Provide excavation and backfill work in conformance with Section 31 23 05,

Excavation and Backfill. 4. Provide concrete work in conformance with Division 3.

D. Unless otherwise noted, install all frame mounted indoor and outdoor panels and sun shields using strut style structural support framing system members, plates and fasteners as specified in Section 26 05 29, Hangers and Supports for Electrical Systems. Frame bases shall be installed on a minimum one inch thick non-shrink grout pad with edges sloped away from the base plate.

E. Install wall mounted enclosures and control panels and sun shields using strut style support channels securely anchored to wall surface to provide offset mounting for air circulation behind panel. Do not install wall mounted panels directly on wall


02270037.D001 7/31/15 10:24:58 AM 40 67 17-11

surfaces. Comply with requirements of Section 26 05 29, Hangers and Supports for Electrical Systems, for support framing system materials and methods.

F. Install anchor bolts and anchor in accordance with Section 05 05 33, Anchor Systems.

G. Install and interconnect all equipment, devices, electrical hardware, instrumentation and controls, and process controller components into and out of and among the enclosures as indicated on the Drawings.

3.2 TESTING AND ADJUSTMENT

A. Perform system testing and make any adjustments necessary in accordance with this Section and with the Specifications of Section Process Control System Start-up and Field Testing and Process Control System Factory Testing.

B. Perform power supply, voltage adjustments to tolerances required by the appurtenant equipment.



02270037.D001 7/31/15 10:24:58 AM 40 67 17-12

SECTION 40 70 05

PRIMARY SENSORS AND FIELD INSTRUMENTS

PART 1 - GENERAL

1.1 DESCRIPTION


as shown, specified and required to furnish, install, calibrate, test, adjust and place into satisfactory operation all primary sensors and field instruments shown and specified herein.

2. Contract Documents illustrate and specify functional and general construction requirements of the sensors and field instruments and do not necessarily show or specify all components, wiring, piping and accessories required to make a completely integrated system. CONTRACTOR shall provide all components, piping, wiring, accessories and labor required for a complete, workable, and integrated system.

3. CONTRACTOR shall be responsible for installing in-line flow elements (magnetic flow meter flow tubes, insert flow tubes, propeller flow meters) and for providing taps in the process piping systems for installation of other flow, pressure, and temperature sensing instrumentation.

4. Instruments provided under another contract are denoted on the Drawings with an asterisk (*).

B. Coordination: Coordinate with other suppliers for installation of all items specified herein and required to ensure the complete and proper interfacing of all components and systems.

C. Related Sections: 1. Section 40 61 13, Process Control System General Provisions. 2. Section 40 61 23, Process Control System Start-up and Field Testing. 3. Section 40 61 26, Process Control System Training. 4. Section 40 05 05, Exposed Piping Installation. 5. Section 40 05 24, Steel Process Pipe. 6. Section 40 05 31, Thermoplastic Process Pipe.



B. Acceptable Manufacturers:

40 70 05 - Primary Sensors and Field Instruments.docx

02270037.D001 7/31/15 10:25:26 AM

40 70 05-1

1. Furnish primary sensors and field instruments by the named manufacturers or equal equipment by other manufacturers.

2. The named manufacturers have been specified to establish the standard of quality and performance of the equipment to be supplied.

3. Obtain all sensors and field instruments of a given type from the same manufacturer.

4. The primary sensors and field devices shall be interchangeable with similar function existing primary sensors and field devices to minimize spare parts inventory.

C. Manufacturers' Responsibilities and Services: 1. Design and manufacture the primary sensors and field instruments in accor-

dance with the applicable general design requirements specified in Section 40 61 13, Process Control System General Provisions, and the detailed Specifications herein.

2. Field supervision, inspection, start-up and training in accordance with the requirements of Section 40 61 23, Process Control System Start-up and Field Testing, and Section 40 61 26, Process Control System Training.


A. Comply with the requirements specified in Section 40 61 13, Process Control System General Provisions.

B. Primary sensors and field instruments shall not be delivered to the Site until all product information and system Shop Drawings for the sensors and instruments have been approved by the Engineer.

1.4 SUBMITTALS

A. Comply with the requirements specified in Section 40 61 13, Process Control System General Provisions.

PART 2 — PRODUCTS

2.0 GENERAL

2.0.1 IDENTIFICATION TAGS

A. Performance Requirements: 1. Tag numbers of sensors and field instruments shall be as shown and as

specified. For items not shown or specifically tagged, the item tag number shall be established by the CONTROL SYSTEM SUPPLIER. All instruments, whether field or panel mounted, shall have an identification tag.


02270037.D001 7/31/15 10:25:26 AM 40 70 05-2

2. Information to be permanently engraved onto the tag shall include the identifying tag number, manufacturer, model number, service, and range.

3. The tags shall be fastened to the device with self-tapping stainless steel screws. Where fastening with screws cannot be accomplished the tags shall be permanently attached to the device by a circlet of stranded stainless steel wire rope and clamp.

4. All sensors and field instruments mounted on or within control panels and enclosures shall have the identification tag installed so that the engravings are easily visible to service personnel. Panel mounted devices shall have the tag attached to the rear of the device.

B. Construction Features: 1. Tags shall be engraved with 3/16-inch letters and constructed as follows.

a. 3/32-inch thick laminated phenolic for engraving composed of core, laminated on both sides with a matte (non-glare) finish cover sheet.

b. Core to be black; cover sheet to be white. c. Mounting holes to be centered on width and 1/4-inch from each end.

2.0.2 PROCESS TAPS, SENSING LINES AND ACCESSORIES

A. Water Pressure Sensing Lines and Accessories for Transmitters: 1. Material: Copper Water Tube, ASTM B-88, Type

annealed.

2. Pressure Rating: 150 psi.

3. Size: 1/2-inch O.D. for water.

4. Connections: Brass Compression Type, "Swagelok" by

5. Shut-off Valves: a. Type: Ball. b. Pressure Rating: 150 psi. c. Body, Ball and Stem: Brass. d. Packing: High Density TFE. e. Handle: Nylon with metal travel stops. f. Support Rings: TFE coated brass.

g. End Connections: Removable "Swagelok", or equal. h. Model: Whitey 45 Series for water, or equal.

6. Manifolds: a. Type: 5-valve and 3-valve meter manifolds. b. Materials: Type 316 stainless steel body, bonnets

seats; teflon packing. c. Manufacturer and Model:

1) Anderson-Greenwood. 2) Or equal.

and stems; delrin

Flow and Pressure

L, drawn temper or

Crawford, or equal.

B. Air Pressure Sensing Lines and Accessories for Air Flow/Pressure Transmitters:


02270037.D001 7/31/15 10:25:26 AM 40 70 05-3

1. Material: Type 316 stainless steel tubing, ASTM A269, medium wall thickness.

2. Pressure Rating: 150 psi.

3. Size: 3/8-inch O.D. for air. 4. Connections: Type 316 stainless steel compression type, "Swagelok" by

Crawford, or equal.

5. Shut-off Valves: a. Type: Ball. b. Pressure Rating: 150 psi. c. Body, Ball and Stem: Type 316 stainless steel. d. Packing: High density TFE. e. Handle: Nylon with metal travel stops. f. Support Rings: TFE coated Type 316 stainless steel. g. End Connections: Removable "Swagelok", or equal. h. Manufacturer and Model:

1) 43 Series, as manufactured by Whitey. 2) Or equal.

6. Manifolds: a. Type: 5-valve and 3-valve meter manifolds. b. Materials: Type 316 stainless steel body, bonnets and stems; delrin

seats; teflon packing. c. Manufacturer and Model:

1) Anderson-Greenwood. 2) Or equal.

C. Pressure Tap Sensing Lines and Accessories for Pressure Gauges and Pressure Switches: 1. For Process Sensing Taps in Ductile Iron, Steel and Stainless Steel Piping

Systems: a. Material and Fittings: Type 304 stainless steel pipe (ASTM A 312) and

threaded fittings and adapters (ASTM A 403). b. Sizes: 1/2-inch minimum for main sensing piping and 1/4-inch gauge

and switch connections. c. Pressure Rating: Equal to or greater than the applicable system test

pressure as specified in Section 40 05 05, Exposed Piping Installation. d. Accessories:

1) For applications not requiring diaphragm seals, provide separate 1/2-inch Type 316 stainless steel threaded ball valve for each gauge and switch.

2) For applications requiring diaphragm seals, provide a separate 1/2-inch threaded Type 316 stainless steel ball valve for seal process side shutoff.

2. For Process Sensing Taps in Copper and Thermoplastic Piping Systems: a. Pipe Material and Fittings: Use same type of pipe material and fittings

as that used in the process piping system. PVC pipe and fittings shall be


02270037.D001 7/31/15 10:25:26 AM 40 70 05-4

provided in accordance with the requirements of Section 40 05 31, Thermoplastic Process Pipe.

b. Sizes: 1/2-inch minimum for main process sensing piping and 1/4-inch for gauge and switch connections.

c. Pressure Rating: Equal to or greater than the applicable system test pressure as specified in Section 40 05 05, Exposed Piping Installation.

d. Accessories: 1) For copper piping system taps with or without seals, provide a

separate 1/2-inch minimum threaded brass or bronze ball valve for each gauge and switch.

2) For PVC piping systems with or without diaphragm seals, provide a separate 1/2-inch true union ball valve for process sensing line shutoff. Ball valves shall be provided in accordance with the Specifications in Section 40 05 53, Process Valves Four-Inch Diameter and Larger.

2.0.3 AC POWER ON-OFF SWITCH

A. Function: Local power on-off selector switch for instruments. All four-wire transmitters, as identified in the individual instrument sub-sections below and as shown, shall be provided with a 120 VAC power on-off selector switch located at the instrument.

B. Construction Features: 1. Selector Switch: NEMA 4X rated, SPDT. Comply with the requirements of

Section 40 78 00, Panel Mounted Instruments and Devices. 2. Enclosure: NEMA 4X rated, non-metallic. 3. Manufacturer and Model:

a. Allen Bradley 800H rosite glass polyester enclosure. b. Or equal.

2.1 LEVEL INSTRUMENTATION

2.1.1 LEVEL SWITCH — FLOAT TYPE

A. Type: Direct acting, pear shaped, eccentric weighted, displacement type liquid level sensor.

B. Construction Features: 1. Float Body: Hollow hermetically sealed, rigidly molded of polypropylene

containing mechanical switch and eccentric metal weight. 2. Mechanical Switch: SPDT switch rated at least ten amps resistive at 120

VAC and five amps resistive at 30 VDC. 3. Weight: Weight to cause sensor to hang straight down from cable when not

immersed and only allow float to pivot when immersed in liquid. 4. Electrical Cable:


02270037.D001 7/31/15 10:25:26 AM 40 70 05-5

a. Heavy duty, three conductor, flexible and submersible cable, sheathed in PVC and connected to float and switch with watertight seal.

b. Length furnished to be sufficient to extend to junction box.

C. Manufacturer and Model: 1. Flygt Model ENM-10. 2. Or equal.

2.2 PRESSURE INSTRUMENTATION

2.2.1 PRESSURE SWITCH

A. Type: Switch assembly with diaphragm/piston pressure sensor.

B. Function: Sense gauge or absolute pressure and open or close a contact when the pressure reaches the specified trip point.

C. Performance Requirements: 1. Operating Range: As specified in the Instrument Schedule. 2. Setpoint: As specified in the Instrument Schedule. 3. Setpoint Repeatability: + One percent of range. 4. Output: Snap action switch, SPDT rated not less than ten amp resistive at 120

VAC and 1/2 amp resistive at 125 VDC. 5. Switch and Reset Action: Adjustable deadband. 6. Adjustable Deadband Range and Setting: As specified in the Instrument

Schedule. 7. Ambient Temperature Limits: -4 degrees F to 140 degrees F.

D. Construction Features: 1. Pressure Transducer Housing and Diaphragm Materials: Coordinate with the

process piping materials. a. Water Service with Copper Pipe: Brass housing with Buna-N

diaphragm. b. Other Services: Housing and diaphragm to be compatible with the

process fluid as indicated in the Instrument Schedule. 2. Set and Reset Point Adjustments: Adjustable external adjusting nuts and

pressure setting scales in psi. 3. Process Connection: 1/4-inch NPT. 4. Housing: Copper-free die cast aluminum, NEMA 4. NEMA 7 construction

required for hazardous locations. 5. External Mounting Lugs. 6. Adjusting Nuts Metal Cover with Gasket. 7. Electrical Connection: 3/4-inch NPT.

E. Manufacturer and Model: 1. Automatic Switch Company Tr-point SA Series.


02270037.D001 7/31/15 10:25:26 AM 40 70 05-6

2. Or equal.

2.2.2 PRESSURE GAUGE — BOURDON TUBE

A. Type: Bourdon Tube Pressure Element Type, Liquid Filled Gauge (for pressure ranges of 15 psi and greater and vacuum ranges to 30-inches Hg):

B. Performance Requirements: 1. Range: As specified in the Instrument Schedule. 2. Accuracy: +0.5 percent of span (ANSI B40.1 Grade 2A).

C. Construction Features:

1. Case: a. Solid front design constructed of phenolic. b. Color: Black.

2. Size: 4-1/2-inch.

3. Ring: Threaded, glass filled polyester.

4. Window: Safety glass.

5. Dial: White with black markings. 6. Filling Liquid: Use silicone except for process fluids containing chlorine.

When the process fluid contains chlorine, the filling liquid shall be Halocarbon 63 or Flurolube 63.

7. Overpressure protection: Full blowout back.

8. Bourdon Tube and Socket: a. Type 316L stainless steel. b. Heliarc welded, unless otherwise specified.

9. Movement: a. Type 400 series stainless steel. b. Rotary geared with Teflon S coating, or cam and roller type. c. Built-in overload and underload movement stops.

10. Connection: 1/4-inch male NPT, bottom. 11. Mounting: Stem Mount. 12. Calibration: Adjustable pointer.

D. Accessories: 1. Pressure Snubber: Sintered stainless steel snubber threaded into gauge socket

or in external stainless steel housing with 1/4-inch NPT male and female connections.

2. Process Isolation: Provide ball valves for process isolation in accordance with the requirements of Article 2.0.2, above.

E. Manufacturer and Model: 1. Ashcroft Duragage 1279 Series. 2. Wika Process Gauge 232 Series. 3. Or equal.


02270037.D001 7/31/15 10:25:26 AM 40 70 05-7

2.2.3 PRESSURE TRANSMITTER

A. Type: Two-wire, differential capacitance, inductive, or resonant type transmitter.

B. Required Features and Accessories:

1. Accuracy (includes combined effects of linearity, hysteresis and repeatability): +/- 0.10% of calibrated span

2. Repeatability: 0.05% of calibrated span

3. Hysteresis: 0.05% of calibrated span 4. Stability (drift over a five year period): Not more than +/- 0.2% of

transmitters upper range limit 5. Ambient Temperature Effect; Total Error per 100°F change between the

limits of -20 and +180°F: Not more than +/- 1.0% of the transmitters upper range limit (maximum span)

6. Supply Voltage Effect: Output change not greater than 0.005% of span for each 1 V change in supply voltage

7. Output: a. Isolated direct acting 4 to 20 mA b. Superimposed HART protocol digital communication

8. Solid state electronic components

9. Positive over range protection of at least 1.25 times the maximum span limit 10. Calibration Adjustments:

a. Zero: Electronically adjustable b. Span: Coarse and fine span electronic adjustments

11. Zero Elevation and Suppression Capability to the extent that the amount of suppression plus calibrated span does not exceed the upper range limits of the sensor

12. Adjustable internal damping 13. Measuring elements protected by sealing diaphragm 14. Built-in electrical surge and RFI protection 15. Valves:

a. Provide a stainless steel 3-valve shutoff at each process line tap to enable live process removal of transmitter. Comply with requirements of subparagraph 2.02 of this Section.

b. Provide stainless steel 3-valve manifold for shutoff and pressure equalization on differential pressure and flow measurement applications. Comply with requirements of subparagraph 2.02 of this Section.

c. Provide 1/2-inch block and bleed valve for isolation on gauge pressure applications.

16. Integral square root extraction to provide linear 4 to 20 mA output proportional to flow where required for flow applications

17. Electric Conduit Connection: 1/2-inch NPT 18. Process Connections:

a. 1/2-inch NPT for gauge pressure applications b. 1/4-inch NPT for differential pressure and flow applications


02270037.D001 7/31/15 10:25:26 AM 40 70 05-8

19. Power Requirement: 24 VDC from receiver or remote power supply 20. Stainless steel mounting bracket and hardware suitable for mounting

transmitter on flat vertical surface or 2-inch diameter pipe 21. Process Wetted Parts: Type 316 Stainless Steel 22. Non-Wetted Parts:

a. Body and Process Connection Bolting: Type 316 Stainless Steel b. Housing and Cover: Die cast low copper aluminum alloy finished with

epoxy paint system; covers shall be threaded and seated on o-rings. 23. Capsule Fill Liquid: Use silicone except for process fluids containing

chlorine. When the process fluid contains chlorine, the filling liquid shall be Halocarbon 63 or Flurolube 63.

24. Indicator: Provide integral indicator scaled in engineering units. 25. NEMA 4X rating. 26. Unit must be capable of configuration via the local non-intrusive

pushbuttons. 27. Magnetically coupled to Hall Effect switches internal to the Aluminum

enclosure, as well as having the ability to configure via HART protocol. C. Manufacturer and Model:

1. Series SITRANS P DS III for gauge pressure as manufactured by Siemens 2. Or equal.

2.3 FLOW INSTRUMENTATION

2.3.1 MAGNETIC FLOWTLTBE AND TRANSMITTER

A. Type: Flowtube with pulsed DC Magnetic Flow Transmitter.

B. Function: Monitor liquid flows as shown and as specified in the Instrument Schedule. The transmitter shall display the monitored flow value and shall output a 4 to 20 mADC signal proportional to the monitored flow.

C. Performance Requirements: 1. Range: As specified in the Instrument Schedule. 2. Local Indication: As specified in the Instrument Schedule. 3. Accuracy (with analog output):

a. ±0.5 percent of flow rate, or better, over a range from 1 fps to 31 fps. b. 10.005 fps, or better, at flows below 1 fps. c. Accuracy unaffected by changes in fluid velocity, density, pressure,

temperature or conductivity (above minimum conductivity limits). d. System accuracy shall be proven by submittal of flow test curves of the

actual meters being furnished. 1) Test curves shall show a minimum of ten equally spaced flow

points. Tests shall be performed using water and a weight or volume tank or reference meters that are traceable and calibrated to NAMAS or NIST standards. The test setup shall be submitted and approved prior to testing.


02270037.D001 7/31/15 10:25:26 AM 40 70 05-9

4. Repeatability: +0.15 percent of flow rate, or +0.0015 fps, whichever is greater.

5. Drift: Complete zero stability. 6. Minimum Fluid Conductivity Limit: Five microsiemens per centimeter or

less. 7. Power:

a. 120 VAC ± 10 percent, 60 Hz, ±3 Hz power supply. b. Power Consumption shall not exceed 50 watts for flowtube and

transmitter combined. 8. Output:

a. 4 to 20 mADC, direct acting and isolated, into 0 to 750 ohms. b. High accuracy, field adjustable scaled pulse output (0.1 to 10 Hz or

greater) to drive local totalizer. 9. Operating Temperature: Suitable for operation with process fluid

temperature from 0° to 140°F. 10. Pressure Rating: Greater than or equal to test pressure specified in Section

40 05 05, Exposed Piping Installation, for appropriate piping system.

D. Construction Features 1. Flowtube:

a. Type: Lined metal flowtubes. b. Interchangeability: Ratio of flow velocity to voltage reference signals

generated identical for all meter sizes to permit interchangeability with transmitter without requiring circuit modifications.

c. Tube Material: Type 304 stainless steel. d. Electrode:

1) Conical or elliptical shaped. 2) Material: To be compatible with the process fluid in the line in

which the flowtube is installed. 3) Lining: To be compatible with the process fluid in the line in which

the flowtube is installed. 2. Enclosure:

a. Materials and Rating: 1) Cast low-copper aluminum alloy or fabricated sheet steel. 2) NEMA 6 rated. 3) Capable of withstanding accidental submergence in 30 feet of water

for 48 hours b. Finish: Finish exterior, except for flange faces, with a high build epoxy

paint. c. End Connections: ANSI Class 150 suitable for mating with pipe

specified. d. Electrical Connections: 3/4-inch NPT tapped holes for power conduit

fitting and signal conduit fittings. 3. Pulsed DC Magnetic Flow Transmitter:

a. Materials and Rating: 1) Die cast, low-copper aluminum alloy.


02270037.D001 7/31/15 10:25:26 AM 40 70 05-10

2) NEMA 4 rated. b. Solid state construction. c. Local Indication:

1) LCD display with field selectable engineering units. 2) Totalization capabilities shall be standard on the transmitter.

Lithium battery backup shall retain the flow total in the event of a power outage.

d. Pulse and analog outputs galvanically isolated from input and earth ground.

e. Automatic zeroing feature making it unnecessary to zero the instrument before or after placing it in operation.

f. Pre-calibrated span adjustment providing continuous span adjustment over entire range.

g. Range Adjustment: Continuously adjustable for full scale settings from 1 to 31 feet per second.

h. Signal Conditioning: Adjustable damping circuit with response times of 1 to 25 seconds minimum.

i. Low Flow Cutoff: Provide automatic low flow cutoff circuitry to stop pulse output and local totalization when flow drops below 0.5 percent 0.2 percent of the calibrated upper range valve.

E. Accessories: 1. Mounting:

a. Provide complete 316 stainless steel mounting hardware. b. All transmitter and driver electronics shall be remotely mounted from

the flow tubes at locations shown. c. Type of mounting (wall, support frame or pipe stand) as required.

2. Shielded cable assemblies of sufficient length for connection between flowtube and transmitter electronics.

3. Type 316 stainless steel grounding rings for flowtubes. 4. NEMA 4X rated SPDT 120 VAC power on-off selector switch as specified

in Paragraph 2.0.3 above. 5. One HART communicator suitable to communicate with all transmitters

provided.

F. Manufacturer and Model: 1. Siemens Sitrans MAGFLO 5100W flowtube w/MAGFLO 5000 transmitter. 2. Or equal.

2.4 SPARE PARTS AND TEST EQUIPMENT

A. Furnish and deliver the spare parts and test equipment as outlined below, identical to and interchangeable with similar parts furnished under this Section.


02270037.D001 7/31/15 10:25:26 AM 40 70 05-11

B. Spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended.

C. The following shall constitute the minimum spare parts: 1. A one-year supply of all expendable materials. 2. One per five of gauges and switches used in field complete with diaphragm

seals, filled and ready for use. Provide one at minimum. 3. One dozen of each type and size of fuse used in instruments. 4. One per five of gas detection transmitters used in field, provide one at

minimum.

D. The following shall constitute the minimum test and calibration equipment. 1. All tooling required to insert, extract and connect any internal or external

connector, including edge connectors. 2. All special calibration equipment required for system calibration.

E. All spare parts shall have been operated and tested in the factory as part of factory testing prior to shipment of the control system.

F. For process sensors and all other analog instruments, the supplier shall submit a separate quotation for a recommended list of spare parts and test equipment. Each item recommended shall be listed and priced separately. The spare parts quotation shall contain a statement that the prices quoted are firm for a period of one year from the installation date of the equipment, and that the supplier understand that the Owner reserves the right to purchase none, any, or all of the parts quoted. The supplier is required to show that a stock of spare parts and test-equipment is obtainable within a 48-hour period.

PART 3- EXECUTION

3.1 INSTALLATION

A. CONTRACTOR shall require the supplier to furnish the services of qualified factory-trained servicemen to assist in the installation of the instrumentation and control system equipment.

B. Install each item in accordance with manufacturer's recommendations and in accordance with the Contract Documents. Transmitters and instruments, which require access for periodic calibration or maintenance, shall be mounted so they are accessible while standing on the floor. Care shall be taken in the installation to ensure sufficient space is provided between instruments and other equipment or piping to allow for easy removal and servicing.


02270037.D001 7/31/15 10:25:26 AM 40 70 05-12

C. All items shall be mounted and anchored using stainless steel hardware, unless otherwise noted.

D. All field instruments shall be rigidly secured to walls, stands or brackets as required by the manufacturer and as shown.

E. Conform to all applicable provisions of the NEMA standards, NEC and local, State and Federal codes when installing the equipment and interconnecting wiring.

3.2 START-UP, CALIBRATION, TESTING, AND TRAINING

A. Comply with the requirements of Section 40 61 13, Process Control System General Provisions, Section 40 61 23, Process Control System Start-up and Field Testing, and Section 40 61 26, Process Control System Training.



02270037.D001 7/31/15 10:25:26 AM 40 70 05-13

SUPPLEMENT INSTRUMENT LIST

TAC NI r M 41* '

LQQVADTBFR. I 00P " ES " ' ON l'NSTRI:r EN' r [ o( A ' ON

LINE Sin'

RAN GI '' SE F A N I SPECIFICATION

SU:3J ON:::: P&ID

DRAWING: LEVEL INSTRUMENTATION

LSH B009 SANITARY HOLDING TANK

LEVEL HIGH SANITARY HOLDING

TANK N/A N/A 731'± 40 70 05 2.1.1 1-3

FLOW INSTRUMENTATION

FE/FIT B004 BOOSTER PUMP (RECYCLE)

FLOW BOOSTER PUMP

DISCHARGE HEADER 16" 0- 2000, GPM N/A 40 70 05 2.3.1 1-3

PRESSURE INSTRUMENTATION

PI/PSH* B011 BOOSTER PL'. IEP NO 1

DISCHARGE PRESSURE BOOSTER PUMP . NO 1

DISCHARGE PIPING N/A 0 - 200 PSI TBD 40 70 05 2.2.1, 2.2.2 1-3







PIT B005 BOOSTER PUMP (RECYCLE)

SYSTEM PRESSURE BOOSTER PUMP

DISCHARGE HEADER N/A 0 - 200 PSI N/A 40 70 05 2.2.3 1-3

++ END OF SECTION ++

02270037.D001 40 70 05-15

SECTION 40 78 00

PANEL MOUNTED INSTRUMENTS AND DEVICES

PART 1 - GENERAL

1.1 DESCRIPTION

A. Scope of Work: 1. CONTROL SYSTEM SUPPLIER shall furnish, install, test, calibrate, adjust

and place into satisfactory operation all panel-mounted instruments and devices as shown on the Drawings and specified herein.

2. Operational and functional requirements for the various panels are shown in control schematics, pneumatic diagrams, and/or functional instrumentation diagrams on the Instrumentation (I) drawings and Electrical (E) drawings.

3. The Drawings and Specifications illustrate and specify functional and general construction requirements of the panel components and do not necessarily show or specify all components, wiring, piping, and accessories required to make a completely integrated system. CONTRACTOR shall provide all piping, wiring, accessories, and labor required for a complete, workable, and integrated system.


A. Standards, Codes and Regulations: 1. Construction of panels and the installation and interconnection of all equipment

and devices mounted within shall comply with applicable provisions of the following standards, codes, and regulations: a. National Electrical Code (NEC). b. National Electrical Manufacturer's Association (NEMA) Standards. c. Institute of Electrical and Electronics Engineers, Inc (IEEE). d. Local and State Building Code. e. Operational Safety and Health Administration (OSHA) Regulations. f. American Society for Testing and Materials (ASTM). g. Where any conflict arises between codes or standards, the more stringent

requirement shall apply. 2. All electrical materials and equipment shall be new and shall bear the label of

the Underwriters Laboratory (UL), Inc., Factory Mutual (FM) or equivalent where standards have been established and label service regularly applies.

B. Acceptable Manufacturers: 1. Furnish panel instruments and devices by the named manufacturers or equal

equipment by other manufacturers. 2. The named manufacturers have been specified to establish the standard of

quality and performance of the equipment to be supplied. 3. Obtain all instruments or devices of a given type from the same manufacturer.

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C. General Design Requirements: 1. Comply with the requirements of Section 40 61 13, Process Control System

General Provisions.

D. Factory Assembly and Testing: 1. Comply with the requirements of Section 40 61 21, Process Control System

Factory Testing.

1.3 SUBMITTALS




PART 2- PRODUCTS

2.1 GENERAL CONSTRUCTION REQUIREMENTS


2.2 IDENTIFICATION

A. Tag all panel mounted instruments in accordance with Section 40 67 17, Process Control Panels and Enclosures, Paragraph 2.2.

2.3 CONTROL RELAY

A. Type: General purpose, plug-in type rated for continuous duty.

B. Performance Requirements: 1. UL recognized. 2. Contact Configuration: Number and arrangement as required to perform the

intended functions, plus a minimum of one spare SPDT contact per relay function.

3. Coil Voltage: 24 VDC or 120 VAC as required.

C. Construction Features: 1. Contact Material and Rating:

a. General Use: Silver or silver cadmium oxide contacts rated for 10 amps minimum at 120 VAC.


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b. Low Power Switching: Fine silver, gold flashed contacts specifically designed for low power switching, rated for 2 amps minimum at 30 VDC.

2. Mounting: Pin or blade mount in sockets for subpanel mounting on DIN rail. Sockets shall have screw terminals for wiring connections which shall accept a minimum of two #14 AWG wires.

D. Accessories: 1. Clear plastic dust cover, with hold down clips. 2. Indicator light.

E. Manufacturer and Model: 1. Potter & Brumfield, KRPA or R10-T. 2. IDEC, RR Series, or RY Series. 3. Or equal.

2.4 TIME DELAY RELAY

A. Type: Dial adjustable, plug-in type time delay relay providing delay-on-make, delay-on-break or interval operation.

B. Construction Features: 1. MOS digital circuit with transformer coupled power. 2. Two different dial selectable timing range versions as listed below. Provide

timing range version as required by the application: a. Six dial selected ranges of 1 or 10 sec/min/hours. b. Six dial selected ranges of 5 or 50 sec/min/hours.

3. Minimum Setting: 2 percent of range, with exception of 50 ms for the 1 second range.

4. Contacts: a. Type: DPDT. b. Rating: 10 amperes resistive at 120/240 VAC and 30 VDC.

5. Housing: Plug-in design with dust and moisture resistant molded plastic case, designed for 11 pin surface/DIN rail socket mounting or panel cutout mounting with rear facing terminal socket.

6. Power Input: Universal 24-240 VAC and 24 V dc, reverse polarity protected. 7. Relays to be UL recognized. 8. Flashing cycle in progress indication via front mounted LED. 9. Large easy to read dial display with decimal points automatically displayed

when fractional ranges are selected.

C. Manufacturer and Model: 1. Automatic Timing and Controls Company, Series 339. 2. Or equal.


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2.5 PUSHBUTTONS, SELECTOR SWITCHES AND INDICATING LIGHTS

A. Type: Full size (30.5 mm), heavy duty, oiltight, round type operators with modular contacts and NEMA rating equal to that of the enclosure on which devices are in-stalled.

B. Performance Requirements: 1. Selector switches, pushbuttons and indicating lights shall be supplied by one

manufacturer and be of the same series or general model type. 2. Common, remote push-to-test circuitry shall be provided for each control panel

to simultaneously test all indicating lights on the panel using a single pushbut-ton when there are 10 or more lights on the panel. Control panels with less than 10 lights shall utilize individual push-to-test lights and control circuitry.

3. Provide individual legend plates for indication of switch, pushbutton, and light functions (e.g. Open, Closed, Hand-Off-Auto). Legend plates shall conform to the requirements of Paragraph 2.2 above.

4. All components shall be flush mounted on front of panel, unless otherwise noted.

C. Construction Features: 1. Selector Switches:

a. Two (2), three (3) and four (4) position as required. b. Maintained or momentary contacts; number and arrangement as required to

perform intended functions specified but not less than one double pole, double throw, double break contact per switch. Contact rating shall be compatible with ac or dc throughput current of devices simultaneously operated by the switch contacts but not less than 10 amperes resistive at 120 volts AC or DC continuous.

c. Black knob operator. 2. Pushbuttons:

a. Maintained or momentary as required and as shown on the Drawings. b. Contacts shall comply with requirements specified for selector switches

above. c. Provide extended head pushbutton for all stop functions and flush head

pushbuttons for all other functions. d. Colors:

1) Green - Start, Open. 2) Red - Stop, Close. 3) Black - Status.

3. Indicating Lights: a. Integral transformer type. b. Low voltage, long life lamps (6 volts). c. 3 watts maximum. d. Remote common test or integral push-to-test as specified above. e. Lens Colors:

1) Green — Running, Open.


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2) Red - Stopped, Closed. 3) Amber - Malfunction. 4) White - Status. 5) Blue - Power On.

D. Product and Manufacturers: 1. Allen-Bradley Types 800T and 800H. 2. Or equal.

2.6 POWER SUPPLY

A. Function: Provide DC power for two wire current loops. Provide a separate dedicated power supply for each current loop.

B. Type: A single output, regulated, plug-in type 24 Vdc power supply.

C. Performance Requirements: 1. Temperature: Operational from -10 to 65°C. 2. Output: 24 VDC, current load determined by equipment. 3. Power Requirements: 120 VAC, 60 Hz, single phase. 4. Regulation: ±1.0%. 5. Ripple: 100 mV RMS. 6. Protection: Overvoltage protection. 7. Approval: U.L. recognized.

D. Construction Features: 1. Mounting: Power supply to snap onto DIN rail.

E. Manufacturer and Model: 1. Phoenix Contact MINI-PS-100-240AC/24DC Series. 2. Sola SDP Series. 3. Or equal.

2.7 UNINTERRUPTIBLE POWER SUPPLY

A. An Uninterruptible Power Supply (UPS) shall be provided for each network rack enclosure and each control panel housing a PLC or remote I/O rack, to provide a reliable source of uninterruptible power with no break in AC output power during a complete or partial interruption of incoming line power. UPS shall include audio/visual alarms. UPS shall be UL listed.

B. Rating: 120 VAC, 60 Hz, with KVA/KW sized to provide uninterrupted conditioned power, fully loaded conditions for 60 minutes

C. Description: Self contained with inverter, charger, transfer switch, circuit breaker and other components in one tower or rack mounted enclosure. True on-line double


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conversion (0 ms transfer time) uninten-uptible power supply providing isolation, line regulation and conditioning, using sealed maintenance free batteries and switch mode power supply for uninterrupted power. Automatic voltage regulation to protect against brownouts (low voltage) and overvoltages. Upon restoration of utility power and after a user settable timeout the UPS shall restore power to the control system.

D. Required Features: 1 Lighting and Surge Protection: Inherent 2000: One spike attenuation. 2. Regulation: One to three percent load regulation with less than 2pF effective

coupling capacitance for line to load. 3. Output Waveform: Computer Dude sine wave with three percent maximum

single harmonic and five percent maximum total harmonic distortion. 4. Output Frequency: 60 Hz +0.5 Hz. 5. Operating Temperature: 1°C to 40°C. 6. Relative Humidity: Five to 90 percent non-condensing. 7. Computer Interface: RS232 port. 8. Input Protection: Independent battery charger fuse and DC fuses. 9. Battery Charger: Two-step charger, 8 A and 2 A. 10. AC Input: 120 VAC, 60Hz, single phase, +15 percent, -20 percent. 11. AC Output: 120 VAC, 60Hz, single phase, +3 percent, -3 percent.

E. Products and Manufacturers: Provide one of the following: 1. Powerware PW9130. 2. American Power Conversion, APC SMART-UPS Online. 3. Or equal.

2.8 SURGE PROTECTION

A. Power Surge Protection. 1. A surge protection device shall be installed on the power feed to each panel

supplied by the CONTROL SYSTEM SUPPLIER. The power surge protection device shall be rated for 120 VAC, Single Phase.

2. The power surge protection device shall have the following features: a. Response Time: Less than 5 nanoseconds. b. Maximum Surge Cun-ent: 40,000 Amps/phase. c. Maximum Energy Absorption (2 ms): 360 Joules/phase. d. Initial Clamping Voltage: 240 Volts Nominal. e. Clamp Voltage at 300A: 395 Volts Nominal. f. Maximum Allowable Voltage (L-N): 150 Vrms, 50-60 Hz. g. Maximum Allowable Voltage (L-L): 275 Vrms, 50-60 Hz. h. Failure Mode: Failsafe (short) and Fused. i. Failure Indication: LED Indicator. j. Surge Life at 10,000A: Greater than 50 Occurrences.

3. Manufacturer and Model Number: a. EDCO, EMC-240B. b. Or equal.


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B. Signal Surge Protection. 1. A signal surge protection device shall be installed on all signal loops that run

outdoors or between buildings. 2. The signal surge protection device shall have the following features:

a. Maximum Signal Voltage: 28 V max. b. DC Clamping Level (L-G): 36V ±10%. c. DC Clamping Level (L-L): 72V ±10%. d. Maximum Let Through Voltage (L-G, 10x700 is): 44V at 400A. e. Maximum Let Through Voltage (L-L, 10x700 is): 90V at 400A. f. Capacitance, zero volts bias (L-G): 1200 pf. g. Capacitance, zero volts bias (L-L): 600 pf. h. Number of Occurrences: 400 at 500A. i. Enclosure: Encapsulates in Stainless Steel Pipe Nipples.

3. Manufacturer and Model Number: a. EDCO, SS-64. b. Or equal.

2.9 SPARE REPLACEMENT UNITS AND PARTS

A. Spare replacement instruments and components shall be provided for the panel mounted devices as follows. Round up to the nearest component. 1. 20% spare bulbs for each type of bulb used in the system. 2. 20% spare fuses for each type of fuse used in the system. 3. 10% spare relays for each type of relay used in the system. 4. 10% spare power supplies for each type of power supply used in the system.

B. All spare parts shall be individually packaged for protection against impact, moisture and dirt. Each package shall be clearly labeled as to its contents with a description and part number.

C. All spare parts shall become the property of the OWNER. CONTROL SYSTEM SUPPLIER shall maintain the spare parts inventory as listed above, and replace, at no additional cost, all spare parts consumed during the one-year warranty period.

PART 3- EXECUTION

3.1 INSTALLATION

A. Install equipment in conformance with NEC.

B. Install and interconnect all equipment, devices, electrical hardware, instrumentation and controls, and process controller components into and out of and among the enclosures as indicated on the Drawings.

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SECTION 41 22 13.13

BRIDGE CRANES

PART 1— GENERAL

1.1 DESCRIPTION

A. Scope: 1. CONTRACTOR shall provide all labor, materials, tools, equipment, and

incidentals as shown, specified and required to furnish and install bridge cranes complete and operational.

2. The Work includes: a. Single-girder, electric, under-running bridge cranes with under-

running electric wire-rope hoist and trolley. b. Pendant operated controls. c. Bridge and trolley electrification systems. d. Rails, splice bars, rail clips, stops, fasteners, and all other

appurtenances required for complete and operational bridge crane systems.

B. Coordination: 1. Review installation procedures under other Sections and coordinate the

installation of items to be installed with or before bridge cranes Work.

C. Related Sections: 1. Section 05 50 13, Miscellaneous Metal Fabrications. 2. Section 09 91 00, Painting.

1.2 REFERENCES

A. Standards referenced in this Section are: 1. ANSI/AGMA 6013-A, Standard for Industrial Enclosed Gear Drives. 2. ASME B30.2, Overhead and Gantry Cranes (Top Running Bridge, Single or

Multiple Girder, Top Running Trolley Hoist). 3. ASME B30.16, Overhead Hoists (LTnderhung). 4. ASME B30.17, Overhead and Gantry Cranes (Top Running Bridge, Single

Girder, Underhung Hoist). 5. ASME HST-1, Performance Standard for Electric Chain Hoists. 6. ASME HST-2, Performance Standard For Hand Chain Manually Operated

Chain Hoists. 7. ASME HST-4, Performance Standard for Overhead Electric Wire Rope

Hoists. 8. ASTM A36/A36M, Specification for Carbon Structural Steel. 9. ASTM A325, Specification for Structural Bolts, Steel, Heat-Treated,

120/105 KSI Minimum Tensile Strength.

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10. ASTM A572/A572M, Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel.

11. ASTM A992/A992M, Specification for Structural Steel Shapes. 12. AWS D1.1, Structural Welding Code — Steel. 13. AWS D14.1, Specification for Welding of Industrial and Mill Cranes and

other Material Handling Equipment. 14. CMAA 70, Top Running Bridge & Gantry Type Multiple Girder Electric

Overhead Traveling Cranes. 15. CMAA 74, Top Running & Under Running Single Girder Electric Traveling

Cranes Utilizing Under Running Trolley Hoist. 16. NEC, Article 610, Cranes and Hoists. 17. NFPA 820, Standard for Fire Protection in Wastewater Treatment and

Collection Facilities. 18. SAE J429, Mechanical and Material Requirements for Externally Threaded

Fasteners.


A. Qualifications: 1. Manufacturer:

a. Minimum of five years of experience producing substantially similar equipment and shall be able to furnish documentation of at least five installations in satisfactory operation for at least five years in the United States.

b. Equipment shall be manufactured in the United States. 2. Installer:

a. Engage to perform the Work under this Section an installer experienced in installing bridge crane equipment similar to that required for the Project and is acceptable to bridge crane manufacturer.

b. Submit name and qualifications, and the following information for at least three successful, completed projects: 1) Names and telephone numbers of each owner and architect or

engineer responsible for project. 2) Approximate contract cost of bridge crane work. 3) Number of installations.

B. Component Supply and Compatibility: 1. Obtain all equipment included in this Section regardless of component

manufacturer from a single bridge crane manufacturer. 2. Bridge crane manufacturer shall review and approve or prepare all

submittals for components furnished under this Section. 3. Components shall be specifically constructed for the specified service

conditions and shall be integrated into overall equipment assembly by bridge crane manufacturer.


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1.4 SUBMITTALS


a. Complete description of materials and equipment in sufficient detail to allow comparison with requirements of this Section.

b. Manufacturer's certified clearance diagram showing arrangement of system and clearances, including plan and sections.

c. Maximum wheel loads. d. Weight of hoist and trolley. e. Specialized wiring diagrams, if applicable.

2. Product Data: a. Manufacturer's literature, illustrations, specifications identifying the

materials of construction, rated capacities, dimensions of individual components, and finishes.

b. Make, model, weight and horsepower of each component. c. External power requirements for each component.

3. Testing Plans: Plan for load testing at the Site.


a. Affidavits of compliance with referenced standards and codes. b. Manufacturer's installation certification.

2. Manufacturer's Instructions: a. Special shipping, storage and protection, and handling instructions. b. Routine maintenance requirements prior to start-up.

3. Field Quality Control Submittals: a. Load test report, including copy of certifications of test weights.

4. Manufacturer's Reports: Submit written report of results of each visit to Site by Supplier's service technician, including purpose and time of visit, tasks performed, and results obtained.

5. Qualifications Statements: a. Manufacturer, when qualifications are requested by ENGINEER. b. Installer, when qualifications are requested by ENGINEER.

C. Closeout Submittals: Submit the following: 1. Operation and Maintenance Data:

a. Submit operation and maintenance manuals in accordance with Section 01 78 23, Operations and Maintenance Data.

b. Include acceptable test reports, maintenance data and schedules, description of operation, wiring diagrams, and list of spare parts recommended for one year of operation with current price list.


A. Packing, Shipping, Handling, and Unloading: 1. Deliver materials and equipment to Site to ensure uninterrupted progress of

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the Work. Deliver anchorage materials to be embedded in concrete in ample time to prevent delaying the Work.

2. Conform to Section 01 65 00, Product Delivery Requirements.

B. Storage and Protection: 1. Comply with Section 01 66 00, Product Storage and Handling.

1.6 WARRANTY

A. General Warranty: Special warranty specified in this Article shall not deprive OWNER of other rights or remedies OWNER may otherwise have under the Contract Documents and shall be in addition to and run concurrent with other warranties made by CONTRACTOR under the Contract Documents. Obligations of CONTRACTOR under the Contract Documents shall not be limited in any way by provisions of specified special warranty

PART 2— PRODUCTS

2.1 SYSTEM PERFORMANCE

A. System Description: 1. Bridge crane shall conform to headroom, hook elevation, and side clearance

requirements shown and indicated in the Contract Documents, and shall provide required available lift height and capacity.

2. Electrical equipment and controls shall conform to applicable NEMA requirements for the equipment environment specified in the Contract Documents.

B. Performance Criteria: 1. Bridge Cranes with Electrically-operated Hoists:


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Designation Bridge Crane No. 1 General Location: Pump Room Hoist Type: Under Running, Single Girder, Dual Motor Driven CMAA Service Classification: CMAA 70 Class C (Moderate Service) Number Required: 1 Capacity (tons): 4 Required Lift (feet): 12 Max Required Hook Elevation (ft):

748.00

Minimum Lift Speed (fpm): 11 Maximum Hoist Horsepower: 5 Trolley Type: Motor Driven Trolley Speed (fpm): 50 Maximum Trolley Horsepower:

1

Bridge Type Motor Driven Maximum Bridge Horsepower 5 Volts: 460 Phase: 3 Frequency (Hertz): 60 Control: Pendant Electrification: C-track Festoon

2.2 MANUFACTURERS

A. Manufacturers: Provide equipment of one of the following: 1. Cleveland TramRail by Gorbel, Inc. 3. Or equal.

2.3 DETAILS OF CONSTRUCTION

A. General 1. Comply with applicable provisions of CMAA 70 or CMAA 74, and ASME

B30.2, ASME B30.16, and ASME B30.17, as applicable to the equipment provided.

2. Design Stresses: Load suspension components shall be constructed so that stresses at rated load do not exceed 20 percent of material's average ultimate strength.

3. Shop welding shall be in accordance with AWS D14.1. 4. Give special consideration to available headroom and vertical clearances. 5. Provide bridge crane with configuration and weight that does not result in

load exceeding design capacity of bridge crane runway beams. 6. Include impact allowance in design calculations for trolley, bridge, and end-

trucks. Impact allowance shall be 1/2 percent of rated load for each foot per minute of hoisting speed with minimum allowance of 15 percent and maximum allowance of 50 percent.

7. Incorporate into equipment provided safety requirements in accordance with ASME B30.2, ASME B30.16, and ASME B30.17, as applicable to the equipment provided.


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B. Electric-powered Wire Rope Hoists: 1. Comply with ASME B30.16 and ASME HST-4. Welding shall comply

with AWS D14.1. 2. Load Blocks: Load blocks shall be enclosed type, constructed to prevent

rope jamming. 3. Hooks: Provide latch-type hooks, free to rotate through 360 degrees under

all loading conditions. Hooks shall be heat-treated drop forged steel. 4. Hoisting Rope: Rated load shall be based on factor of safety factor of five

on rope's nominal breaking strength. Attach rope ends to hoist drum to prevent rope from coming off drum on full extension. Rope shall be extra-flexible improved plow steel with hemp core.

5. Rope Sheaves: Sheave grooves shall be smoothly finished to close, form- fitting saddle for rope with sides of groove tapered outward. Provide running sheaves with means for lubrication. Pitch diameter of sheaves shall not be less than 16 times rope diameter for running sheaves, and for non-running sheaves not less than 12 times rope diameter.

6. Drum: Rope drum diameter shall not be less than 18 times rope diameter. At least one complete wrap of rope shall remain on drum after rope's full rated extension.

7. Hoist shall be true vertical lift. 8. Gearing: Machined and heat-treated. Hoist gear box shall be in accordance

with AGMA 6013-A. Provide means for adequate lubrication of gearing. 9. Hoist Brakes: Breaking system shall consist of break and control breaking

means, and shall perform the following functions under normal operating conditions both with rated load and under test conditions with 125 percent of rated load: a. Stop and hold the load when controls are released. b. Control the load during lowering to maximum speed of 120 percent of

rated lowering speed for load being handled. c. Stop and hold the load during a complete power failure. d. Breaking system shall have heat dissipation capability for frequency of

operation required by hoist duty cycle classification. e. Breaking system shall have provision for adjustments to compensate

for wear. 10. Provide overload protection device that prevents lifting of loads beyond

rated capacity. 11. Motor: Specifically constructed for reversing and hoisting service and

capable of operating at specified loads. Motor shall be heavy-duty, thermally protected, 30-minute rated, H3 duty classification. Motor at rated frequency shall be capable of operation at plus or minus ten percent of rated motor voltage.

12. Hoist shall contain upper and lower limit switches to limit hook travel. 13. Housing and Covers: Cast aluminum. 14. Provide supports, fasteners, brackets, and all accessories required.

C. Electric-powered Trolleys: 1. Wheels: Fabricated of heat-treated drop forged steel. Wheels shall have

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uniform surface hardness and capable of carrying maximum applied load. 2. Trolley motor shall be thermally protected. 3. Gearing: Machined and heat-treated. Hoist gear box shall be in accordance

with AGMA 6013-A. Provide means for adequate lubrication of gearing.

D. Crane Bridge: 1. Bridge Girders: ASTM A992, A572 Grade 50, or ASTM A36 structural

steel. 2. Maximum Deflection: 1/1000 of bridge span. 3. Provide rubber stops on ends of bridge girders and ends of runways.

E. Bridge End-trucks: 1. Fabricate of structural steel shapes. 2. Wheelbase of end-truck shall be 1/8 of span or greater. 3. Lugs shall be provided on end-trucks to limit drop of end-truck to one-inch

or less in the event of wheel or axle failures. Provide rail sweeps in front of each outside wheel, projecting below runway rail.

4. Wheels: Double flanged, and of drop forged or rolled steel. a. Minimum Tread Hardness: 200 Brinell. b. Bearings: Pre-lubricated and sealed, or provided with fittings and seals

for pressure lubrication.

2.4 CONTROLS FOR ELECTRIC HOIST AND TROLLEY

A. Hoist Speed Control: 1. Hoist motor shall be single-speed or dual-speed, as specified in Article 2.1

of this Section, with magnetic control. 2. Each magnetic control shall have contactors sized for specified service class.

Reversing contactors shall be mechanically and electrically interlocked to prevent line-to-line faults and shall be provided with automatic reset thermal overloads for hoist motor.

B. Control Station: 1. Control station shall be rated in accordance with Paragraph 2.1. A.2 of this

Section. Motion control pushbuttons shall spring return to "Off' position when released. Clearly mark function of each pushbutton, and indicate direction of resultant motion. a. Control station shall contain the following functions for single-speed

hoists: 1) "Power On" 2) "Power Off' 3) "Raise" 4) "Lower" 5) "Trolley — Right" 6) "Trolley — Left" 7) "Bridge — Forward" 8) "Bridge — Reverse"


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2. Pendant Control: Control of hoist, trolley, and bridge shall be by pendant pushbutton control station. a. Pendant mounting shall include steel cable to provide strain relief for

pendant's electric control cable. Provide isolating transformer to reduce voltage to 120 volts (or less) in control circuits.

b. Mount control pendant and cable on 12-gage stainless steel C-track festoon system that allows hoist and trolley to move independently of control station.

2.5 ELECTRIFICATION

A. C-Track Festoon: 1. Provide power cable on 12-gage stainless steel C-track festoon system. 2. System Components: Electrification system shall include, but is not limited

to, the following: a C-track b. Track hangers. c. Cable carriers. d. Lead carrier. e. End stop. f. Splices. g. Clamps. h. Cable and connectors required for power and control connections.

B. Manual Safety Switch: Provide manual safety switch to disconnect power to bridge crane.

2.6 FINISHING

A. Surface Preparation and Painting: 1. Surface preparation and shop painting is required for ferrous metals,

equipment, and accessories. Do not paint stainless steel and machined surfaces.

2. Clean and apply in the shop prime coat in accordance with Section 09 91 00, Painting.

3. Apply in the shop finish coat in accordance with Section 09 91 00, Painting. 4. Paint the bridge "Safety Yellow". Stencil system's hoisting capacity in

black-painted characters, clearly visible from loading floor.

B. Gears, bearing surfaces, and other machined surfaces shall receive heavy application of rust-inhibiting coating that shall be maintained during storage and until equipment is Substantially Complete.

2.7 IDENTIFICATION

A. Identify component subassemblies with stainless steel nameplates and each labeled with the following:


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1. Manufacturer and model number. 2. Date of manufacture with pertinent ratings, operation, and maintenance

information. 3. Certification, stamp, or approval, in accordance with Laws and Regulations.

PART 3— EXECUTION

3.1 INSPECTION

A. Examine conditions under which materials and equipment are to be installed and notify ENGINEER in writing of conditions detrimental to proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions have been corrected.

B. Before installing bridge cranes, verify the following: that design strength of cast-in-place concrete supporting elements has been attained, structural steel or other support framing is properly erected, plumb and level, in accordance with the Contract Documents, adequately bolted, braced and welded, and ready for installation of bridge crane system. Do not begin installing bridge crane equipment until building or structure is enclosed and weathertight.

C. Inspect and verify that no part of building, structure, piping, mechanical systems including ductwork, electrical systems including lighting and conduit, or other elements will interfere with proper operation of bridge crane system along entire length of runway and entire span of bridge. Verify that there is at least three inches clear between topmost part of bridge crane and lowest overhead obstruction.

3.2 INSTALLATION

A. Crane Rails: 1. Bridge crane installer shall install runway rails. Set and adjust gage,

alignment, and elevation of bridge crane rails to tolerances of CMAA 70 or CMAA 74, as applicable for the equipment provided. Stagger joint locations on opposite sides of runway. Rail joints shall be at least two feet from crane girder joints. Provide flush joints at top of bridge crane rails.

2. Weld rail clips to runway girders in the shop. Field welding is not allowed unless approved by ENGINEER in writing.

B. Install materials and equipment in conformance with Laws and Regulations, applicable standards, manufacturer's instructions and recommendations, and the Contract Documents. Field welding of equipment shall be in accordance with manufacturer's written instructions. Field welding to building or structure shall be in accordance with AWS D1.1.

C. Refer to Section 05 50 13, Miscellaneous Metal Fabrications, for requirements for


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bridge crane supporting steel.


A. Site Tests: 1. After installing equipment and associated controls, perform at the Site

running tests for bridge crane and appurtenances. Should testing indicate malfunction, make repairs and adjustments as required. Repeat testing and adjusting until, in ENGINEER's opinion, installation is complete and equipment is functioning properly and accurately, and is Substantially Complete. Equipment will not be Substantially Completion until field tests are successfully completed.

2. Load Test: a.

Perform load tests under supervision of manufacturer's factory-trained service technician, in presence of ENGINEER.

b.

Weights used in load testing shall be certified by a state or local bureau of weights and measures. Submit weight certification as part of load test report.

c.

Load testing shall conform to ASME B30.2 or ASME B30.17, as applicable, and the following: 1) Power failure test with rated load: Load shall be held suspended

when power is removed. 2) Bridge travel full length of runway with rated load, while verifying

that all functions operate properly. 3) Trolley travel full length of bridge with rated load, while verifying

that all functions operate properly. 4) Hoist brake drift test with rated load: Lift weight, measure distance

to floor, allow five minutes to elapse, and re-measure. Record the results measured. Criteria for Acceptance: No difference in measurements.

5) Upper/lower limit switch test with no load. 6) Emergency stop test with no load.

d.

Load Test Report: Submit results of load testing in a report that lists tests performed, data collected, results of each test, and corrective actions taken (if any). Test report shall be signed by manufacturer's service technician present during testing.

B. Manufacturer's Services: Provide services of qualified, factory-trained service technician to perform the following: 1. Instruct CONTRACTOR in installing equipment and assist with installing

equipment. 2. Inspect and adjust equipment after installation, ensure proper operation, and

supervise initial operations and load tests. 3. Instruct OWNER's personnel in operating and maintaining the equipment. 4. Manufacturer's technician shall make a minimum of 3 visits to the Site, with

minimum number of hours on-Site for each visit as specified.


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a. First visit shall be for instructing CONTRACTOR in proper equipment installation, and assisting in installing equipment. Minimum number of hours on-Site: 8 hours.

b. Second visit shall be for checking completed installation, start-up of system; and performing field quality control testing. Minimum number of hours on-Site: 8 hours.

c. Third visit shall be to instruct operations and maintenance personnel. Number of hours on-Site shall be in accordance with Section 01 79 23, Instruction of Operations and Maintenance Personnel.

d. Technician shall revisit the Site as often as necessary until installation is acceptable.

5. Manufacturer's Installation Certification: Submit certification that manufacturer's technician has checked completed installation and equipment, as specified in the Contract Documents, has been provided in accordance with manufacturer's recommendations, and that operation of equipment is satisfactory. Certification shall be signed by manufacturer's technician present at the Site and CONTRACTOR.

6. Training: Furnish services of Supplier's qualified factory trained specialists to instruct OWNER's operations and maintenance personnel in recommended operation and maintenance of equipment. Training requirements, duration of instruction and qualifications shall be in accordance with Section 01 79 23, Instruction of Operations and Maintenance Personnel.

7. All costs, including expenses for travel, lodging, meals and incidentals, and cost of travel time, for visits to the Site shall be included in the Contract Price.



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SECTION 43 21 13.23

HORIZONTAL CENTRIFUGAL SPLIT CASE PUMPS

PART 1 - GENERAL

1.1 DESCRIPTION


required to furnish and install horizontally mounted, two stage centrifugal, axial split case pumps complete and operational with motors, control equipment and accessories as shown and specified. Anchor bolts are included in this Section.

B. Coordination: 1. Review installation procedures under this and other Sections and coordinate the

installation of items that must be installed with, or before the centrifugal axial split case pumps Work.

2. Coordinate with the variable frequency drives (VFD) manufacturer specified in Section 26 29 23, Low-voltage Variable Frequency Drives to ensure equipment compatibility.

C. Related Sections: 1. Section 03 30 00, Cast-in-Place Concrete. 2. Section 05 05 33, Anchor Systems. 3. Section 09 91 00, Painting. 4. Section 26 29 23, Low-Voltage Variable Frequency Drives.

1.2 REFERENCES

A. Standards referenced in this Section are listed below: 1 American Bearing Manufacturers Association, (ABMA). 2. American National Standards Institute, (ANSI). 3. American Water Works Association, (AWWA). 4. Hydraulic Institute, (HI). 5. Institute of Electrical and Electronic Engineers, (IEEE).

a. IEEE 85, Airborne Sound Measurements — Rotating Electrical Machinery.

6. National Electrical Code, (NEC). 7. National Electrical Manufacturers Association, (NEMA). 8. National Sanitation Foundation, (NSF).


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A. Manufacturer's Qualifications: 1. Manufacturer shall have a minimum of five years experience producing

substantially similar equipment and shall be able to show evidence of at least five installations in satisfactory operation for at least five years.

B. Component Supply and Compatibility: 1. Obtain all equipment included in this Section regardless of the component

manufacturer from a single centrifugal axial split case pumps manufacturer. 2. The two stage centrifugal axial split case pumps equipment manufacturer to

review and approve or to prepare all Shop Drawings and other submittals for all components furnished under this Section.

3. All components shall be specifically constructed for the specified service conditions and shall be integrated into the overall assembly by the centrifugal axial split case pumps equipment manufacturer.

C. The equipment covered by these specifications is intended to be standard pumping equipment of proven ability as manufactured by reputable concerns having extensive experience in the production of such equipment. Units specified herein shall be furnished by a single manufacturer. The equipment furnished shall be designed and constructed in accordance with the best practice and methods, and shall operate satisfactorily when installed as shown on the Drawings.

D. The pump manufacturer shall be fully responsible for the design, arrangement, and operation of all connected rotating components, including soleplates, if any, of the assembled pumping unit mounted on a fabricated steel baseplate to ensure that neither harmful nor damaging vibrations occur at any point within the specified operating range.

E. Field Vibration: 1. The pump manufacturer shall review the specifications and drawings,

including piping, pipe supports, harnessing arrangements, and foundations to familiarize themselves with field conditions. This shall be done to ensure that the pumps are designed to conform to the specified vibration limits. Field vibrations in excess of allowable Hydraulic Institute Standards 9.6.4.12 (2000) limits shall not be acceptable.

1.4 SUBMITTALS

A. Action Submittals: Submit the following: 1. Product Data:

a. Manufacturer's literature, illustrations, specifications and engineering data including: dimensions, materials, size, weight, performance data and curves showing overall pump efficiencies, required net positive suction head, allowable suction lift, flow rate, head, brake horsepower, motor horsepower, speed and shut-off head. Where variable speed units are


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specified, curves shall have at least five speeds plotted between maximum and minimum rpm.

b. Motor tests and data as described in Part 2. c. Submit certification for ANSI / NSF 372

2. Shop Drawings: a. Fabrication, assembly, installation and wiring diagrams.

B. Informational Submittals: Submit the following: 1. Source Quality Control:

a. Guarantee. b. Certified pump tests for Potable Water Pumps.

C. Closeout Submittals: Submit the following: 1. Operation and Maintenance Data:

a. Submit complete installation, operation and maintenance manuals including test reports, maintenance data and schedules, description of operation and spare parts information.

b. Furnish Operation and Maintenance Manuals in conformance with the requirements of Section 01 78 23, Operations and Maintenance Data.

D. Certificates: Submit the following: 1. Certification letters from the VFD manufacturer specified in Section 26 29 23,

Low-voltage Variable Frequency Drives and pump equipment manufacturer that the approved driven equipment has been reviewed and that the variable frequency drive units and motors are compatible and provided in accordance with the requirements specified herein.


A. Packing, Shipping, Handling and Unloading: 1. Deliver materials to the Site to ensure uninterrupted progress of the Work.

Deliver anchor bolts and anchorage devices which are to be embedded in cast-in-place concrete in ample time to prevent delay of that Work.

B. Storage and Protection: 1. Store materials to permit easy access for inspection and identification. Keep all

material off the ground, using pallets, platforms, or other supports. Protect steel members and packaged materials from corrosion and deterioration.

C. Acceptance at Site: 1. All boxes, crates and packages shall be inspected by CONTRACTOR upon

delivery to the Site. CONTRACTOR shall notify ENGINEER, in writing, if any loss or damage exists to equipment or components. Replace loss and repair damage to new condition in accordance with manufacturer's instructions.


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1.6 GUARANTEE

A. In addition to the manufacturer's standard guarantee, CONTRACTOR shall include the services of a factory-trained serviceman to provide repair service for the equipment for the period of one year commencing with the time the equipment is placed in continuous permanent operation. This service shall include the cost of all replacement parts required during the interval.

PART 2- PRODUCTS

2.1 SERVICE CONDITIONS

A. Description: 1. Pumps shall be two stage axial split case horizontal centrifugal type. Pumps

shall be certified to ANSI / NSF 372 for drinking water service. They shall be specially designed, constructed, and installed for the service specified, and shall comply with the following minimum conditions:

B. Design Criteria:

Design Conditions BRBP-1 BRBP-2 BRBP-3 Location: Benner Road Booster

Pump Station Benner Road Booster

Pump Station Benner Road Booster

Pump Station Use: Potable Water

Distribution Potable Water Distribution

Potable Water Distribution

Number Required: 1 1 1 Design Flow, (gpm): 600 600 600 Design TDH, (ft.): 300 300 300 Efficiency at Design, (percent): 73 73 73 Motor, (Hp): 75 75 75 Maximum Speed, (rpm): 1,783 1,783 1,783 Suction Size, (in): 5 5 5 Discharge Size, (in.): 4 4 4 Available NPSH at

Design, (ft.): 100 100 100

Flow at 2nd Design Point, (gpm): 900 900 900 TDH at 2nd Design Point, (ft.): 200 200 200 TDH at Shutoff, (ft.): 334.7 334.7 334.7 Liquid Pumped: Potable Water Potable Water Potable Water Temperature, (°F): 35-70 35-70 35-70 Drive Type: VFD VFD VFD Basis of Design Peerless 4TU14 Peerless 4TU14 Peerless 4TU14

2.2 MANUFACTURERS

A. Products and Manufacturers: Provide one of the following:


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1. Peerless Pump. 2. Or equal.

2.3 DETAILS OF CONSTRUCTION

A. Pump Materials and Construction: 1. Casing: Cast-iron. Provide the casing joint with dowels for accurate

reassembly. The casing shall be furnished with valve openings for venting the high points of the casing and for draining. Pressure instrument taps shall be provided at suction and discharge flanges.

2. Impeller Type: Enclosed, statically and dynamically balanced. 3. Impeller Material: Nickel Aluminum Bronze ASTM B 148, Alloy C95800 with

Belzona coating. 4. Impeller Wear Ring: Nickel Aluminum Bronze ASTM B 148, Alloy C95800. 5. Casing Wear Ring: Nickel Aluminum Bronze, ASTM B 148, Alloy C95800. 6. Shaft: 4165S — ASTM A582 Condition A 7. Seals:

a) Pumps shall be supplied with standard mechanical seals. Seats shall have a temperature rating of 225°F. Design shaft seals and related items shall conform to the following: 1) Seal shall be John Crane, or equal, face type mechanical seal with

Tungsten Carbide stationary seat, carbon sealing washer, Buna rubber flexible members, stainless steel metal parts and spring.

8. Bearings: Anti-friction, grease or oil lubricated with a minimum B-10 life of 100,000 hours.

9. Baseplate: Structural steel or cast-iron provided with means for collecting and draining oil and water.

10. Furnish with 125 pound ANSI connection flanges. 11. Coupling: Shall have a minimum 1.5 service factor based on the drive rated

horsepower and protected with an approved guard. 12. Type 316 stainless steel anchor bolts and inserts shall be furnished under this

Section and shall be sized and installed in accordance with the manufacturer's recommendations. Anchor bolts shall conform to the requirements of Section 05 05 33, Anchor Systems.

13. All bolts, nuts and cap screws shall have hexagon heads. 14. Stainless steel nameplates providing the manufacturer's model and serial

number, rated capacity, head, speed and all other pertinent data shall be attached to the pump.

B. Motors: 1. Drip-proof, 480V, 3 phase, 60 Hz, solid shaft, ball bearing type. 2. Motors shall be in accordance with all current applicable standards ofNEMA,

IEEE, ABMA, NEC, and ANSI. 3. Motors shall be normal starting torque, normal slip, squirrel cage induction

type.


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4. Motors shall be capable of carrying full load current continuously without injurious temperature rise in an ambient temperature of 40°C.

5. Motors shall be provided with a service factor of 1.0. 6. Motors shall be of sufficient size so that there will be no overload on the motor

above rated nameplate horsepower under any condition of operation from shut-off to zero head, unless otherwise specifically permitted in this Section.

7. Motors shall have Class F insulation with Class B temperature rise in 40C ambient at 1.0 SF.

8. Motors shall be inverter duty rated and comply with NEMA MG-1 part 31. 9. Motor thrust bearings, if required, shall be adequate to carry continuous thrust

loads under all conditions of operation. 10. Locked rotor currents shall be as specified in NEMA Standards. 11. Lubrication may be grease or oil type. 12. Motor Sensors:

a. Each pump motor shall be equipped with a minimum of three thermal switches embedded in the stator windings and wired to the control panel for supplemental motor protection.

13. Motor Tests and Data: a. Perform shop testing on the motors at the manufacturer's facility. Shop

test shall be in accordance with NEMA MG 1, UL 674, and UL 1004 and shall demonstrate that the motors tested comply with the Contract Documents.

b. Submit shop test reports identifying tests performed and results obtained. c. Motors shall be given Routine Test in accordance with NEMA MG 1-

12.55 and IEEE 112. Test shall include the following: 1. Measurement of winding resistance. 2. No-load readings of current and speed at normal voltage and

frequency. 3. Current input at rated frequency with rotor at standstill for squirrel-

cage motors (locked rotor amperes). 4. High-potential test. 5. Bearing inspection.

C. Manufacturers: Provide motors as manufactured by one of the following: 1. US Motors/Nidec. 2. WEG 3. General Electric 4. Or Equal

D. Rotating shafting shall be completely enclosed by approved guards where it is within seven feet of a floor or landing.

2.4 CONTROLS AND ACCESSORIES


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A. Pumps shall be controlled to increase fluid level at the Byer's Road Elevated Storage Tank using a discrete control scheme. A variable frequency drive shall be provided for each pump and will act as a soft starter for the pump only. Level measurement system is located at the Byer's Road Elevated Storage Tank and will communicate with the Benner Road Pump Station via new telemetry system, and as shown on the Drawings. The VFD is provided under Section 26 29 23, Low-Voltage Variable Frequency Drives.

2.5 TOOLS, SPARE PARTS AND MAINTENANCE MATERIALS

A. Each pump shall be furnished with the following: 1. One mechanical seal or packing for each gland. 2. One set of gaskets. 3. One set of casing wear rings 4. Two sets of special tools required for normal maintenance or operation.

B. Spare parts shall be packed in sturdy containers with clear indelible identification markings and shall be stored in a dry, warm location until transferred to the OWNER at the conclusion of the Project.

2.6 PREPARATION AND PAINTING

A. Pump impellers shall have a Belzona coating.

B. Pumps, motors, frames, baseplates, appurtenances, etc., shall receive shop primer coating conforming to the requirements of Section 09 91 00, Painting.

B. Surface preparation and painting shall conform to the requirements of Section 09 91 00, Painting.

C. All gears, bearing surfaces, machined surfaces and other surfaces which are to remain unpainted shall receive a heavy application of grease or other rust-resistant coating. This coating shall be maintained during storage and until the equipment is placed into operation.

D. CONTRACTOR shall certify, in writing, that the shop primer and finish coating system conforms to the requirements of Section 09 91 00, Painting.

E. Field painting shall conform to the requirements of Section 09 91 00, Painting.


A. Shop Tests: 1. Pump casings shall be hydrostatically tested to twice the discharge head or

1-1/2 times the shutoff head, whichever is greater.


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2. Running Test: Pump assembly shall be operated from zero to maximum capacity as shown on the approved curve. Results of the test shall be shown in a plot of test curves showing head, flow, horsepower, efficiency, and current. Readings shall be taken at a minimum of five evenly spaced capacity points including shut-off, design point and minimum head for which pump is designed to operate.

3. Each test shall be witnessed by a Registered Professional Engineer, who may be an employee of the manufacturer. The Registered Professional Engineer shall sign and seal all copies of curves and shall certify that hydrostatic tests were performed. Tests shall be conducted in conformance with the methods described in Section A6 of AWWA E101.

4. Pumps shall not be shipped until the ENGINEER has approved the test reports.

PART 3- EXECUTION

3.1 INSPECTION

A. CONTRACTOR shall verify that structures, pipes and equipment are compatible.

B. Make adjustments required to place system in proper operating condition.

3.2 INSTALLATION

A. Manufacturer's representative shall check and approve the installation prior to operation. Manufacturer's representative shall field test and calibrate the equipment to assure that the system operates to the OWNER'S satisfaction.

B. All pumping units shall be installed on concrete bases and secured with anchor bolts in accordance with the manufacturer's recommendations and as shown. The concrete bases shall be poured up to 1-inch below the metal bases or soleplates. Concrete work and grout are in Division 03, Concrete. The base with the equipment mounted thereon, or the soleplate, shall then be accurately shimmed to grade and the spaces between filled with an approved non-shrink grout. After the grout has reached its initial set, exposed edges shall be cut back 1/2-inch and the edges neatly finished with 1 to 2 cement mortar. Where channel baseplates are used, the void inside the channel shall be filled with non-shrink mortar and the open ends plastered with 1 to 2 cement mortar.

C. Neatly placed 1/2-inch hard copper pipe shall be provided on each pump to convey leakage to nearest acceptable drainage inlet.

D. Installation shall include furnishing and applying an initial supply of grease and oil, recommended by the manufacturer.


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E. Support piping independent of pump.

F. Check and align all pumps, motor and drive shafting, to the standards of the Hydraulic Institute.


A. All equipment will be given running tests by CONTRACTOR at the job Site following installation of the equipment and controls. Should the tests indicate any malfunction, CONTRACTOR shall make any necessary repairs and adjustments. Such tests and adjustments shall be repeated until, in the opinion of the ENGINEER, the installation is complete and the equipment is functioning properly and accurately, and is ready for permanent operation.

B. A factory trained representative shall be provided for installation supervision, start-up and test services and operation and maintenance personnel training services. The representative shall make a minimum of 2 visits, minimum 8 hours on-Site for each visit, to the Site. The first visit shall be for assistance in the installation of equipment. Subsequent visits shall be for checking the completed installation, start-up and

training of the system. Manufacturer's representative shall test operate the system in the presence of the ENGINEER and verify that the equipment conforms to the requirements. Representative shall revisit the Site as often as necessary until all trouble is corrected and the installation is entirely satisfactory.

C. All costs, including travel, lodging, meals and incidentals, for additional visits shall be at no additional cost to the OWNER.



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SECTION 43 21 39

SUMP PUMPS

PART 1 - GENERAL

1.1 DESCRIPTION

A. Scope: CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish and install sump pumps and appurtenances complete and operational as shown and specified.

B. The level switches for sump pump control, and interconnecting cable, shall be furnished by the pump manufacturer. The CONTRACTOR shall coordinate control panel locations, as required, with level switch installations to ensure that sufficient cable length is installed for a complete and operable installation.

C. General: 1. The Drawings show a general arrangement of pumping equipment, connected

piping and valves, with the approximate sizes and locations required unless specified herein or shown. The Plans are not intended to show exact dimensions for any specific pumping equipment. It is therefore anticipated that the dimensions of some equipment, in part or in whole, may have to be changed in order to accommodate the pumping equipment furnished.

2. The pumps shall be totally submersible capable of continuous or intermittent operation while pumping drainage, in a totally, partially, or non-submerged condition without any excessive lateral or torsional vibration, heat build-up, or damage to motor or seals.

3. Pumps shall be provided with automatic temperature cut-out, cut-in controls to protect the motor against overheating and clogging.

4. The submersible pump and major components of the submersible pumping systems shall be the products of a single manufacturer.


A. Manufacturer's Qualifications: Manufacturer shall have experience in manufacturing sump pump equipment of the same or larger size to the pumping units specified. For a manufacturer to be determined acceptable for providing pumping equipment on this project, it must show evidence of five separate, substantially similar installations which have been in satisfactory operation for a minimum of 5 years.

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B. All equipment provided under this Section shall be obtained from a single supplier or manufacturer who, with the CONTRACTOR, shall assume full responsibility for the completeness of the system. The supplier or manufacturer shall be the source of information on all equipment furnished regardless of the manufacturing source of that equipment.

C. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1. Local Plumbing Code, Latest Edition. 2. Standards of the Hydraulic Institute. 3. National Electric Code. 4. Standards of National Electrical Manufacturers Association. 5. Institute of Electrical and Electronic Engineers. 6. American National Standards Institute. 7. Standards of the American Water Works Association.

D. Shop Tests: 1. Control Panel Tests: A complete operational test of the pump control panel

shall be performed at the factory prior to shipment.

1.3 SUBMITTALS

A. Shop Drawings: Submit for approval the following: 1. Manufacturer's literature, illustrations, specifications and engineering data

including: dimensions, materials, size, weight, performance data and curves showing overall pump efficiencies, flow rate, head, brake horsepower, motor horsepower, speed and shut-off head.

2. Shop Drawings Showing: Fabrication, assembly, installation and wiring diagrams.

3. Sump Layout Drawings: Detailed layout drawings of each sump showing the locations of the sump pumps to be installed within the sump, pump discharges, and discharge valves.

B. Operation and Maintenance Data: Submit Operations and Maintenance Manuals in accordance with Section 01 78 23, Operations and Maintenance Data.

C. Warranty.


A. Deliver materials to the site to insure uninterrupted progress of the Work. Deliver anchor bolts and anchorage devices which are to be embedded in cast-in-place concrete in ample time not to delay that Work.


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B. Handle all sump pumps and appurtenances very carefully. Equipment which is damaged will not be acceptable. Protect all bolt threads, etc. from damage and corrosion.

C. Storage of equipment shall be in accordance with Section 01 66 00, Product Storage and Handling Requirements.

1.5 WARRANTY

A. The CONTRACTOR shall obtain from the manufacturer a wan-anty for all sump pumps, controls and appurtenances for 5 years from the date of Substantial Completion.

B. During the wananty period, the CONTRACTOR shall provide the services of a trained manufacturer's representative to make all adjustments, repairs and replace all defective equipment at no cost to the OWNER.

C. The CONTRACTOR shall include all costs incurred by the manufacturer, including travel and expenses, under the terms of the warranty.

PART 2- PRODUCTS

2.1 TRENCH SUMP PUMPS

A. Design Criteria: 1. Pumps shall be submersible end suction centrifugal. They shall be specially

design, constructed, and installed for the service intended and shall comply with the following minimum design conditions:

Design Conditions:

No. Required 2 Design Flow, gpm 15 Design TDH, Ft. 6 Min. Shutoff TDH, Ft. 10 Minimum Motor Hp 1/3 Minimum Discharge Size, in. 1-1/2 Maximum Speed, rpm 3,000 Maximum Sphere Size, in. 1/2


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B. Fabrication: 1. Pump and Motor:

a. Pump and motor shall be designed for continuous operation under submergence without leakage.

b. The pump shall include an all cast iron housing, cover, base, and control chamber.

c. The motor chambers shall be hermetically sealed against entry of moisture and oil filled. Oil shall be food grade biodegradable.

d. The shaft seal shall be of high quality carbon, stainless steel and Buna-N seal and ceramic seat combination.

e. The impeller shall be enclosed, two-vane. f. The bearings shall be sleeve type, permanently lubricated. g. The motor shall be as specified, suitable for operation on 115 volt,

single-phase power. The motor shall have built-in overload protection. h. The power cord shall have a grounding conductor, be 50 feet long,

waterproof, oil resistant, and UL approved. i. Motor shall be non-overloading for the entire pump operating curve. j. Manufacturer: Provide submersible pumps as manufactured by one of

the following: 1) Hydromatic. 2) Or equal.

C. Painting: 1. Pumps, motors, appurtenances, etc., shall receive manufacturer's standard

finish paint system prior to shipment. 2. Machined, polished, and non-ferrous surfaces shall be coated with corrosion

prevention compound. 3. Field Painting: Refer to Section 09 91 00, Painting.

2.2 CONTROLS

A. Dewatering Sump Pumps, Duplex System: 1. Provide a NEMA 4X control panel enclosure fabricated by the pump

manufacturer for use with non-mercury float switches provided by the pump manufacturer. Control panel shall have the following features: a. Main circuit breaker for the panel b. Dry contacts for relaying remote high sump level alarm and pump

running status. c. Numbered terminal strip for connecting pumps and variable level float

switches. d. Include four non-mercury float switches with cable of sufficient length,

minimum 20 feet, for each duplex sump system. e. 120 volt operation, with each pump on individual circuit breaker. Each

pump shall have a magnetic starter.


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f. Individually fused alternator and 120 VAC circuit.

g. UL Listed. h. 2 year warranty. i. Door mounted devices:

1) Run-indicating pilot light for each pump. Light color shall be Green.

2) HAND/OFF/AUTO selector switches for each pump. 3) High sump level indicating beacon (amber). 4) Audible alarm for high sump level installed on control panel door. 5) Alarm SILENCE/NORMAL/TEST selector switch.

2. Sequences of Operation, Duplex system. a. When a pump's HAND/OFF/AUTO selector switch is in the HAND

position, the pump shall run. In the OFF position, the pump shall not run.

b. When a pump's HAND/OFF/AUTO selector switch is in the AUTO position, the pump shall run according to the following sequence: 1) The second float switch shall start the lead pump. 2) The third float switch shall start the lag pump. 3) The fourth float switch shall sound the alarm horn and flash the

light beacon. 4) When the liquid drops below the first float, the pumps stop. Liquid

rising above the first float shall cause the alternator to cycle lead and lag duty.

B. Non-mercury Float Switches:

1. Materials: a. Support Pole: One-inch diameter Type 304 stainless steel pipe

threaded one end. b. Support Bracket: Stainless steel. c. Float Switch: Normally open non-mercury switches encapsulated in

epoxy resin. Float casing shall be polypropylene. Provide snap-action type switch activated by steel ball rolling back and forth within switching tube in plastic float housing. Provide float switches by Anchor Scientific INc. "Eco-Float"; Model G, Zoeller non-mercury float switches; or equal.

d. Switch Cable: Cable within sump Type SO neoprene jacket. Four No. 18 conductor, 41 strand, 300-volt insulation. Cable between control panel and sump shall conform to requirements of Division 26, Electrical.

e. Cable Supports: Polypropylene composition clamp with stainless steel bolts.


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PART 3- EXECUTION

3.1 INSPECTION

A. Inspect and verify that structures or surfaces on which the equipment will be installed have no defects which would adversely affect the installation.

B. The CONTRACTOR shall promptly report, in writing, defects which may affect the Work to the ENGINEER. A copy of the manufacturer's field report shall be provided to the ENGINEER.

3.2 INSTALLATION

A. Install pumps and piping in a manner and to the tolerances recommended by the equipment manufacturer.

B. Discharge piping and valves shall be supported independent of pump.

C. Set level switches in accordance with elevations shown on the Drawings. If no elevations are indicated, request information from ENGINEER.

D. All anchor bolts, nuts and other fasteners required for the connection of the equipment and other miscellaneous items to the concrete structure or base pads shall be furnished by the equipment manufacturer. Anchorage items shall conform to the applicable requirements of this Section and of Section 05 05 33, Anchor Systems.

E. All anchoring and connecting hardware shall be Type 304 stainless steel.

3.3 START-UP AND FIELD TEST

A. Perform operating tests to demonstrate that the equipment operates in the manner intended.

B. Make adjustments required to place equipment in proper operating condition.

3.4 MANUFACTURER'S FIELD SERVICES

A. Field Services: Retain a factory trained manufacturer's representative with demonstrated ability and experience in the installation and operation of the equipment included herein to perform the services listed below: 1. Supervise the installation. 2. Test, calibrate and adjust all components for optimum performance. 3. Assist in initial start-up and field testing.


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4. Inspect the completed installation and prepare an inspection and performance test report.

5. Instruct OWNER'S personnel in the operation and user maintenance of all components.

6. Supervise the correction of any defective or faulty work before and after acceptance by OWNER.



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PART 1 - GENERAL 1.1 DESCRIPTION · SECTION 40 05 05 EXPOSED PIPING INSTALLATION PART 1 - GENERAL...

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