February 28, 2018 Addendum No. 1 Central Park Pumping ... · CDWMCPPS 40 05 01-2 Supports And...

CDWM 1 ADDENDUM NO. 1 DWM PROJECT NO. 13-102 SPECIFICATION NO. 146286A

February 28, 2018

Addendum No. 1

Central Park Pumping Station Electrification Project DWM PROJECT NO. 13-102

SPECIFICATION NO. 146286A

For which bids will be opened in the office of the Department of Procurement Services, Room 103, City Hall Chicago, Illinois 60602, on Tuesday, April 10, 2018 at 11:00 a.m. Chicago time.

BIDDER WILL ACKNOWLEDGE RECEIPT OF THIS ADDENDUM IN THE SPACE PROVIDED ON THE PROPOSAL PAGE

REVISION 1

NOTICE OF Addendum

Book 1 – Terms and Conditions for Construction 1. None.

Book 2 – Instructions and Execution Documents 1. In Section One – Project Information, on Page 4 under Inspection of Site, replace text

“Site inspections are available on Wednesdays at 8:00 AM beginning on the first Wednesday following the date of the Pre-Bid Conference...” with “Site inspections are available on Tuesdays at 8:00 AM beginning on the first Tuesday following the date of the Pre-Bid Conference...”.

Book 3 – Technical Specifications

1. The following Sections were inadvertently omitted from Book 3, Volume II of II, and are included in this Addendum No. 1.

40 05 01 – Supports and Anchors 40 05 10 – Erecting and Jointing Interior and Exposed Exterior Piping 40 05 16 – Ductile-Iron Pipe and Fittings 40 05 17 – Steel Pipe and Fittings 40 05 18 – Miscellaneous Pipe and Fittings 40 05 20 – Valves

CDWM 2 ADDENDUM NO. 1 DWM PROJECT NO. 13-102 SPECIFICATION NO. 146286A

40 42 00 – Mechanical Insulation – Process 40 80 50 – Process Control System Commissioning 40 90 00 – Process Control System General Requirements 40 90 50 – Process Control System Description 40 91 00 – Process Control System Instruments 40 93 50 – Fiber Optic Cable and Accessories

2. Section 40 94 13, 2.10.M. – First sentence, replace text “Allocated adequate hours for additional…” with “Allocate 400 hours for additional…”.

Drawings:

1. None. Questions: Question No. 1 Specification Section 40 94 13 -2.10.M Reads: “Allocate adequate hours for additional HMI programming at the eleven pumping stations for configuration and modifications requested by Commissioner. These hours do not include the programming time required to implement the CPPS operation at these remote locations. The commissioner shall advise the Contractor of the purpose and functions of this additional programming when appropriate.” This is an undefined amount of time being requested on a fix priced project. Can the City either provide an estimated number of hours to be included, or some guidelines as to what may be in need of changing? Otherwise may I suggest striking this from the contract and either handling it as a change order when the time arises or dealing with the need with the previously Contracted Maintenance Integrators. Answer: Addressed in this Addendum No. 1.

END OF ADDENDUM

CDWMCPPS 40 05 01-1 Supports And Anchors

Addendum No. 1

SECTION 40 05 01

SUPPORTS AND ANCHORS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing all hanging and supporting devices

of construction shown, specified, or required for pipelines, apparatus, and

equipment other than electrical equipment.

B. Related work specified in other Sections includes, but is not limited to, the

following:

1. Section 01 11 10 - Compliance with Iron and Steel Requirements

2. Section 05 05 13 - Galvanizing

3. Section 05 12 00 - Structural Steel

4. Section 05 56 00 - Metal Castings

5. Section 09 96 00 - High Performance Coatings

6. Section 40 05 10 - Erecting and Jointing Interior and Exposed Exterior

Piping

7. Section 40 05 16 - Ductile Iron Pipe and Fittings

8. Section 40 05 17 - Steel Pipe and Fittings

C. Comply with the “American Iron and Steel (AIS)” requirements as contained in

Section 436 of the Consolidated Appropriations Act, 2014, further described in

Section 01 11 10 Compliance with Iron and Steel Requirements.

1.2 REFERENCES

A. Codes and standards referred to in this Section are:

1. ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Class

25, 125, 250, 800

2. ASME B31.1 - Power Piping (Includes Revision Service)

3. ASTM A 307 - Specification for Carbon Steel Bolts and Studs,

60,000 PSI Tensile Strength

4. MSS SP-58 - Pipe Hangers and Supports - Materials, Design

and Manufacture


Addendum No. 1

5. MSS SP-69 - Pipe Hangers and Supports - Selection and

Application

6. MSS SP-89 - Pipe Hangers and Supports - Fabrication and

Installation Practices

7. MSS SP-90 - Guidelines on Terminology for Pipe Hangers and

Supports

1.3 SUBMITTALS

A. General: Provide all submittals, including the following, as specified in

Division 1.

B. Shop Drawings: Submit shop drawings to show the quantity, type, design and

location of all supports, hangers and anchors required.

C. Submit a certificate, signed and sealed by a Licensed Professional Engineer

experienced in structural Engineering and registered in the State of Illinois, that

certifies that the Licensed Professional Engineer has evaluated and approved the

Contractor’s supports and anchors as detailed on the submittal drawings and has

prepared complete design calculations confirming the adequacy of all supports,

hangers, anchors and expansion compensating devices used. Provide a separate

certificate for each piping system before starting the installation.

1.4 SYSTEM DESCRIPTION

A. General: System includes supporting devices adequate to maintain the pipelines,

apparatus, and equipment in proper position and alignment under all operating and

testing conditions with due allowance for expansion and contraction. Unless

otherwise shown or specified, provide steel hangers and supports.

B. Design Requirements: Design supporting devices in accordance with the best

practice and provide supporting devices that are not unnecessarily heavy. Design

supporting devices to accommodate loads imposed during leakage tests for the test

pressures specified. Base the required strength of supporting devices on the

combined weight of the piping and connected equipment, the weight of the denser

of the fluids used in operations or testing and the weight of insulation where

applicable. Install supports with a working safety factor of not less than 5, and

conform installation to requirements of Section 05 12 00.

C. Provide springs where necessary. Make hangers and supports of standard design

where possible and best suited for the service required. Include proper pipe

protection saddles for hangers and supports on pipes which are covered with

insulation. Where required, make supports screw adjustable after installation

unless approved otherwise.


Addendum No. 1

D. Provide spring hangers at points that are subject to vertical thermal movement or

as shown. Provide pre-engineered type spring hangers with housed and guided

spring coils as recommended by the manufacturer. Provide load indicator, load

scale on an identification plate and a rod turnbuckle for each spring hanger.

Provide spring hangers capable of accommodating at least 1-1/4 inches of

deflection to solid compression.

E. Interference: Design all supporting devices so as to minimize interference with

access and movement. Eliminate the potential for injuries due to protruding

supporting devices.

F. Sizing: Provide base piping support, hanger rod size, brackets and spacing

meeting the requirements of ASME B31.1, MSS SP-58, SP-69, SP-89 and SP-90

except as modified herein.

1. Modify hangers for plastic pipes to increase the bearing area by inserting a

protective sleeve of medium-gauge aluminum sheet metal between the pipe

and the hanger.

a. Align hangers such that no sharp edges come in contact with the pipe.

b. Provide a thermoplastic pad between the plastic pipe and any concrete

or masonry surface.

c. Use supports for vertical lines of a type which do not exert a

compressive strain on the pipe. Riser-type clamps that squeeze the

pipe will not be permitted.

1.5 DELIVERY, STORAGE AND HANDLING

A. Deliver, store and handle all products and materials as specified in Division 1.

1.6 SPARE PARTS

A. Not Used

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable manufacturers are listed below.

1. Pipe hangers and supports

a. Grinnell Corporation, Cranston, RI

b. Globe Pipe Hanger Products, Inc., Cleveland, OH


Addendum No. 1

2. Sheet metal shield

a. "Thermal-Hanger Shields" by Pipe Shields Incorporated, Vacaville,

CA

b. Thermal Pipe Shields, Stanwood, WA

2.2 MATERIALS

A. Use structural and miscellaneous steel, metal castings, ductile iron pipe and

fittings, steel pipe and fittings, and supports meeting the requirements of Sections

05 12 00.

B. Support overhead hangers using threaded rods properly fastened in place by

suitable screws, clamps, inserts, or bolts, or by welding. Subject hangers to tensile

loading only. Where lateral or axial movement may occur, provide suitable

linkage to permit sway.

C. Suspended Piping: Support suspended piping by adjustable ring or clevis hangers

and threaded rods from heavy duty concrete inserts or other fastening devices,

except as otherwise specified or noted.

D. Brackets: Make brackets of welded steel and designed for the following load

classifications.

Load Classification Maximum Load

per Bracket

Light 750 pounds

Medium 1,500 pounds

Heavy 3,000 pounds

1. When medium or heavy brackets are bolted to vertical surfaces, furnish and

install backplates of adequate size and thickness to distribute the load

against the vertical surfaces.

2. When the use of backplates is not practicable, fasten the brackets to the

vertical surfaces in such a manner that the safe bearing strength of the

vertical surfaces will not be exceeded.

E. Chairs and Pipe Rolls: Use cast-iron pipe rolls or chairs. Provide pipe rolls with

threaded nuts or with sockets to take threaded rods.

F. Saddle Stands: Use adjustable saddle stands.

1. Provide each stand with a length of steel pipe fitted at the base with standard

threaded cast-iron flange or steel base plate and at the top with an adjustable


Addendum No. 1

saddle or roll. Bolt the base flange or plate to the floor, foundation or

concrete base.

2. Use stanchions of construction similar to the saddle stand, except fit them at

the top with cast-iron pipe saddle supports or with pipe stanchion saddles

with yokes and nuts.

G. Insulation Support Requirements: At support points, protect insulated pipes by a

360 degree insert of high density, 100 psi, waterproofed calcium silicate encased in

a 360 degree sheet metal shield.

1. Make inserts of the same thickness as the adjoining pipe insulation.

2. Provide the shield length, minimum galvanized sheet metal gauge and

installation procedure in accordance with the manufacturer's

recommendations.

3. Extend insulation inserts one inch beyond the sheet metal shields on cold

water lines, and jacket and vapor seal as required when the abutting

insulation is installed.

H. Expansion: Connect, support and guide piping to permit and control pipe

expansion and contraction and to accommodate building expansion, contraction

and settling without damage to the piping or support system.

1. Furnish and install anchors when specified, shown, or required for holding

the pipelines and equipment in position or alignment. Design anchors for

rigid fastening to the structures, either directly or through brackets.

2. Provide cast-iron chair type anchors for piping with steel straps, except

where anchors form an integral part of pipe fittings or where an anchor of

special design is required.

3. Inserts: Provide galvanized concrete inserts.

a. Design inserts to permit the rods to be adjusted horizontally in one

plane and to lock the rod nut or head automatically.

b. Recess inserts near the upper flange to receive reinforcing rods.

c. Design inserts so that they may be held in position during concrete

placing operations. Design inserts to carry safely the maximum load

that can be imposed by the rod which they engage.


Addendum No. 1

PART 3 EXECUTION

3.1 INSTALLATION

A. Install hanger and supports in accordance with the manufacturer's

recommendations and approved shop drawings and as specified in Division 01 and

Section 40 05 10.

3.2 GALVANIZING AND PAINTING

A. Galvanizing: When specified and when supporting uninsulated galvanized piping

system, galvanize hangers and supports as specified in Section 05 05 13.

B. Painting: Paint hangers, supports, anchors, and similar devices as specified in

Section 09 96 00.

C. Touch-Up Painting: Clean and touch-up painting of field welds, bolted

connections and abraded areas as specified in Section 09 96 00.

END OF SECTION

CDWMCPPS 40 05 10-1 Erecting And Jointing Interior

Addendum No. 1 and Exposed Exterior Piping

SECTION 40 05 10

ERECTING AND JOINTING INTERIOR AND EXPOSED EXTERIOR PIPING

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Furnishing of supports and hangers and installation of all

interior and exposed exterior piping and supports.

1. Furnish, support, hang and install piping of the materials, coatings and

linings shown or specified at locations as specified or where shown.


following:

1. Section 01 45 50 - Leakage Tests


3. Section 07 90 00 - Joint Sealers


5. Section 33 13 00 - Disinfection

6. Section 40 05 01 - Supports and Anchors

7. Section 40 42 00 - Mechanical Insulation - Process

1.2 REFERENCES


1. ASME B1.20.1 - Pipe Threads, General Purpose, Inch

2. ASME B31.1 - Power Piping with Addenda

3. AWWA C600 - Installation of Ductile-Iron Water Mains and Their

Appurtenances

1.3 SUBMITTALS

A. Not Used


A. Not Used




A. Deliver, store and handle all products and materials as specified in Division 1 and

as follows:

1. Take extreme care in loading and unloading the pipe and fittings. Do the

work slowly using skids or suitable power equipment, and keep the pipe

under control at all times.

2. Handling Procedures: Under no condition is the pipe to be dropped,

bumped, dragged, pushed or moved in any way which will cause damage to

the pipe, lining or coating.

3. Use of Slings: When handling the pipe with a crane, use a suitable pipe

hook or sling around the pipe. Under no condition is the sling to be allowed

to pass through the pipe unless adequate measures are taken to prevent

damage to the pipe ends, lining and coating.

4. Damage: If any piping or fittings are damaged in the process of delivery,

storing, handling, or laying, replace or repair such piping or fittings as

approved.

1.6 SPARE PARTS

A. Not Used

PART 2 PRODUCTS

2.1 MATERIALS

A. Provide hangers and supports and all necessary appurtenances as specified in

Section 40 05 01.

2.2 FABRICATION

A. Coating: Provide all threads coated with a suitable pipe dope, Masters Metallic

Compound, graphite and engine oil, or equal, before jointing.

PART 3 EXECUTION

3.1 PREPARATION

A. Galvanizing and Painting:

1. Galvanize as specified, in accordance with Section 05 05 13.



2. Paint hangers, supports, anchors, and similar devices as specified in Section

09 96 00.

3.2 INSTALLATION

A. General: Install all piping in accordance with the manufacturer's recommendations

and approved shop drawings and as specified in Division 1.

1. Install exposed piping at right angles or parallel to building walls. Diagonal

runs are not permitted, unless expressly indicated.

2. Install piping free of sags or bends and with ample space between piping to

permit proper insulation applications, with 1-inch clearance outside the

insulation.

3. Place pipe runs to minimize obstruction to other work.

4. Install piping to allow for expansion and contraction without stressing pipe,

joints or connected equipment.

5. Slope piping as shown and arrange systems to drain at low points.

6. Do not penetrate building structural members unless shown.

7. Locate groups of piping parallel to each other and at common elevations

whenever practical, spaced to permit applying insulation and servicing of

valves.

8. Fire Barrier Penetrations: Where pipes pass through fire rated walls,

partitions, ceilings, and floors, maintain the fire rated integrity. Refer to

Section 07 90 00 for special sealers and materials.

9. Arrange miscellaneous pipelines, which are shown in diagram form on the

Plans, clear of other pipelines and equipment.

10. Fit and install pipelines in a neat and workmanlike manner in accordance

with approved shop drawings.

11. Provide an adequate number of unions in main pipe and branch pipe runs to

facilitate dismantling or removal of pipeline sections without disturbing

adjacent branch or connecting lines.

12. Install suitable sleeves at all points where pipes pass through walls or floors

of structures and where wall castings are not provided.



13. Include proper pipe protection saddles on pipes which are covered with

insulation.

B. Flanged Joints: Make flanged joints with bolts or bolt studs with a nut on each

end.

1. Field Flanges: Shop screw threaded flanges to pipe unless threading in the

field is permitted with prior approval.

2. Flange to Pipe Assembly: Assemble pipe to be fitted with threaded flanges

as follows:

a. Accurately thread pipe and flanges to the appropriate gauge, screw

flanges on by heavy machinery until the end of the pipe projects

beyond the face of the flange and a tight metal-to-metal joint is

produced without evidence of heat in the threaded portion.

b. Cut the projecting end of the pipe off flush with the face of the flange.

c. Make a light refacing cut across both the end of the pipe and the face

of the flange at right angles to the center line of the pipe and then

ream the pipe.

d. Flanged to Flange Assembly: Align flange surfaces parallel.

Assemble joints by sequencing bolt tightening to make initial contact

of flanges and gaskets as flat and parallel as possible. Use suitable

lubricants on bolt threads. Tighten bolts gradually and uniformly to

appropriate torque specified by bolt manufacturer.

C. Threaded Joints: Conform threaded joints to ASME B1.20.1, tapered pipe threads

for field cut threads unless otherwise specified. Join pipe, fittings, and valves as

follows:

1. Note internal length of threads in fittings or valve ends, and proximity of

internal seat or wall, to determine how far pipe should be threaded into joint.

2. Align threads at point of assembly.

3. Apply appropriate tape or thread compound to the external pipe threads.

4. Assemble joint to appropriate thread depth. Assemble joint to produce a

tight joint without evidence of heat in the threaded portion. When using a

pipe wrench on valves, place wrench on valve end into which pipe is being

threaded.



5. Damaged Threads: Do not use pipe with threads which are corroded, or

damaged. If weld opens during cutting or threading operations, do not use

that portion of pipe.

6. Retightening: Once a threaded joint has been assembled, it is not to be

backed off unless the threads are recleaned and new compound or tape

applied before rejointing.

D. Mechanical Joints: In making up mechanical joints, center the spigot in the bell.

1. Thoroughly brush the surfaces with which the rubber gasket comes in

contact, with a wire brush just prior to assembly of the joint.

2. Brush pipe manufacturers recommended lubricant over the gasket just prior

to installation.

3. Place the gasket and gland in position, insert bolts, and fingertighten nuts.

4. Tighten the nuts with a torque wrench to bring the gland up toward the pipe

evenly.

5. Torques: Apply bolt torques complying with AWWA C600.

6. Effective Sealing: If effective sealing is not obtained at the maximum

torque listed, disassemble and reassemble the joint after thorough cleaning.

E. Sleeve Type Couplings: For sleeve type couplings, equally tighten diametrically

opposite bolts on the coupling to bring the gaskets up evenly all around the pipe.

1. Torque Wrenches: Do final tightening with torque wrenches set for the

torque recommended by the coupling manufacturer.

F. Welding: Comply welding of pipe joints with the requirements of ASME B31.1

unless otherwise specified. Do all off site welding of steel pipe conforming to the

appropriate requirements.

1. Procedures: Confirm that pipe and fittings with wall thickness of 3/16-inch

and larger have ends beveled for welding, and that the parts to be welded are

securely held in place and are in proper alignment during welding.

a. Separate the abutting pipe ends before welding to permit complete

fusion to the inside wall of the pipe without overlapping.

b. Provide welding continuous around the joint and completed without

interruption.



c. Provide welds of the single vee butt type, of sound weld metal

thoroughly fused into the ends of the pipe and into the bottom of the

vee.

d. Provide welds free from cold shuts, pinholes, oxide inclusions or

other defects.

G. Anchors and Stands: Furnish and install anchors and stands when specified,

shown, or required for holding the pipelines and equipment in position or

alignment.

1. Small Piping Supports: Where adjustable supporting devices are not

required, support pipelines 3 inches in diameter and smaller on cast-iron,

malleable iron, or steel hooks, hook plates, rings or ring plates.

H. Hangers and Supports

1. Direction Changes: Provide pipe hangers at each change in pipe direction,

on both sides of pipe mounted valves and equipment and on both sides of

pipe loops and expansion absorbing devices.

2. Brackets: Use brackets for the support of piping from vertical surfaces.

3. Anchors: Furnish and install anchors when specified, shown, or required for

holding the pipelines and equipment in position or alignment.

4. Inserts: Install galvanized inserts in concrete structures where required for

fastening supporting devices.

5. Fire Protection System Piping: Support fire protection system piping

independently from other piping systems.

6. Controlled Movements: Install hangers and supports to allow controlled

movement of piping systems, to permit freedom of movement between pipe

anchors, and to facilitate action of expansion joints, expansion loops,

expansion bends and similar units.

7. Load Distribution: Adjust hangers to distribute loads equally on the

attachment and to achieve any indicated slope of the pipe.

I. Cast Iron Soil Pipe and Fittings

1. Joints: Provide joints of neoprene gasket compression type or lead and

oakum.

a. Thoroughly caulk leaded joints with picked oakum and molten lead.



b. Use twelve ounces of soft pig or bar lead in each joint for each 1-inch

of pipe diameter.

c. Pour all lead in at one time.

d. Finish the face of lead joints with the face of the hub and leave

without putty, paint or cement.

e. Extend gasket on rubber gasket joints the full depth of the bell and

overlap the face of the bell

2. Connection: Provide all joints to be leakproof and gastight.

3.3 FIELD QUALITY CONTROL

A. Tests: After installation of the interior and exposed exterior piping and supports,

control equipment and all appurtenances, subject the units to a field running test, as

specified in Division 1, under actual operating conditions. Where field welding of

pipe joints shown, specified, permitted, or required, meet the requirements of

ASME B31.1 -Power Piping, Chapter VI Section 136.4.2 Visual Examination,

Section 137.4 Hydrostatic Testing, or Section 137.5 Pneumatic Testing.

1. Perform testing of pipelines in accordance with the requirements of Section

01 45 50.

3.4 CLEANING

A. General: Clean the interior of pipelines of all dirt and superfluous material of

every description in an approved manner.

B. Thoroughly clean threads for threaded joints after reaming.

C. Disinfection: Disinfect pipelines carrying potable water in accordance with

requirements of Section 33 13 00.

3.5 SCHEDULE

A. Definitions: Abbreviations used in the schedule are as follows:

1. Pipe Materials:

a. Al Aluminum

b. Br Brass

c. C Concrete

d. CI Cast-iron

e. CISP Cast-iron soil pipe



f. Cl Clay

g. CPVC Chlorinated Polyvinyl Chloride

h. CU Copper

i. DI Ductile Iron

j. PCCP Prestressed Concrete Cylinder Pipe

k. PE Polyethylene

l. PVC Polyvinyl Chloride

m. RCP Reinforced Concrete Pipe

n. RCPP Reinforced Concrete Pressure Pipe

o. SS Stainless Steel

p. St Steel

2. Joints:

a. B Bituminous

b. B&S Bell and Spigot

c. F Flanged

d. G Grooved End

e. H Harnessed

f. HC Hubless Coupling

g. HSC Hub and Spigot - Compression Gasket

h. HSL Hub and Spigot - Lead and Oakum

i. MJ Mechanical Joint

j. PO Push-on Joint

k. RRG Restrained Retainer Gland

l. RS Rubber and Steel

m. Sc Screwed

n. Sd Soldered

o. SF Socket Fusion

p. Sl Sleeve Type Coupling

q. SW Solvent Welded

r. W Welded

3. Coatings and Linings:

a. BC Bituminous - Cold Application

b. CE Concrete Encased

c. CL Cement-Mortar Lined

d. E Epoxy

e. G Galvanized

f. GL Glass Lined

g. I Insulated

h. KL Polyvinylidene Fluoride (PVDF or KYNAR®) Lined

i. P Painted

j. PCL Polyvinylidene Chloride (PVDC) Lined

k. PEW Polyethylene Wrapped



l. PPL Polypropylene Lined

m. RC Rubber Coated

n. RL Rubber Lined

o. W Wrapped

B. Schedule: Provide products as listed in the following schedule.

INTERIOR AND EXPOSED EXTERIOR PIPING SCHEDULE

CDWMCPPS 40 05 10-10 Erecting and Jointing Interior and

Addendum No. 1 Exposed Exterior Piping

Service

Size

(Inches)

Pipe

Material

Protective Coatings

Joints

Test Pressure

(psig)1

Remarks Int. Ext.2

Vents3 3 & Larger DI CL P F --

Less than 3 PVC -- -- SW, Sc --

Natural Gas 3 & Larger St -- P F, W 100 Sched. 40

Less than 3 St -- P Sc4 100 Sched. 40

Refrigerant Less than 3 CU -- I, P Sd5 250 Type K

Soil, Waste, Drain, Vent

and Storm

3 & Larger

Less than 3

CISP

St

BC

G

P

G, P

HS

Sc6

7 7

Service Wt

Sched. 40

Potable Cold Water, Hot Water,

and Hot Water Circulating

Less than 3

CU

--

I, P

Sd

100

Type K

Cooling Coil Condensate Drain Less than 3 CU -- I, P Sd 100 Type K

Hot Water Heating 2 1/2 &

Larger

St -- I, P F, W 100 Sched. 40

Less than 2

1/2

St -- I, P Sc 100 Sched. 40

Sump Pump Discharge All DI CL P F 30 Class 53

1 Measure the test pressures shown in the schedule at the centerline of the pipeline’s low point. Adjust test pressures measured at other locations accordingly. 2 Do not insulate sections of pipe that pass through or are within structures containing water. 3 Provide vents as indicated in the schedule unless shown or specified otherwise. 4 Malleable iron screwed fittings. 5 Use high temperature silver brazing flux and 45 percent silver solder. 6 Cast iron drainage fittings. 7 Test by filling with water to top of system or with 5 psi compressed air.

INTERIOR AND EXPOSED EXTERIOR PIPING SCHEDULE

CDWMCPPS 40 05 10-11 Erecting and Jointing Interior and

Addendum No. 1 Exposed Exterior Piping

Service

Size

(Inches)

Pipe

Material

Protective Coatings

Joints

Test Pressure

(psig)1

Remarks Int. Ext.2

Hydraulic Actuation Piping 1 CU, Type

K

-- I Sd 215 Pneumatically

tested

Hydraulic Water Larger than

1 & 3 and

Less

St G P,G,I Sc 215 Pneumatically

tested

Vacuum Priming 3 and Less DI CL -- F --

Oil Lubrication System

(Lube Oil Return, Lube Oil Supply)

2 and Less St -- -- W 215 Pneumatically

tested, Schedule 40

Main Pump Suction 36 DI CL I F 15 Class 51

Seal Water 2 St G P,G,I Sc 100

3/4, 1 Cu -- P,I Sd 100

Process Water 3 and Less St G P,G, I Sc 215 Pneumatically

tested

Compressed Air 1 St G P,G Sc 200 Schedule 40

Curb Pressure 1 St G P,G Sc 100

Dewatering Pump Discharge 8 DI CL P F 100 Class 53

END OF SECTION



(NO TEXT FOR THIS PAGE)

CDWMCPPS 40 05 16-1 Ductile-Iron Pipe And Fittings

Addendum No. 1

SECTION 40 05 16

DUCTILE-IRON PIPE AND FITTINGS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing ductile-iron pipe, fittings and

appurtenances, except soil pipe.

1. Provide ductile-iron pipe and fittings complete with all necessary jointing

facilities and materials, specials, adapters and other appurtenances required

for installation in and completion of the pipelines to be constructed.

2. Provide flanged, plain end, rubber gasket, push-on, or mechanical joint of

the types, sizes and classes shown or specified.


following:


2. Section 01 45 50 - Leakage Test





Piping


8. Section 40 05 18 - Miscellaneous Pipe and Fittings

9. Section 40 42 00 - Mechanical Insulation – Process




1.2 REFERENCES


1. AWWA C104/A21.4 - Cement-Mortar Lining for Ductile-Iron and Gray-

Iron Pipe and Fittings for Water AWWA

C104/A21.4


Addendum No. 1

2. AWWA C105/A21.5 - Polyethylene Encasement for Ductile-Iron Piping

for Water and Other Liquids AWWA C105/A21.5

3. AWWA C110/A21.10 - Ductile-Iron and Gray-Iron Fittings 3 inches

through 48 inches, for Water and Other Liquids

AWWA C110/A21.10

4. AWWA C111/A21.11 - Rubber-Gasket Joints for Ductile-Iron and Gray-

Iron Pressure Pipe and Fittings AWWA

C111/A21.11

5. AWWA C115/A21.15 - Flanged Ductile-Iron and Gray-Iron Pipe with

Threaded Flanges AWWA C115/A21.15

6. AWWA C151/A 21.51 - Ductile-Iron Pipe, Centrifugally Cast in Metal

Molds or Sand-Lined Molds, for Water and Other

Liquids AWWA C151/A21.51

7. AWWA C153/A21.53 - Ductile-Iron Compact Fittings, 3 inches through

12 inches, for Water and Other Liquids AWWA

C153/A21.53

8. ASTM A 307 - Specification for Carbon Steel bolts and Studs


A. Design Standards: Provide ductile-iron pipe meeting the requirements of AWWA

C 151/A21.51.

1. Place pipe in structures using a minimum wall thickness of Thickness

Class 52 for sizes up to and including 12-inch diameter and Thickness Class

51 for larger sizes, except provide Thickness Class 53 for pipe with threaded

flanges.

2. Construct concrete encasement where shown.

1.4 SUBMITTALS

A. General: Provide all submittals, including the following, as specified in Division

1.

B. Submit the following shop drawings:

1. Pipe joints and fittings, sleeves, cleanouts and couplings. Where special

designs or fittings are required, show the Work in large detail and

completely describe and dimension all items.


Addendum No. 1

2. Fully dimensioned layout of pipes, fittings, couplings, sleeves, cleanouts,

expansion joints, harnessing, valves, supports, anchors and equipment.

Label pipe size, materials, type, and class on drawings and include schedule.

3. Cross sections showing elevations of cleanouts, pipes, fittings, couplings,

sleeves, valves, supports, anchors and equipment.

4. Catalog data for pipe, fittings, couplings, sleeves, harnessing and cleanouts.

C. Quality Controls: Submit certificates of compliance for pipe, fittings, gaskets,

lining, polyethylene encasement, coatings, specials, couplings, sleeves and

cleanouts in accordance with this Section.


A. Deliver, store and handle all pipe, fittings and couplings as specified in Division 1

and Section 40 05 10.

1.6 SPARE PARTS

A. Not Used

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Acceptable manufacturers are listed below:

1. Ductile-iron pipe and fittings.

a. American Cast Iron Pipe Company

b. McWane Incorporated

c. United States Pipe and Foundry

2. Ductile-iron retainer glands.

a. 3-inch through 24-inch diameter

(1) Nappco, Inc. Series 1246

(2) Ebba Iron, Inc., Series 100

3. Sleeve-type couplings.

a. 12-inches in diameter and smaller

(1) Dresser Industries, Style 153


Addendum No. 1

(2) Smith-Blair, Type 441 Omni Coupling System

b. larger than 12-inches in diameter

(1) Dresser Industries, Style 38

(2) Smith-Blair, Type 411

c. Gaskets.

(1) Dresser Plain Grade 27

(2) Smith-Blair 003

4. Restrained push-on joints.

a. U.S. Pipe, TR Flex

b. McWane Incorporated, Super-Lock

c. American Cast Iron Pipe Company, Lok-Ring or Flex-Ring

5. Gaskets.

a. John Crane, Inc.

b. Garlock Packing Company

c. U.S. Rubber Company

d. American Cast Iron Pipe Company

e. United States Pipe and Foundry

f. McWane Incorporated

6. Coatings and Linings

a. Kop-coat

b. Tnemec

c. American Cast Iron Pipe Company

d. United States Pipe and Foundry

2.2 MATERIALS

A. Fittings:

1. General: Provide all fittings meeting the requirements of ANSI A21.10,

unless shown or specified otherwise. Fittings 14 inches and larger require a

pressure rating of 150 psi, or as specified, whichever is greater.

2. Flanged: Where long radius flanged fittings and other flanged fittings not

covered in ANSI A21.10 are shown or indicated, provide items meeting the

requirements of ANSI A21.10 and having laying lengths conforming to

ANSI B16.1 for 125 pound American Standard fittings.


Addendum No. 1

3. Nonflange: Where compact mechanical joint or rubber gasket joint fittings

are shown or indicated, provide items meeting the requirements of AWWA

C153/A21.53.

B. Flanged Joints

1. Threaded Flanges: Provide threaded, ductile-iron, long hub flanges meeting

the requirements of AWWA C115/A21.15.

a. Screw flanges pipe on the threaded end of the pipe in the shop.

b. Reface the face of the flange and the end of the pipe together.

c. Design the flanges to prevent corrosion of the threads from the

outside and to prevent leakage through the pipe threads.

2. Facing and Drilling: Provide flanges faced and drilled to the requirements

of AWWA C115/A21.15, unless special drilling is called for or required.

Face flange accurately at right angles to the pipe axis. Drill flanges smooth

and true, and cover machined faces with zinc dust and tallow or equivalent

material.

3. Taps: Tap flanges where tap or stud bolts are required.

4. Fasteners: Provide bolts, stud bolts, and nuts meeting the requirements of

ASTM A 307, Grade B.

5. Gaskets: Provide full-face gaskets for flanged joints on 12-inch diameter

and smaller pipe and gaskets of the ring type for flanged joints on larger

pipe. Provide flange gaskets meeting the requirements of AWWA

C115/A21.15 except make gaskets for gas lines with neoprene and aramid.

C. Rubber Gasket Joints

1. Provide mechanical joints and push-on type joints meeting the requirements

of AWWA C111/A21.11.

D. Harnessing

1. General: For ductile-iron pipe and fittings with mechanical joints that

require harnessing, provide ductile-iron mechanical joint retainer glands.

2. Joint Assemblies: Design the joint assemblies to resist pullout of the joints

at the test pressures specified.


Addendum No. 1

E. Wall Pipes and Sleeves

1. Wall Pipes

a. Where wall pipes are shown or specified, provide ductile iron wall

pipes that meet the requirements of AWWA C110/A21.10 with end

connections that are 1) of the types shown and 2) flush with the

surfaces of the walls or floors. Unless otherwise shown or specified,

provide wall pipes with intermediate collars located at the centers of

the walls or floors.

2. Sleeves

a. Where pipes pass through exterior walls or floors or wetted interior

walls or floors of structures and where wall pipes are not to be

provided, provide ductile-iron sleeves meeting the requirements of

AWWA C110/A21.10, with ends that are flush with the wall or floor

surfaces and with intermediate collars located at the centers of the

walls or floors.

b. Where pipes pass through non-wetted interior walls or floors and

where wall pipes are not to be provided, provide ductile-iron sleeves

meeting the requirements of AWWA C110/A21.10; steel pipe sleeves

meeting the requirements of Section 40 05 17 or as shown or

specified otherwise. Provide sleeves with ends that are flush with the

wall or floor surfaces. Where shown or specified, provide

intermediate collars located at the centers of the walls or floors.

c. Provide sleeves having large enough diameters to accommodate the

passage of pipe joints, if required.

d. Where shown or specified, provide modular, mechanical sleeve seals,

meeting the requirements in Section 40 05 18, in the annular spaces

between pipes and sleeves. In all other locations, caulk the annular

spaces between pipes and sleeves with caulk meeting the

requirements in Section 07 90 00.

F. Sleeve-Type Couplings

1. General: Manufacture middle rings to the following sizes.

a. At least 1/4 inch thick and 5 inches wide for 8-inch diameter and

smaller pipe.

b. 3/8 inch thick and 7 inches wide for 10- through 30-inch diameter

pipe.


Addendum No. 1

c. 1/2 inch thick and 10 inches wide for 36-inch diameter and larger

pipe.

2. Design: Manufacture middle rings without a pipe stop. Provide follower

rings of proper thickness. Provide molded rubber gaskets.

G. Cleanouts

1. General: Provide cleanouts where shown or specified.

2. Size: Provide not less than 6 inch diameter cleanout openings for pipe 8

inches in diameter or larger. Provide cleanout openings for pipe 6 inches in

diameter or smaller of the same diameter as the pipe.

3. Cleanout Covers: Provide cleanout covers which are blind flanges meeting

the requirements of AWWA C110/A21.10, except where conformation is

required with the inside curvature of the pipeline, in which case the covers

are flanged plugs of proper shape with American Standard flange drilling.

a. Fasten covers by means of steel studs and bronze nuts. Drill and tap

covers for a 1-1/2-inch diameter pipe connection.

4. Plugs: Equip the flange of conformed plugs with a dowel or other suitable

means to provide proper setting.

H. Connecting Pieces, and Special Fittings

1. Connecting Pieces: Provide connecting pieces, such as bell and bell, bell

and spigot, bell and flange, flange and flange, flange and spigot, and flange

and flare, meeting the requirements of AWWA C110/A21.10.

2. Special Fittings : Provide special fittings, where required, of an approved

design that have the same diameters and thicknesses as standard fittings,

unless otherwise required, but their laying lengths and other functional

dimensions are determined by their positions in the pipeline and by the

particular piping materials to which they connect.

I. Temporary Bulkheads: Provide temporary bulkheads at the ends of pipeline

sections where adjoining pipelines have not been completed and are not ready to

connect.

1. Removal: Remove all temporary bulkheads when they are no longer

needed.


Addendum No. 1

J. Coatings and Linings

1. Cement Lining: Provide all ductile-iron pipe and fittings having a cement-

mortar lining not less than standard thickness meeting the requirements of

ANSI A21.4, unless shown or specified otherwise.

2. Exterior Primer: Shop coat ductile-iron pipe and fittings on the outside with

one coat of Kop-Coat 340 Gold Primer, 2.0 mils minimum dry thickness, for

use in exposed locations, such as inside buildings, where finish painting or

insulating is required.

3. Asphaltic Coating: Coat pipe for use not exposed to view with the standard

asphaltic outside coating specified in AWWA C151/A21.51.

4. Encased Pipe: Do not coat or paint the outside of fittings and pipe which are

to be encased in concrete where watertightness is to be obtained.

5. Labels: Paint the weight and class designation conspicuously in white on

the outside of each pipe, fitting, and special casting after the shop coat has

hardened.

6. Flange Joints: Immediately after facing and drilling, coat the back of the

flanges and bolt holes with asphaltic coating meeting the requirements of

AWWA C151/A21.51, Section 51-8.1.

7. Sleeve-type Couplings:

a. Shop coat couplings with Dresser Industries Red D or Smith-Blair

Standard Blue shop coat.

b. Provide an additional shop coat of Kop-Coat Hi-Guard epoxy or

Tnemec Pota-pox on the interior of the middle ring.

c. Finish coat exterior of sleeve-type coupling after installation with the

same coating specified in Section 09 96 00 for the pipeline of which it

is a part.

d. Ensure shop coats and finish coats are compatible.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all ductile-iron pipe and fittings in accordance with the

manufacturer's recommendations and approved shop drawings and as specified in

Division 1 and Section 40 05 10.


Addendum No. 1

B. Insulation: Where shown or specified provide insulation, as specified in Section

40 42 00, for pipes and fittings that are exposed to atmosphere after installation.

3.2 LEAKAGE TESTING

A. Cleaning: Flush clean and test all pipes after installation.

B. Testing: Test pipes for leaks and repair or tighten as required.

C. Procedures: Conduct tests in accordance with Section 01 45 50.

3.3 DISINFECTION

A. Disinfect all pipelines that are to carry potable water before they are placed into

service as specified in Section 33 13 00.

3.4 SCHEDULES

A. Refer to the Schedule contained in Section 40 05 10 for information on the piping

that is to be constructed using the pipe materials and methods specified herein.

END OF SECTION


Addendum No. 1


CDWMCPPS 40 05 17-1 Steel Pipe and Fittings

Addendum No. 1

SECTION 40 05 17

STEEL PIPE AND FITTINGS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing steel pipe and fittings, except for

steel pipe in buried applications, as follows:

1. Steel pipe and fittings include all fabricated and wrought steel pipe fittings.

Use steel pipe only where specifically shown or specified. Provide pipe of

the flanged, screwed, welded, or plain end type of the sizes and thicknesses

as shown or specified.

B. Related Work Specified in Other Sections Includes, But is Not Limited to, the

Following:


2. Section 01 45 50 - Leakage Test




Piping



8. Section 40 42 00 - Mechanical Insulation – Process




1.2 REFERENCES


1. AWWA C200 - Steel Water Pipe 6 In. and Larger

2. AWWA C205 - Cement-Mortar Protective Lining and Coating for

Steel Water Pipe - 4 In. and Larger - Shop Applied

3. AWWA C207 - Steel Pipe Flanges for Waterworks Service - Sizes 4

In. Through 144 In.


Addendum No. 1

4. AWWA C208 - Dimensions for Fabricated Steel Water Pipe Fittings

5. AWWA C210 - Liquid Epoxy Coating Systems for Interior and

Exterior of Steel Water Pipelines

6. AWWA M11 - Steel Water Pipe: A Guide for Design and

Installation

7. ASTM A 47 - Specification for Ferritic Malleable Iron Castings

8. ASTM A 53 - Specification for Pipe, Steel, Black and Hot-Dipped,

Zinc-Coated, Welded and Seamless

9. ASTM A 181/A181M - Specification for Carbon Steel Forgings, for General

Purpose Piping

10. ASTM A 197 - Specification for Cupola Malleable Iron

11. ASTM A 283/A283M - Specification for Low and Intermediate Tensile

Strength Carbon Steel Plates, Shapes and Bars

12. ASTM A 307 - Specification for Carbon Steel Bolts and Studs,

50,000 psi Tensile

13. ASTM A 536 - Specification for Ductile-Iron Castings

14. ASTM D 2000 - Classification System for Rubber Products in

Automotive Applications

15. ASME B16.1 - Cast Iron Flanges and Flanged Fittings

16. ASME B16.21 - Non-metallic Gaskets for Pipe Flanges

17. ASME B16.3 - Malleable Iron Threaded Fittings

18. ASME B16.5 - Steel Pipe Flanges and Flanged Fittings: NPS 1/2

through 24 with Appendixes

19. ASME B16.9 - Factory-Made Wrought Steel Butt welding Fittings

20. ASME B36.10 - Welded and Seamless Wrought Steel Pipe


Addendum No. 1


A. Design Standards: Use dimensions for steel pipe in accordance with ASME

B36.10, unless specified otherwise.

1. Provide pipe of 6-inch diameter and smaller not less than Schedule 40.

2. Provide pipe of 8- through 16-inch diameter not less than Schedule 30.

B. Small Steel Pipe: Provide steel pipe less than 30 inches in diameter meeting the

requirements of ASTM A 53.

1.4 SUBMITTALS


Division 1.

B. Submit the following shop drawings:

1. Flanged, screwed, welding and mechanical coupling fittings and pipe,

couplings, harnessing and special fittings. When special designs or fittings

are required, show the Work in large detail and completely describe and

dimension the special or fitting.

2. Fully Dimensioned layout of pipe, fittings, couplings, sleeves, expansion

joints, supports, anchors, harnessing, valves and equipment. Label pipe size,

type and materials on drawing and include schedule.

3. Cross sections showing elevation of pipe, fittings, sleeves, couplings,

supports, anchors, harnessing, valves and equipment.

4. Catalog data for pipe, couplings, harnessing and fittings.

C. Quality Control: Submit the following certifications:

1. Certificate of compliance for pipe, fittings, couplings, sleeves, cleanouts and

harnessing.

2. Welders' certifications.

1.5 QUALITY ASSURANCE

A. Utilize certified welders, having current certificates conforming to the

requirements of the ASME code to perform all welding on steel pipelines.


Addendum No. 1

1.6 SPARE PARTS

A. Not Used


A. Deliver, store and handle pipe, fittings and couplings as specified in Division 01

and Section 40 05 10.

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Steel pipe and fittings

a. U.S. Steel

b. L.B. Foster

c. Northwest Pipe Company

2. Dielectric insulating fitting

a. Walter Vallett Company

b. EPCO Inc.

3. Seamless steel welded fittings

a. Taylor Forge and Pipe Works

b. Tube-Turns

c. Walworth

4. Gaskets for flanged joints

a. Garlock Packing Company

b. Crane Company

c. U.S. Rubber Company

5. Sleeve-Type Couplings

a. Dresser, Style 38 with Grade 27 gasket

b. Smith-Blair, Inc., Type 411 with Type 003 gasket


Addendum No. 1

6. Expansion Joints (Short Type)

a. Anamet, Inc.

b. Hyspan,

7. Coatings

a. Kop-Coat

b. Tnemec

2.2 MATERIALS

A. Fittings

1. Manufacture fittings for steel pipe to standard dimensions, suitable for the

pressures specified. Provide steel fittings of the same or heavier wall

thickness as the pipe of which they are a part.

a. Provide fittings used in pipelines 2-inch diameter or smaller of the

screwed pattern.

b. Provide fittings used in pipelines 2.5-inch diameter or larger of the

seamless steel welded type or flanged type, except as shown or

specified otherwise.

2. Unions: Use screwed unions on all steel pipelines 2-inch diameter and

smaller and flanged unions on pipelines 2.5-inch diameter and larger.

a. Provide an adequate number of unions of the screwed or flanged type

in each main pipeline and each branch to facilitate the dismantling or

removal of any branch line or any part thereof or the section of the

main pipe to which it connects, without disturbing adjacent branch

lines or their related main pipeline.

3. Screwed Fittings: Provide malleable iron ASME B16.3 screwed fittings

where shown or specified for steel pipelines meeting the requirements of

ASTM A 197. Provide unions with brass or iron seats.

4. Welding Fittings: Provide butt welding fittings meeting the requirements of

ASME B16.9.

a. Provide outlets for welded connections that are made with Weldolets

of the butt welding type.

b. Provide outlets for threaded connections that are made with

Threadolets.


Addendum No. 1

5. Fabricated Steel Fittings: Unless otherwise shown, provide steel flange

fittings meeting the requirements of ASME B16.5 for 150-pound standard,

except provide flanges that are plain faced.

a. Fabricate steel fittings from the same plates as the pipeline of which

they are a part and meet the requirements of AWWA C208, unless

otherwise shown or specified.

b. Provide fittings and elbows that are made of pipe segments or

preformed plates.

c. Provide reducers and increasers with the same laying length as

American Standard Class 125.

d. Provide fabricated steel fittings with plain ends or welded flanges.

e. Provide tees, wyes, laterals and outlets reinforced in accordance with

AWWA M11.

B. Flanges and Flanged Joints

1. Flanges: Unless otherwise shown, provide all flanges for steel pipe, except

blind flanges, of the slip-on welding type with hubs meeting the

requirements of AWWA C207 Class D and made of metal meeting the

requirements of ASTM A 181 Class 60

a. Attach the flanges to the barrel of the pipe with two continuous fillet

welds.

b. Provide plain faced blind flanges in accordance with ASME B16.5

Class 150.

2. Flanged Joints: Make flanged joints with bolts or bolt studs with a nut on

each end.

a. Provide bolts, stud bolts, and nuts meeting the requirements of ASTM

A 307 Grade B and ASME B16.1.

b. Provide bolts which have a 1/4-inch projection beyond the nut when

joint with gasket is assembled.

3. Gaskets: Provide rubber gaskets for flanged joints meeting the requirements

of AWWA C207 as modified and supplemented herein. Provide 1/8-inch

thick gaskets. Provide full face gaskets for pipe sizes 12 inches in diameter

and smaller. Provide ring type gaskets for pipe larger than 12 inches in

diameter.


Addendum No. 1

4. Insulation: Provide insulated flanged joints as required. Provide flange

insulation kits to include flange insulating gasket, flange bolt insulating

sleeves, and flange bolt insulating washers.

C. Sleeve-Type Coupling

1. General: Provide couplings with rolled steel followers, steel sleeves, rubber

compound gasket and high strength bolts and nuts.

2. Gasket Material: Use gaskets that are not affected by the fluid service of the

pipeline.

3. Pressure Rating: Provide couplings with a minimum pressure rating equal to

the test pressure of the pipeline.

4. Middle Rings: Provide middle rings without a pipe stop, and at least 1/4-

inch thick and 5 inches wide for 8-inch and smaller pipe, 3/8-inch thick and

7 inches wide for 10-inch through 30-inch pipe, and 1/2 inch thick and 10

inches wide for 36-inch and larger pipe, with follower rings of the proper

thickness.

5. Harnessing: Unless shown or specified otherwise, design, furnish and install

harnessing for sleeve-type couplings in accordance with the applicable

portions of AWWA Manual M11, Chapter 13 -Supplementary Design Data

and Details, Section 13.10 - Joint Harnesses. Furnish harnessing having a

design pressure equal to or greater than the test pressure of the pipeline on

which it is installed.

D. Expansion

1. General: Make ample provisions for flexibility in all pipelines to

compensate for expansion.

2. Expansion Device: Provide adequate expansion devices to allow the lines to

expand and contract freely without damage to any part of the piping system.

a. Provide expansion devices in the form of expansion joints, expansion

couplings, swivel or swing joints or pipe bends, and include such

anchors as may be shown, specified or required to make the devices

effective.

b. If expansion devices are not required, fabricate all runs of pipe subject

to expansion shorter than their theoretical length to the extent that

there is freedom to expand without increasing the stresses imposed

when cold.


Addendum No. 1

3. Expansion Joints: Provide expansion joints that are of the single short type

and are designed for the specified test pressures. Provide expansion joints

with adequate tie rods to limit the axial movement at the specified test

pressures, except where noted or specified otherwise.

E. Wall Pipes and Sleeves

1. Wall Pipes



connections that are 1) of the type shown and 2) flush with the




2. Sleeves




AWWA C110/A21.10 with ends that are flush with the wall or floor


walls or floors.




meeting the requirements of this Section or as shown or specified

otherwise. Provide sleeves with ends that are flush with the wall or

floor surfaces. Where shown or specified, provide intermediate

collars located at the centers of the walls or floors.



d. Provide steel sleeves 12 inches in diameter and larger with a

minimum wall thickness of 0.375 inch. For steel sleeves that are

smaller than 12 inches in diameter provide Schedule 40 or thicker

sleeves. Where shown or specified, provide steel sleeves with

intermediate collars located at the centers of the walls or floors.

Provide collars having outside diameters four inches greater than the

outside diameters of the sleeves, fabricated from steel plates having

minimum thickness equal to the sleeve thickness and double welded

to the sleeves.


Addendum No. 1

e. Where shown or specified, provide modular, mechanical sleeve seals,

meeting the requirements in Section 40 05 18, in the annular spaces


spaces between pipes and sleeve with caulk meeting the requirements

in Section 07 90 00.

F. Cleanouts

1. Where shown or specified provide cleanouts as specified in Section 40 05

16.

G. Coatings and Linings

1. General: Line and coat steel pipelines in accordance with the piping

schedule.

a. Coat all bolts, nuts, couplings and the like after the joint has been

made.

b. Paint in accordance with Section 09 96 00.

c. Do not paint the outside of pipe and fittings that are to be concrete

encased.

2. Liquid Epoxy: Where liquid epoxy lining and coating is shown, specified or

required, line and coat in accordance with the requirements of AWWA

C210.

3. Galvanizing: Provide galvanizing in accordance with ASTM A 53 where

shown or specified.

4. Sleeve-type Couplings: Shop coat all surfaces with Dresser Red D, Smith-

Blair Standard Blue Shop-coat, or equal nontoxic material compatible with

the finish coatings specified. Give the inside coating of the middle ring an

additional shop coat of Kop-Coat Hi-Guard epoxy or Tnemec Pota-pox.

Finish coat as specified in Section 09 96 00 for the pipeline of which it is a

part.

H. Dielectric Insulation

1. Provide dielectric insulating joints or fittings at connections between

exterior piping and interior piping.


Addendum No. 1

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all steel pipe and fittings in accordance with the manufacturer's

recommendations and approved shop drawings and as specified in Division 01 and

Section 40 05 10.

B. Insulation: Where shown or specified provide insulation, as specified in Section

40 42 00, for pipes and fittings that are exposed to atmosphere after installation.

C. Reducing Fittings: Use ample fittings for all changes in pipe size. Do not use

bushings.

3.2 LEAKAGE TESTING

A. Cleaning: Flush clean and test all pipes after installation.

B. Testing: Test pipes for leaks and repair or tighten as required.

C. Procedures: Conduct tests in accordance with Section 01 45 50.

3.3 DISINFECTION

A. Disinfect all pipelines that are to carry potable water before they are placed into

service as specified in Section 33 13 00.

3.4 SCHEDULES

A. Refer to the Schedule contained in Section 40 05 10 for information on the piping


END OF SECTION

CDWMCPPS 40 05 18-1 Miscellaneous Pipe and Fittings

Addendum No. 1

SECTION 40 05 18

MISCELLANEOUS PIPE AND FITTINGS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing miscellaneous pipe and fittings as

indicated. Miscellaneous pipe and fittings include all aluminum, copper, brass,

plastic, cast-iron soil and lined steel pipe and fittings.

B. Related work specified in other sections includes, but is not limited to, the

following:


2. Section 01 45 50 - Leakage Tests



5. Section 22 10 00 - Plumbing Piping and Fittings

6. Section 23 21 00 - Hydronic Piping Valves and Specialties

7. Section 23 23 00 - Refrigeration Piping and Specialties

8. Section 23 31 00 - Ductwork


10. Section 40 05 01 - Supports and Anchors


Piping






1.2 REFERENCES


1. ASTM A 74 - Specification for Cast Iron Soil Pipe and Fittings

2. ASTM A 269/269M - Standard Specification for Seamless and Welded

Austenitic Stainless Steel Tubing for General

Service

3. ASTM B 26/B26M - Aluminum Alloy Sand Castings


Addendum No. 1

4. ASTM B 32 - Specification for Solder Metal

5. ASTM B 42 - Specification for Seamless Copper Pipe,

Standard Sizes

6. ASTM B 43 - Specification for Seamless Red Brass Pipe,

Standard Sizes

7. ASTM C 564 - Specification for Rubber Gaskets for Cast Iron

Soil Pipe and Fittings

8. ASTM D 1784 - Specification for Rigid Poly (Vinyl Chloride)

(PVC) Compounds and Chlorinated Poly (Vinyl

Chloride) (CPVC) Compounds

9. ASTM D 1785 - Specification for Poly (Vinyl Chloride) (PVC)

Plastic Pipe, Schedules 40, 80, and 120

10. ASTM D 2464 - Specification for Threaded Poly (Vinyl

Chloride) (PVC) Plastic Pipe Fittings, Schedule

80

11. ASTM D 2564 - Specification for Solvent Cements for Poly

(Vinyl Chloride) (PVC) Plastic Piping Systems

12. ASTM D 2855 - Recommended Practice for Making Solvent-

Cemented Joints with Poly (Vinyl Chloride)

(PVC) Pipe and Fittings

13. ASTM F 491 - Specification for Poly (Vinylidene Fluoride)

(PVDF) Plastic-Lined Ferrous Metal Pipe and

Fittings

14. ASTM F 492 - Specification for Propylene and Polypropylene

(PP) Plastic-Lined Ferrous Metal Pipe and

Fittings

15. ASTM F 599 - Specification for Poly (Vinylidene Chloride)

(PVDC) Plastic-Lined Ferrous Metal Pipe and

Fittings

16. ASME B1.20.1 - Screw Threads - Pipe Threads, General Purpose

(Inch)

17. ASME B16.15 - Cast Bronze Threaded Fittings, Classes 125 and

250 (Includes Revisions Service)


Addendum No. 1

18. ASME B16.18 - Cast Copper Alloy Solder Joint Pressure Fittings

(Includes Revision Service)

19. ASME B16.22 - Wrought Copper and Copper Alloy Solder-Joint

Pressure Fitting (Includes Revision Service)

20. ASME - Boiler and Pressure Vessel Codes, Section IX -

Qualification Standard for Welding and Brazing

Procedures, Welders, Brazers, and Welding and

Brazing Operators.

21. AWWA C151/A21.51 - Ductile-Iron Pipe Centrifugally Cast in Metal

Molds or Sand-Lined Molds, for Water or Other

Liquids

22. CISPI 301 - Hubless Cast Iron Sanitary System

23. CISPI 310 - Hubless Cast Iron Soil Pipe and Fittings for

Sanitary and Storm Drain, Waste, and Vent

Piping Applications

24. AWS A5.8 - Brazing Filler Metal

1.3 SUBMITTALS


1.

B. Shop Drawings: Submit the following Shop Drawings.

1. Submit complete detailed shop drawings in conformance with the specified

requirements.

2. Include drawings that show the piping layouts and schedules of all pipe,

fittings, valves, expansion joints, flexible couplings, hangers, supports and

other appurtenances.

3. When any work is of special design show in large detail and completely

describe and dimension.

4. Welders Certificate: Include welders’ certification with ASME/Section IX.


A. Not Used


Addendum No. 1


A. Deliver, store and handle all products and materials as specified in Division 1.

1.6 SPARE PARTS

A. Not Used

PART 2 PRODUCTS

2.1 MANUFACTURERS


1. Pipe and Fittings:

a. Cast-Iron Soil Pipe and Fittings

(1) U.S. Pipe and Foundry Co., Birmingham, AL

(2) Tyler Pipe Industries, Tyler, TX

(3) Charlotte Pipe and Foundry, Charlotte, NC

b. Copper pipe and Fittings

(1) Mueller Industries, Inc., Wichita, KS

(2) Nibco, Elkhart, IN

c. PVC and CPVC Pipe and Fittings

(1) United States Plastic Corp., Lima, Ohio

(2) Harvel Plastics Inc., Easton, Pennsylvania

d. Wall Sleeve Annular Seals

(1) Thunderline Corp. (Link-Seal), Belleville, MI

(2) GPT, Wheat Ridge, CO

2. Dielectric Insulating Fittings:

a. Walter Vallett Co., Detroit, MI

b. EPCO, Inc., Cleveland, OH

2.2 MATERIALS

A. Cast-Iron Soil Pipe and Fittings


Addendum No. 1

1. Pipe and Fittings: Provide service weight, hub and spigot, cast-iron soil pipe

and fittings meeting the requirements of ASTM A 74 or hubless cast iron

soil pipe and fittings meeting the requirements of CISPI 301. Do not use

hubless pipe and joints for buried pipe. Do not use hubless pipe and joints

for plumbing systems (sanitary, waste, drain, storm and vent).

2. Protective Coatings: Provide interior protective coatings (linings) and

exterior protective coatings for pipe and fittings in the finished work as

follows and as indicated in the piping schedules:

a. For pipe and fittings not exposed in the finished work, provide an

interior bituminous lining and an exterior bituminous coating that

meet AWWA C151/A21.51 requirements.

b. For pipe and fittings exposed in the finished work, provide an interior

bituminous lining that meets AWWA C151/A21.51 requirements.

(1) If the pipe schedules indicate that the pipe exterior is to be

painted, paint in accordance with the requirements in Section

09 96 00.

(2) If the pipe schedules indicate that the pipe exterior is to have a

bituminous coating, coat the pipe in accordance with the

requirements in AWWA C151/A21.51.

3. Joints: Provide lead and oakum joints or neoprene gasket, compression type

joints in accordance with ASTM C 564 for hub and spigot pipe. Consult the

piping schedules. Provide hubless couplings for hubless pipe. Compose

hubless couplings of a stainless steel shield, clamp assembly and an

elastomeric sealing sleeve conforming to CISPI 310.

4. Cleanouts: Provide cleanouts where shown or specified, and meeting the

requirements of Section 22 10 00, unless otherwise specified.

B. Copper Pipe and Fittings

1. Small Copper Piping: For copper pipe 3 inches in diameter and smaller,

provide Type K hard drawn copper tubing that meets ASTM B 88

requirements.

a. Fittings: Provide ASME B16.18, cast copper alloy or ASME B16.22

wrought copper and copper alloy fittings.

b. Joints: Threaded or ASTM B 32 lead-free soldered joints.

c. Joints: Brazed joints, AWS A5.8 BCUP silver/phosphorus/copper

alloy with melting range 1190-1480 degrees F.


Addendum No. 1

2. Large Copper Piping: For copper pipe larger than 3 inches in diameter,

provide regular seamless copper pipe that meets the ASTM B 42

requirements.

a. Fittings: Provide solder type fittings of the same material as the pipe.

b. Joints: Use threaded or brazed joints.

3. Potable Water Piping: Use ASTM B 32 alloy Grade 95TA (95 percent tin

and 5 percent antimony) solder for piping carrying potable water.

4. Unacceptable Uses: Do not use copper pipe with soldered joints for

transporting fuel oil or other flammable or toxic liquids inside buildings.

C. Polyvinyl Chloride (PVC) and Chlorinated Polyvinyl Chloride (CPVC) Pipe and

Fittings

1. Pipe and Fittings: Provide PVC pipe and fittings that are Schedule 80 and

meet the requirements of ASTM D 1784 Class 12454-B and ASTM D 1785

unless otherwise shown or specified. Provide CPVC pipe and fittings that

are Schedule 80 and meet the requirements of ASTM D 1784 Class 23447-B

and ASTM D 1785, unless otherwise shown.

2. Joints: Provide ASTM D 2855 solvent welded joints utilizing ASTM D

2564 solvent cement or ASTM D 2464 threaded joints, as indicated in the

piping schedules.

D. Stainless Steel Tubing

1. General: Provide Type 304L stainless steel tubing meeting the requirements

of ASTM A269/A269M

E. Wall Pipes and Sleeves for Miscellaneous Pipe and Fittings

1. Wall Pipes



connections that are 1) of the types shown and 2) flush with the




2. Sleeves




Addendum No. 1


AWWA C110/A21.10 with ends that are flush with the wall or floor


walls or floors.




meeting the requirements of Section 40 05 17 or as shown or

specified otherwise. Provide sleeves with ends flush with the wall or

floor surfaces. Where shown or specified, provide intermediate

collars located at the centers of the walls or floors.



d. HDPE Sleeves: Where shown or specified, provide molded HDPE

sleeves as manufactured by the Thunderline Corporation with

integrally formed intermediate collars or waterstops.

e. Where shown or specified, provide modular, mechanical sleeve seals,

meeting the requirements of this Section, in the annular spaces


spaces between pipes and sleeves with caulk meeting the

requirements in Section 07 90 00.

F. Modular, Mechanical Sleeve Seals: Provide modular, mechanical type seals

consisting of interlocking, synthetic-rubber links shaped to continuously fill the

annular space between the pipe and the sleeve. Provide an elastomeric sealing

element that is of the size, quantity, type and material that the manufacturer

recommends for the intended service and that will provide an effective hydraulic

seal. Provide stainless steel bolts and nuts.

G. Supports and Anchors: Provide all pipelines with supporting and anchoring

devices as specified in Section 40 05 01. Provide drip pan hangers and supports as

specified for sheet metal ductwork in Section 23 31 00.

PART 3 EXECUTION

3.1 INSTALLATION

A. General: Install all miscellaneous pipe and fittings in accordance with the

specifications contained herein and in Section 40 05 10 and in accordance with the

manufacturer's recommendations and approved shop drawings and as specified in

Division 1.


Addendum No. 1

B. Connections Between Dissimilar Metals: Where connections are to be made

between pipelines or equipment of corrosion causing dissimilar metals make the

connections using dielectric insulating couplings, unions or other approved

dielectric insulating devices.

C. Couplings: Only use couplings to join standard lengths of pipe and as required to

complete a straight run of pipe. Do not use couplings to join random lengths of

pipe and cuttings from standard lengths.

D. Reducing Fittings: Use reducing fittings for all changes in pipe size. Do not use

bushings.

E. Pipe Flexibility: Make ample provisions for flexibility in all pipelines in

accordance with Section 40 05 10 for interior pipelines.

3.2 CLEANING AND PAINTING

A. Cleaning: Flush all process and potable water pipelines with clean water.

B. Leakage: Test pipes at the pressures specified in the piping schedules located in

Section 40 05 10.

C. Paint in accordance with Section 09 96 00, unless otherwise specified.

3.3 DISINFECTION

A. Disinfect all potable water pipelines in accordance with Section 33 13 00.

3.4 SCHEDULES

A. Refer to the schedules contained in Section 40 05 10 for information on the piping


END OF SECTION

CDWMCPPS 40 05 20-1 Valves

Addendum No. 1

SECTION 40 05 20

VALVES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for furnishing and installing all valves and

operators. Work includes, but is not limited to, the following:

1. One 36-inch non-rising stem gate valve with electric motor operator to be

installed in the suction pipe of each of Main Pumps No.1 (SV-1B) and No.2.

(SV-2B)

2. New hydraulic actuation and accumulator systems for all existing discharge

check valves. Existing hydraulic cylinders to remain.

3. New electric motor operators for all existing isolation discharge valves for

Main Pumps No. 1 (DV-1), No. 2 (DV-2), No. 3 (DV-3), No. 4 (DV-4), and

No. 5 (DV-5).

4. New electric motor operators for isolation suction valves for Main Pumps

No. 3 (SV-3), No. 4 (SV-4), and No. 5 (SV-5).

5. Inspection, evaluation and reporting on conditions of all isolation discharge

valves for Main Pumps No. 1(DV-1), No. 2 (DV-2), No. 3 (DV-3), No. 4

(DV-4), and No. 5 (DV-5) and check valves for Main Pumps No. 1 (CV-1),

No. 2 (CV-2), No. 3 (CV-3), No. 4 (CV-4), and No. 5 (CV-5).

6. Pending results of the valves inspection, refurbishing of pump isolation

discharge and check valves.

B. For all other special regulating valves, telescopic valves, flap valves, etc., refer to

Section 22 10 00.

C. Provide valve operators complete, including a suitable enclosure, with all

appurtenances necessary for the operator to perform its intended function. Such

appurtenances include, but are not limited to, anchor bolts and other mounting

hardware, control switches, limit switches, pressure switches, torque switches,

gauges, control valves, electrical supply connections, internal electric wiring and

controls, terminal blocks, hydraulic water piping, solenoid valves, miscellaneous

valves, regulating controls, push button controls, miscellaneous controls, extension

stems, local and remote indicators, operating nuts, purge water service with all

associated piping, indicating lights, floor boxes, direct burial valve boxes and other

such items.


Addendum No. 1

1. For each valve, provide the type of operator specified for the valve in the

Valve Schedule.

D. Related Work specified in other sections includes, but is not limited to, the

following:


2. Section 01 12 16 - Construction Work Sequence and Limitations



5. Section 22 10 00 - Plumbing Piping and Valves

6. Section 26 05 19 - Low-Voltage Electrical Conductors and Cables

7. Section 26 05 60 - Electrical Requirements for Shop-Assembled Equipment

8. Section 26 27 26 - Wiring Devices

9. Section 26 20 10 - Low-Voltage Motors


11. Section 40 90 50 - Process Control System Description

12. Section 40 91 00 - Process Control Systems Instrument

13. Section 40 94 43 - Programmable Logic Controller Systems

E. Comply with the “American Iron and Steel (AIS)” requirements as contained in



1.2 REFERENCES


1. ASME B1.20.1 - Pipe Threads, General Purpose

2. ASME B1.20.7 - Hose Coupling Screw Treads

3. ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings

4. ASTM A 27/A27M - Specification for Steel Castings, Carbon, for

General Application

5. ASTM A 29/A29M - Specification for Steel Bars, Carbon and Alloy,

Hot Wrought and Cold-Finished, General

Requirements

6. ASTM A 48 - Specifications for Gray Cast Iron Castings

7. ASTM A 126 - Specification for Gray Iron Castings for Valves,

Flanges, and Pipe Fittings

8. ASTM A 197 - Specification for Cupola Malleable Iron


Addendum No. 1

9. ASTM A 276 - Specification for Stainless and Heat-Resisting

Steel Bars and Shapes

10. ASTM A 278 - Specification for Gray Iron Castings for Pressure-

Containing Parts for Temperatures Up to 650 F

11. ASTM A 395 - Specification for Ferritic Ductile Iron Pressure-

Retaining Castings for Use at Elevated

Temperatures

12. ASTM A 436 - Specification for Austenitic Gray Iron Castings

13. ASTM A 479/A479M - Specification for Stainless and Heat Resisting

Steel Wire Bars, and Shapes for Use in Boilers

and Other Pressure Vessels

14. ASTM A 536 - Specification for Ductile Iron Castings

15. ASTM A 564/A564M - Hot Rolled and Cold Finished Age Hardening

Stainless and Heat Resisting Steel Bars and

Shapes

16. ASTM A 572/A572M - Specification for High Strength Low Alloy

Columbium Vanadium Steels of Structural

Quality

17. ASTM A 743/A743M - Specifications for Castings, Iron-Chromium, Iron-

Chromium - Nickel, and Nickel-Base Corrosion-

Resistant for General Application

18. ASTM A 744/A744M - Specification for Castings, Iron-Chromium-

Nickel, Corrosion-Resistant, for Severe Service

19. ASTM B 30 - Specification for Copper Base Alloys in Ingot

Form

20. ASTM B 62 - Specification for Composition Bronze or Ounce

Metal Castings

21. ASTM B 148 - Specification for Aluminum-Bronze Castings

22. ASTM B 584 - Specification for Copper Alloy Sand Castings for

General Applications

23. AWWA C500 - Metal Seated Gate Valves for Water and Sewerage

Systems

24. AWWA C504 - Rubber-Seated Butterfly Valves


Addendum No. 1

25. AWWA C508 - Swing Check Valves for Waterworks Service, 2

inch through 24 inch NPS

26. AWWA C509 - Resilient-Seated Gate Valves for Water Supply

Service

27. AWWA C540 - Power-Actuating Devices for Valves and Sluice

Gates

28. MSS SP-70 - Cast Iron Gate Valves, Flanged and Threaded

Ends

29. MSS SP-71 - Cast Iron Swing Check Valves, Flanged and

Threaded Ends

30. MSS SP-80 - Bronze, Globe, Angle and Check Valves

31. NACM - Welded and Weldless Chain Specifications

32. SAE J356 - Welded Flash Controlled Low-Carbon Steel

Tubing Normalized for Bending, Double Flaring,

and Beading

33. SAE J524 - Seamless Low-Carbon Steel Tubing Annealed for

Bending and Flaring

34. SAE J525 - Welded and Cold-Drawn Low-Carbon Steel

Tubing Annealed for Bending and Flaring

1.3 SUBMITTALS


1.

B. Shop Drawings: Submit the following:

1. Complete detailed drawings for all new valves.

2. Complete detailed drawings for all electric motor operators.

3. Complete detailed drawings for refurbished valves, if applicable.

4. Working drawings, including arrangement and erection drawings of the

operators and control equipment; schematic control diagrams, electrical

connection diagrams, and complete description of the control system; and

operating characteristics.


Addendum No. 1

C. Quality Control Submittals: Submit the following:

1. If requested, manufacturer's certified performance and material records.

2. If requested, complete calculations for each size of motor operator indicating

the force required to operate the valve, the operator force provided, full load

and locked rotor current, and horsepower.

D. Operation and Maintenance: Submit operation and maintenance manuals for the

valve operators.


A. Furnish all valves of the same type from the same manufacturer. Provide parts that

are interchangeable for all valves of the same type and size.


A. General: Deliver, store and handle all products as specified in Division 1 and as

follows.

B. Storage and Erection: Pack and store all valves in satisfactory operating condition.

Carefully erect all valves in their respective positions, free from all distortion and

strain.

1.6 SPARE PARTS

A. Not used

PART 2 PRODUCT

2.1 MANUFACTURERS

A. Acceptable manufacturers are listed below.

1. Gate Valves:

a. American Flow Control

b. M&H Valve Company

c. Mueller Company

d. Kennedy Valve

e. NIBCO, Inc.

f. Stockham

g. United States Pipe and Foundry

2. AWWA Butterfly Valves:


Addendum No. 1


b. DeZurik

c. Keystone

d. Pratt

3. Single Disc Swing Check Valves:


b. Clow Valve Company

c. M&H Valve Company

d. Mueller Company

4. Solenoid Valves:

a. Automatic Switch Company

b. Magnetrol

c. Versa

d. Midland

5. Globe and Angle Valves:

a. NIBCO, Inc.

b. Stockham

6. Electric Motor Operator - Nonmodulating:

a. Limitorque Corporation

b. Rotork, Inc.

7. Water Hydraulic Actuation and Accumulator System:

a. SunSource, Addison, IL

b. Parco Engineering Corp. (represented by Stonkus Hydraulic,

Bellingham, MA)

2.2 MATERIALS

A. General:

1. Fabricate valves of materials resistant to corrosion for the required service.

2. Unless other materials are needed for corrosion resistance or are specified

elsewhere, fabricate valves that are to be installed in metal pipelines and that

are 2 inches in diameter and smaller of all brass or bronze, except fabricate

the handwheel of ASTM A 197 malleable iron. Fabricate valves that are to

be installed in metal pipelines and that are 2-1/2 inches in diameter and

larger of the materials specified herein.


Addendum No. 1

3. Fabricate gate, globe and angle valves with a minimum steam working

pressure rating of 125 psig and a minimum nonshock cold water, oil or gas

pressure rating of 200 psig, unless otherwise specified.

4. Fabricate operators of materials resistant to corrosion for the required

services. Provide operator materials as specified.

5. Operator housings and pedestal handwheels:

a. Cast iron ASTM A 126, Class B

ASTM A 48, Class 30 or 35

b. Ductile iron ASTM A 395

ASTM A 536, Grade 65-45-12

c. Cast steel ASTM A 27/A27M

6. Operator worms, steel ASTM A 29/A29M Grade

Designation 8620

7. Operator gears, steel

(spur & helical) ASTM A 572/A572M

8. Worm gears, bronze ASTM B 148, Alloy C95400 or C95500

ASTM B 584, Alloy C86300

B. Valve Joints

1. Fabricate valves 2 inches in diameter and smaller of the threaded or solder

end type for valves to be installed in copper pipelines, and of the threaded

end type for valves to be installed in metal pipelines.

2. Fabricate all valves 2-1/2 inches in diameter and larger, except bronze

valves 2-1/2 and 3 inches in diameter, with flanged ends, unless otherwise

specified.

3. Fabricate bronze valves 2-1/2 and 3 inches in diameter with solder or

threaded type ends for valves installed in copper pipelines and threaded type

ends for all other pipelines.

4. For metallic flanged joints, provide flanges that are faced accurately at right

angles to the axis of the casting. Face and drill flanges and shop coat with a

rust-preventive compound before shipment.

5. For flanged joints, provide flanges whose dimensions and drillings meet the

requirements of ASME B16.1, 125 pounds as a minimum. For valves

installed in pipelines with test pressure requirements higher than 125 psi,

provide flanges whose pressure ratings equal or exceed the specified test


Addendum No. 1

pressure of the pipeline. Furnish special drillings where required. For

valves having flanges that do not conform with the thickness requirements

of ASME B16.1, test each valve in accordance with the hydrostatic shell test

pressure requirements of ASME B16.1.

C. Operating Force: Fabricate valves to limit the maximum force required to operate

all manual valves, including but not limited to valves with wrench operated nuts,

levers, handwheels and chainwheels, to 40 pounds. Limit the overall length of

each wrench or single-arm lever to 18 inches. Limit the overall length of each

dual-arm lever to 36 inches.

D. Handwheel: Mark each valve handwheel with an arrow and the word OPEN.

Mark each nut with an arrow.

E. Manually Operated Valves: Equip all manually operated valves that have

operating nuts, levers or handwheels and that are more than 7 feet above the floor

with chain operated levers or chainwheels. Extend chains to 7 feet above the floor.

2.3 GATE VALVES

A. Materials: Unless otherwise shown or specified, furnish and install gate valves

meeting the following requirements:

Nominal Valve Size, Inches Standard Type

16 and larger, except for HVAC Service AWWA C500 Double disc

B. Non-rising Stem: Equip non-rising stem valves, except for buried or submerged

service, with externally visible indication of the disc position at all points of travel.

C. Stem Seals: Use the following types of stem seals:

Valve Type Stem Seal

Geared Non-rising stem O-ring or stuffing box

D. Packing: Provide non-asbestos braided, twisted or formed ring type packing

suitable for the pressure-temperature ratings of the valve.

E. Bonnet: Provide 4-inch and larger gate valves with outside screw and yoke

bonnets.

F. Accessories: Provide zinc plated bonnet bolts, studs and nuts except for

submerged service. Provide stainless bonnet bolts, studs and nuts for submerged

service. Make wedging devices bronze to iron or bronze to bronze. Provide

glands which are bronze or bronze bushed and bronze gland bolts and nuts.


Addendum No. 1

G. SV-1B and SV-2B: Provide non-rising stem double disc or rotating disc, NSF-61

certified gate valves without bypass valve.

2.4 BUTTERFLY VALVES

A. General:

1. Provide butterfly valves 4 inches and smaller of the full lug pattern with

drilled and tapped bolt holes.

2. Provide butterfly valves 6 inches and larger of the full flanged pattern that

meet the requirements of AWWA C504.

3. Provide butterfly valves of the rubber-seated, tight-closing type.

4. For fluid temperatures equal to or less than 180 degrees F, provide Buna-N

seats. For fluid temperatures greater than 180 degrees F, provide EPDM or

Viton seats. For fluid temperatures exceeding the temperature ratings of

EPDM and Viton, provide seats that are appropriate for the intended service.

B. Materials:

1. For butterfly valves 4 inches and smaller, provide valve materials as

specified below or as required for the service.

a. Valve bodies:

Cast iron ASTM A 126, Class B

b. Valve shafts:

Stainless steel ASTM A 564, Type 630 (17-4 PH stainless

steel)

ASTM A 276 Grade 316

c. Valve discs:

Aluminum Bronze ASTM B 148

Bronze ASTM B 30

d. Bearings: TFE coated stainless steel

2. For butterfly valves 6 inches and larger, provide valve materials as specified

below or as required for the service:

a. Valve bodies:

Cast iron ASTM A 126, Class B

ASTM A 48, Class 40

b. Valve shafts: ASTM A 276 or A 479/A479M, Type 304,


Addendum No. 1

stainless steel or carbon steel with A 276 or A

479, Type 304 stainless steel journals

c. Valve discs:

Cast iron ASTM A 48, Class 40

Alloy cast iron ASTM A 436, Type 1

Ductile iron ASTM A 536, Grade 65-45-12

Bronze AWWA C504 Grade A, D or E

d. Mating seat surface:

Stainless steel

(castings) ASTM A 743/A743M, A 744 Grade

CF-8 or CF-8M

Stainless steel ASTM A 276 or A479,Type 304

Alloy cast iron ASTM A 436, Type 1

e. Seats: Buna-N (Wastewater)

New natural rubber or Buna-N (Water)

Neoprene (Air)

C. General AWWA C504 Construction: For butterfly valves 6 inches and larger,

manufacture valves and all accessories, including operators, to meet the

requirements of AWWA C504, except as otherwise specified. Provide valve

bodies of the short-body flanged type or mechanical joint-end type, as shown or

specified. Wafer body type valves without lugs are not acceptable.

D. Pressure: Provide butterfly valves of pressure classes that are not less than Class

25B, that exceed the pipeline test pressure in which the valve is installed, or that

are as specified, whichever is greater.

E. Shafts: If stub shafts are furnished, extend the shafts a minimum of 1-1/2

diameters into the discs and provide clearance between the shaft and discs not

exceeding the following:

Shaft Diameter

(Inches)___ Maximum Radial

Clearance (Inches) 1/2 to 1-1/2 .002 2 to 4 .0025 5 .003 6 .004

F. Extended Necks: Provide butterfly valves in insulated lines with extended necks

to clear insulation.

2.5 SOLENOID VALVES

A. Provide solenoid valves of the direct acting, all electric, normally closed, packless

type with full area ports, unless otherwise shown or specified.


Addendum No. 1

B. Design valves to not require a pressure assist from the process fluid to open or

close. Size the solenoids in accordance with the pressure conditions in the pipeline

in which valves are installed.

C. Construct the valve body and bonnet of forged brass and construct the solenoid

core of stainless steel.

D. Design solenoid the coils for 115-volt, 60-hertz operation. Embed solenoid coils

in molded plastic and install coils in NEMA Type 1 general purpose enclosures,

DIN plug connections preferred for service without unwiring connections except

as shown or specified.

2.6 CONTROL VALVES

A. Provide 4-way, differential-operated, packless, poppet seat type solenoid-operated

control valves with all parts rustproof and non-corrosive. Provide coils of the

molded type, Class B insulated, in NEMA Type 4 Enclosure for nonhazardous

areas, designed for operation using 120-volt, 60-hertz current. Provide single-

solenoid type valves. Arrange the solenoid such that when energized it positions

the 4-way valve to open the cylinder-operated valve and when de-energized, it

positions the 4-way valve to close the cylinder-operated valve. Arrange the 4-way

valves for manual operation independent of and without disturbing the electrical

control. Provide emergency close function with additional single solenoid valve

which overrides any other function or operation that may be in process.

2.7 GLOBE AND ANGLE VALVES

A. General: Provide globe and angle valves that meet the requirements of MSS SP-

80.

B. Disc and Seats: Equip gate and globe valves with renewable bronze discs and

renewable seats.

C. Bonnet: Equip globe and angle valves with threaded bonnets.

D. Packing: Provide non-asbestos braided, twisted or formed ring type packing

suitable for the pressure-temperature ratings of the valve.

2.8 BALL VALVES

A. In accordance with Section 22 10 00.

2.9 BACKFLOW PREVENTERS

A. In accordance with Section 22 10 00.


Addendum No. 1

2.10 MANUAL BUTTERFLY VALVE OPERATORS

A. General: Provide operators as an integral part of the valve. Manufacture manual

operators of the enclosed, hand-lever, traveling-nut or worm-gear type, as shown

or specified.

B. Hand-Lever Type: Fabricate hand-lever type operators of cast-iron or steel

construction with a nonmetallic, nonslip handgrip. Equip the lever with a locking

device to secure the valve disc in the fully open or fully closed position, or at a

minimum of 5 intermediate positions at 15 degree intervals. Provide mechanical

stop-limiting devices to prevent overtravel of the disc in either direction.

Permanently lubricate operators or provide operators with grease fittings.

C. Traveling-Nut Type: Fabricate traveling-nut type operators with a threaded steel

screw and a bronze nut. Provide a slotted-lever or link-lever system to transfer the

applied torque to the disc shaft. Equip all rotating shafts, screws and links with

separate bearings. Provide thrust bearings.

D. Worm-Gear Type: Fabricate worm-gear type operators with a worm gear and

matching drive worm. Provide bearings for each rotating member.

E. Stop-Limiting Devices: Provide stop-limiting devices on traveling-nut and

worm-gear type operators to prevent overtravel of the disc in either direction.

Design the operator to hold the disc in any position without flutter or wear on the

valve or operator. House the operator in a watertight enclosure. Pack operators

with grease or with oil. For buried or submerged service, equip valve operators

with stainless steel external bolting.

F. Position Indicators: For buried or submerged service, equip manually operated

butterfly valves, with externally visible indication of the disc position.

2.11 ELECTRIC MOTOR OPERATORS – NON-MODULATING

A. Provide electric motor operators for the following valves:

1. Existing isolation discharge valve: DV-1, DV-2, DV-3, DV-4, and DV-5

2. Existing isolation suction valve: SV-3, SV-4, and SV-5

3. New isolation suction valve: SV-1B and SV-2B

B. General: Provide non-modulating electric motor operators of the close-coupled,

electric motor-driven, worm gear type, complete with motor, gearing, limit

switches and auxiliary contacts, torque switches, position indicator, handwheel,

integral controller, and all required appurtenances. Design the operators to rotate

valve discs through 90 degrees from the fully open to the fully closed position and

back, as in butterfly, ball valves, lift gate discs from the fully closed to the fully

open position and back, as in gate valves. Provide operators that hold the discs in

any position from fully open to fully close without vibration.


Addendum No. 1

C. Operator Mounting: Design the operator to be mounted in the position shown or

specified.

D. Standard: Except as otherwise specified, provide operators meeting AWWA

C540.

E. Open and Close Time Periods: Provide valve operators that fully open the valve

from the closed position in approximately 3 minutes and fully close it in

approximately 3 minutes when the differential pressure and flow are at the values

specified for the valve and the voltage at the terminals is within 15 percent of the

nominal voltage. Design the operator to operate the valve through three

consecutive opening and closing cycles or for a period of 15 minutes, whichever is

longer, during every 60-minute period, at specified ambient temperature conditions

under full differential pressure.

F. Temperature Range: Design the operator for indoor operation and for an ambient

temperature range of -20 to 140 degrees F.

G. Torque: Design the operator to exert an unseating torque of at least 50 percent in

excess of the required disc seating torque at the specified voltage, neglecting

hammer-blow effect.

H. Power Gearing: Provide power gearing consisting of helical or spur gears and

worming gearing. Fabricate helical and spur gears of accurately machined

hardened alloy steel. Provide a hardened alloy steel worm with threads ground and

polished after heat treating. Provide a nickel or manganese bronze worm gear.

Use antifriction bearings throughout. Grease pack or oil bath lubricate the

operator. Provide lubricants suitable for the ambient temperatures specified.

I. Lost-Motion Device: Design operators for gate valves to include a lost-motion

device that will permit the motor to attain full speed, and then impart a hammer

blow to the stem nut to start movement of the disc in both the opening and closing

directions. Do not include this feature if the valve is for modulating service.

J. Handwheel - Manual Operation: Provide a handwheel for manual operation with a

maximum rim pull of 40 pounds. Design the handwheel so that it does not rotate

during electrical operation and the motor does not rotate during manual handwheel

operation. Provide an operator that is arranged so that motor or motor gearing

failure does not prevent manual operation. Arrange the operator to automatically

change from manual operation to electrical operation when its motor is energized

and to continue electric operation until the operator is reset to manual operation.

Provide a means for locking the drive in either manual or motor operation.

Provide removable handwheels. Provide an adaptor key or drive nut to permit

operation by a portable operator.

K. Declutching Mechanism: Provide a declutching mechanism to disengage the

motor mechanically but not electrically from motor to handwheel operation. If the


Addendum No. 1

clutch is of the external lever type, arrange it such that the lever does not move

when the motor is energized.

L. Position Indication: Provide an operator-mounted disc position indicator of

indicating light type. For OPEN-CLOSED service, indicate the fully open, fully

closed and intermediate disc position by lights. For modulating or throttling

service, provide continuous disc position indication between the fully open and

fully closed positions. Provide electrical contacts as required for remote indication

of disc position.

M. Electric Motor Design: Provide an operator motor of the high torque, ball or roller

bearing, squirrel-cage type designed for continuous valve duty. Provide motor

rated for 15 minute duty cycle or three complete opening and closing valve

strokes, whichever is longer, during a 60 minute period under full differential

pressure at 40 degrees C ambient. Design the motor for use on a nominal 480

volts, 3-phase, 60-hertz electrical service. Provide motor windings and leads with

Class F or better insulation with built-in thermal overload protection. In other

respects, provide motors meeting the requirements of Section 26 20 10.

N. Housing: Provide housings for controls, gears, and motors with integrally cast

flanges. Fully machine and template drill the flanges and their mating surfaces.

Provide joints which are metal-to-metal or gasket or O-ring sealed as required.

O. Control and Motor Enclosures: Provide NEMA 4 control and motor enclosures,

except as otherwise specified. Provide the controller with mechanical interlocks

and mount as an integral part of the operator.

P. Electrical Compartment Heater: Provide electrical compartment heaters, unless

other means can be proven effective for moisture elimination.

Q. Electrical Requirements: Provide electrical controls for the operator as shown or

specified. Design operators for 208-volt, 3-phase, 60-hertz service for DV-1, DV-

2, DV-3, DV-4, and DV-5. Design operators for 480-volt, 3-phase, 60-hertz

service for SV-1B, SV-2B, SV-3, SV-4, and SV-5. Design all control circuits for

120-volt, single-phase, 60-hertz ac. Provide an integral control transformer with

fused secondary.

R. Reversing Controller, Overload Protection and Internal Wiring: Provide a NEMA

rated reversing controller, or an approved special duty rated reversing controller,

complete with mechanical interlocks and controls as an integral part of the

operator. Provide adequate overload protection in the controller or embedded in

the motor windings. Install an overload device in each phase. If overload devices

are installed in the motor windings, provide devices of the bimetallic automatic

reset type with the contacts in the control circuit. Arrange the internal wiring in

the operator so that the opening and closing coils cannot be energized

simultaneously at any time, regardless of external wiring conditions.


Addendum No. 1

S. Push Buttons and Selector Switches: Where operators are 7 feet or closer to the

floor and in an accessible location, mount OPEN- STOP-CLOSE push buttons or a

selector switch as shown on the operator housing. Also mount red and green

position indicator lights and, where shown or required, an amber ready light or

MANUAL-AUTO mode selector on the operator housing. Where the operators

are located over 7 feet from the floor or in an inaccessible location, connect all

internal control and indication wiring to a terminal block within the operator

enclosure and provide a separate control station for remote mounting. Provide the

remote control station with the same NEMA rating as the operator.

T. Limit and Torque Switches: Provide the operator with limit and torque switches,

either direct or gear driven. Provide adjustable limit and torque switches with

auxiliary contacts that are operative in either direction of travel. Provide limit

switches that are "in step" with torque switches at all times, whether in motor or

manual operation. Equip the operator with limit switches to stop movement in

each direction and torque switches for protection against mechanical overload and

to stop movement in either direction if an obstruction is encountered. Provide the

number, function and arrangement of limit switches as shown, specified or

required.

1. Provide the following limit switches for all existing check valves and

existing discharge valves:

a. NEMA 4X enclosure

b. Visual Indicator

c. Captive Cover Bolts

d. Mechanical SPDT

e. Quick Set Spring loaded cam.

f. Manufacturers:

(1) A-T Control

(2) DeZurik

2. All limit Switches shall be wired to SCADA system as shown on P&IDs

U. Additional Accessories:

1. Provide additional limit switches, indicating lights, position transmitters and

remote position indicators, remote operating controls and other accessories

and controls as shown, specified or required.

2. Provide position transmitters for all existing check valves, existing discharge

valves, and suction valves (new and existing):

a. NEMA 4X enclosure

b. Epoxy Coated

c. Settings: Less than 1 degree

d. 4-20ma Signal


Addendum No. 1

e. 24 VDC Power Supply

f. Manufacturers:

(1) A-T Control

(2) Dezurik

g. All position transmitters shall be wired to SCADA system as shown

on P&IDs

V. Control Components, Operator Housing and Operator Wiring: Provide control

components and operator housing that meets the requirements of Section 26 05 60.

Provide operator wiring that meets the requirements of Section 26 05 19.

2.12 WATER HYDRAULIC ACTUATION AND ACCUMULATOR SYSTEMS

A. System includes:

1. Two hydraulic accumulator systems

2. Five hydraulic actuation systems (one per pump discharge check valve)

3. Piping and controls for each check valve

B. Each hydraulic accumulator system includes:

1. One hydropneumatic tank

2. Two hydraulic water pumps

3. Two air compressors

4. One system control panel

5. Switches, valves, gauges, and all accessories for a complete operable system

C. Each hydraulic actuation system includes:

1. One valve control panel

2. Switches, valves, gauges, and all accessories for a complete operable system

D. Each hydraulic accumulator system shall supply water under hydropneumatic tank

design pressures of approximately 100 psig minimum and 150 psig maximum.

Each assembly and piping system shall provide a minimum of 200 gallons of water

under pressure to the valves for one complete stroke for emergency closure

without operations of the water pumps or air compressors, on power failure.

E. Each hydraulic accumulator unit shall be provided with a fabricated steel base

which extend beyond each end of the assembly and be equipped with mounting

holes. Lifting eyes shall be provided for each assembly to permit loading,

unloading, and moving of the unit. The entire assembly shall be provided as a

complete, self-contained unit with all components factory piped and wired, except

for the tanks where field connection between the tanks and the mechanical

equipment is acceptable. It must be capable of being disassembled for repair

and/or replacement.


Addendum No. 1

F. Hydropneumatic Tank

1. Construct tank in accordance with ASME Boiler and Pressure Vessel Code,

Section VIII, Division I, for Unfired Pressure Vessels.

2. Vertical configuration

3. Design each tank for a maximum working pressure of 175 psig

4. Design each tank to handle all five check valves operation at any one time

under emergency condition.

5. Test tank under 1.5 times the maximum working pressure. Test shall be

performed after assembly, but before painting, with all openings closed.

Continuously test tank until all seams and joints have been demonstrated to

be thoroughly tight. All of the necessary equipment, material, and labor

must be furnished for conducting the test. Stamp tank to show compliance

with ASME code.

6. Provide the following for each tank:

a. Pressure relief valve

b. Sight gauge with shutoff cocks

c. Drain line with valve

d. Piping connections

e. Pressure switch connections

f. Level switches

g. Gauges, pressure switches, pressure regulators, level switches, and

other field instrumentation and appurtenances for a complete operable

system. Provide field instrumentation in accordance with Section 40

91 00.

G. Hydraulic Water Pumps

1. Type: Positive displacement, single vane type.

2. Capacity: 20 gpm at 200 psi maximum pressure

3. Motor: 10 Hp. Horizontal shaft, totally enclosed, fan cooled, squirrel-cage

induction motor. Rated at 460 V, 3 Phase, 60 Hz. In accordance with

Section 26 20 10.


Addendum No. 1

H. Air Compressors

1. Type: Two-stage, reciprocating, single acting, air-cooled

2. Capacity: 17 SCFM at 175 psi maximum pressure

3. Motor: 5 Hp, 480 V, 3 Phase, 60 Hz. In accordance with Section 26 20 10.

I. Valve Control Panels

1. Provide a total of five (5) valve control panels, one valve control panel for

each pump check valve.

2. The valve control panel shall be an integrated design, furnished by one

manufacturer who shall provide all of the equipment and accessories, and

shall be incorporated with the hydraulic actuation system. The manufacturer

shall be responsible for the satisfactory operation of the entire system.

Solenoid Control Valves prewired to terminal box for interface with Pump

operation. See #6 below.

3. Steel components must be painted gray epoxy over epoxy primer.

4. External hardware: bright nickel or chromium plated

5. Nameplate: engrave plastic or metal

6. Termination enclosure needed for prewiring solenoid valves for interface to

the process pump controller panel.

7. Valve control system shall have the ability for manual operation of the pump

outlet manually as long as pressurized fluid is available. Isolation valves

and manual operators for control valves as needed.

8. Provide all auxiliary devices required for the control equipment. All

hydraulic devices shall be internally piped to pressure, drain and (2) cylinder

connections. All hydraulic hose shall be fitted with female swivel ends. All

soldered joints shall be made of solid silver wire solder of 95 percent tin and

5 percent antimony. Electrical devices shall be wired to a numbered terminal

block in the panel.

9. Mount the control panel on a floor stand. Provide a valved water supply

pressure connection to the panel drain from the panel and two connections

between the panel and the hydraulic cylinder on the valve operator. All

piping shall be type K hard copper sized by the manufacturer with all joints

soldered.

10. The control system shall operate each pump check valve as follows based

upon inputs received from the process pumps controller:


Addendum No. 1

a. When the pump is not operating, the valve must remain close.

b. When the pump is energized, the control valve shall start to open at a

uniform rate. The control valve’s opening time shall be field

adjustable from 15 to 150 seconds, with an initial setting at 30

seconds.

c. In the event of a power failure or Emergency Stop conditions as

specified in Section 40 90 50, the check valve shall close rapidly and

the speed of closure shall be independently adjustable from 10 to 30

seconds with an initial setting at 15 seconds.

J. Water Supply to Accumulators

1. Supply water to the hydraulic accumulator systems from a non-potable

water system as shown on Contract Drawings.

2. Feed the supply directly into the hydraulic accumulator system water pumps,

providing a flooded suction at all times.

3. An automatic shut-off is required on the hydraulic water pumps feed to the

accumulator to prevent over filling from source water pressure once hydro-

pneumatic tank is full.

K. Valves

1. Provide valves in accordance with this section.

2. Hydraulic Actuation System Valve Control Panels: Provide an additional

speed control valve for emergency close cycle. Provide solenoid valves

rated 120 V AC for normal close operation and emergency close operation.

Provide the control valve, needle valve type, with a calibrated adjusting

knob and constructed of brass or stainless steel materials.

3. Operate the directional valves at a hydraulic water pressure of 60 psig

minimum and 150 psig maximum.

L. Field Instrumentations for Hydraulic Actuation System Valve Control Panels:

1. Provide gauges in accordance with Section 40 91 00.

2. Pressure gauge for each check valve control system: Provide gauges with a

minimum of 4-1/2 inch diameter dial plainly marked and 1/2- inch NPT

bottom connection. Connect the gauges with brass pipe, fittings and

isolating stopcocks. The scale range of each gauge must be 0 to 300 psig.

3. Gauges shall be in accordance with ANSI B40.1 Grade 2A. The bourbon

tube shall be of bronze construction. The case shall be black phenolic with

clear acrylic window. Gauges shall have provision for zero adjustment.


Addendum No. 1

4. All fittings must be brass, copper, or stainless steel.

5. Provide full open and full close limit switches for each check valve.

6. Provide differential pressure switch. The differential pressure switch shall

be piped across the check and the discharge valve.

M. Hydraulic Piping

1. Piping installation: In accordance with Section 22 10 00.

2. Piping support: In accordance with Section 40 05 01.

3. Water Piping: For 1 inch and smaller, Type K copper tubing soldered with

95/5 solder. The central system piping, as well as extensions to each pump

shall be tested at 215 psig for 1 hour.

4. Air Piping: Stainless steel.

N. Shop Painting

1. Interior of hydropneumatic tank: sandblasted and painted.

2. Exterior of hydropneumatic units: painted grey epoxy over an epoxy primer.

3. Provide painting in accordance with Section 09 96 00.

O. System Controls for Hydraulic Accumulator Systems

1. Control system shall be PLC based. Provide PLC system conforming to

Section 40 94 43.

2. Provide Ethernet connection to the Pumping Station Local Area Network

through Network Access Panel (by others).

3. Provide the tag names and/or registers of the signals to be monitored by the

SCADA system to the System Integrator.

4. Provide a NEMA 12 painted steel control panel containing the necessary

main circuit breaker, motor circuit protectors, motor starting contactors for

the air compressor motors and the hydraulic pump motors, transformers,

reset buttons, hand-off-automatic selector switches, LED type pilot lights,

control relays, terminal strips, pressure gauge, pressure switches, and any

additional equipment necessary by the manufacturer for proper operation of

the system. Provide an adequately sized single power feed to each control

panel at 480 V AC for power to the entire hydraulic accumulator system.

Provide control panel and equipment in accordance with Section 40 94 43.

Provide all process control instrumentation in accordance with Section 40 91

00.


Addendum No. 1

5. The hydraulic pumps shall work alternately with a lead/lag circuit in such a

manner that if the lead pump fails to properly fill the accumulator tank, and

level continues to drop, the lag pump shall run to fill the accumulator tank.

A local, visual alarm with manual reset shall indicate operation of the lag

pump. If a pump fails to start, a pump failure alarm shall be transmitted to

the SCADA.

6. Pump “ON” status shall be transmitted to SCADA.

7. The air compressors shall operate in an alternating lead/lag circuit in such a

way that if the lead compressor is unable to build air pressure within the

pressure tank, the lag compressor shall be started. A local, visual alarm with

manual reset shall indicate operation of the lag air compressor. Each air

compressor “ON” status shall be transmitted to SCADA.

8. Provide fluid level control devices for each accumulator tank. Accumulator

low air pressure and low level alarms shall be transmitted to SCADA.

9. Provide sight gages with shutoff cocks to show the water level in the

accumulator tank.

P. Accessories

1. Provide drain lines and dirt pockets to collect foreign matter with cleanout

facilities.

2. Provide all necessary safety valves, strainers, pressure gauges and pressure

switches in accordance with Section 40 91 00 for proper system operation.

Q. Prior to shipping the systems, conduct a shop test that demonstrates that the unit

fulfills the operating requirements of the Specifications.

R. Upon completion of installation, provide service of a qualified field service

engineer to inspect the installation, place the equipment in service, and instruct

City’s personnel in the proper operation, care and maintenance of the equipment.

Schedule the startup and training service with the Commissioner after the system is

completely installed and ready for start up.

2.13 RECORD EXISTING INFORMATION PRIOR TO INSPECTION OF THE

CHECK VALVES AND DISCHARGE VALVES

A. Record all existing field information prior to disturbing pumps and valves. This

field information will be presented to the Commissioner for approval.

B. Include the following within the field information:

1. Pressure differentials upstream and downstream of valve


Addendum No. 1

2. Supply pressure to the hydraulic cylinders (if applicable)

3. Opening and closing times (normal condition)

4. Closing time (emergency condition)

5. Orientation of valve, torque unit, and location of controls

2.14 INSPECTION, TESTING AND REPORTING ON CONDITION OF CHECK

VALVES CV-1, CV-2, CV-3, CV-4, CV-5 AND DISCHARGE VALVES DV-1,

DV-2, DV-3, DV-4 AND DV-5

A. Perform the following prior to inspection and testing of the valves:

1. Perform Work in accordance with Section 01 12 16.

2. Remove and abate the discharge piping insulation prior to removal of the

pump or inspection of the Pump discharge valve.

3. Close the pump’s corresponding suction valve, remove the Main Pump and

cap the suction inlet with a blind flange.

4. Coordinate with the City to locate and close the associated distribution

valve/s located on Fillmore Street and Central Park Avenue. All valves

outside of the Pump Station shall be operated (opened and closed) by the

City.

5. Prepare the project site for any leakage during the test such that the station

is not flooded.

B. Inspection and Testing of the Check and the Discharge Valves:

1. Inspection of the Check Valves (when not under pressure)

a. Close the associated Pump discharge valve.

b. Close the associated distribution valves.

c. Drain the pipe in between the check valve and the Pump discharge

valve.

d. Operate the check valve with the existing actuation cylinder 10

times and note for any abnormalities in open or close operation.

e. Inspect the valve, visible seating surfaces, operator, and linkage

components, if feasible, prior to installation of blind flange.

2. Leakage Testing of the Check Valves (under pressure): Perform leakage test

upon completion of the inspection of the check valve as follows:


Addendum No. 1

a. Close the check valve.

b. Open the Pump discharge valve.

c. Open the distribution valve.

d. Fill the discharge pipe with water.

e. Measure leakage through the valve against header pressure for 10

minutes or until 50 gallons has leaked.

f. Repeat the leakage test three (3) times.

g. In between testing, close the Pump discharge valve and empty the

water in between Pump discharge and check valve by opening the

check valve and then reclose the check valve for testing.

3. Inspection of the Pump Discharge Valve (when not under pressure)

a. Open the check valve.

b. Close the distribution valve.

c. Drain the pipe in between the Pump discharge valve and the

distribution valve.

d. Operate both check and discharge valve 10 times and note for any

abnormalities in open or close operation.

4. Leakage Testing of the Pump Discharge Valves (under pressure): Perform

leakage test upon completion of the inspection of the Pump discharge valve

as follows:

a. Open the check valve.

b. Close the Pump discharge valve.

c. Open the distribution valve/s.

d. Fill discharge pipe in between the Pump discharge valve and the

distribution valve with water.

e. Measure leakage through the valve against header pressure for 10

minutes or until 50 gallons has leaked.

f. Repeat the leakage test three (3) times.

C. Reporting on the Inspection and Testing of the Check and the Pump Discharge

Valves: Submit a certified report on each valve by a company that is a member of


Addendum No. 1

the Valve Repair Council of the Valve Manufacturers of America. The report at a

minimum to include the following:

1. Existing field information listed within 2.13.B with pictures.

2. Abnormalities in open and close operation.

3. Inspection of the valve, visible seating surfaces, operator and linkage

components.

4. Leakage test procedures and test data.

5. Recommendations for refurbishment that include refurbishment procedures,

materials, and costs associated with the refurbishment and a schedule.

6. Recommendations for replacement that include the conditions of the valve

are non-repairable, replacement options, costs and a schedule.

7. Submit 10 copies of the report to the Commissioner. The refurbishment and

replacement of a valve will commence upon an acceptance and approval of

the scope of work from the Commissioner.

PART 3 EXECUTION

3.1 EXAMINATION

A. Examine piping system for compliance with requirements for installation

tolerances and other conditions affecting performance of valves. Proceed with

installation until unsatisfactory conditions have been corrected.

B. Examine valve interior for cleanliness, freedom from foreign matter and corrosion.

Remove special packing materials such as blocks that are used to prevent

movement during shipping and handling.

C. Examine threads on valve and mating pipe for form and cleanliness.

D. Examine mating flange faces for conditions that might cause leakage. Check

bolting for proper size, length, and material. Check gasket material for proper size,

material composition suitable for service, and freedom from defects and damages.

3.2 INSTALLATION

A. General: Install valves as indicated on Drawings, in accordance with the

manufacturer's recommendations approved shop drawings and as specified in

Division 1.

B. Install valves with unions or flanges at each piece of equipment at an orientation to

allow servicing, maintenance, and equipment removal without system shutdown.


Addendum No. 1

C. Install valves in a position to allow full stem movement.

D. Install valves in horizontal piping with stem at or above the center of the pipe.

E. Locate valves for easy access and provide separate support where necessary.

3.3 REFURBISHING OF CHECK VALVES CV-1, CV-2, CV-3, CV-4, CV-5 AND

DISCHARGE VALVES DV-1, DV-2, DV-3, DV-4 AND DV-5

A. Perform Work in this section only if the valve is approved for off-site refurbishment

by the Commissioner.

B. Upon approval to refurbish a check or discharge valve off site, provide blind

flanges as required to prevent water leakage into the Pumping Station.

C. Shipment of the valves:

1. Check the valve for any hazardous waste prior to removal from line and

remediate valve if necessary for hazardous substances.

2. Disconnect valve from piping and prepare for shipment by completing the

following:

a. Drain the water from the valve.

b. Close the valve

3. Package the valve for transport to the refurbishment facility in a manner that

no damages are incurred during transportation of the valve or any

components to or from the refurbishment facility.

D. Inspection:

1. Perform the following procedures on the valves and include within the

inspection report:

a. Identify each part by stamp or etching.

b. Document the following with photographs:

(1) Condition of the existing bushings and journals.

(2) Condition of the shaft nut threads.

(3) Condition of the lift/operating shaft along wear seal area –

looking for washout, wear, or galling.


Addendum No. 1

(4) Metal seats – provide touch up weld, machine, and regrind

surface to meet AWWA C507 requirements.

(5) Resilient seals such as o-rings, seals, or v-packing.

c. Shaft:

(1) Remove the shafts and set-up on V blocks.

(2) Inspect the shaft by using a dial indicator.

(3) Measure using a micrometer, measure all of the various sizes

used to locate the associated parts found on the shaft. Note

these sizes on the shaft profile shop drawing.

E. Inspection Report: Prepare a written inspection report, complete with photographs

of “as received” condition, for each element. Include results of the inspection

along with recommendations to restore the element to like new condition, the cost

for refurbishment, and a schedule in the report. Include discussion of any special

procedure such as weld repair.

F. Factory Witness Test and Inspection

1. For witness test and inspection requirements refer to Section 26 05 10.

2. The Commissioner will witness test and inspect the valves and all

components. Provide the Commissioner with 10 sets of certified factory

inspection reports (reports must include complete test procedures and all

Work proposed for the valve and its components). The Commissioner will

conduct an onsite inspection to verify the result of the inspection report.

These certified factory inspection reports and test procedures will be

reviewed and accepted by the Commissioner prior to scheduling the factory

visit date. Provide the Commissioner with the factory testing date in writing.

Provide a minimum of two weeks advance notice prior to the factory test.

3. Complete the factory witness inspection for each valve in one trip.

G. Refurbishment

1. Replace the bushings and journals.

2. Replace all resilient seats.

3. Replace shafts and nuts if necessary.

4. Using vertical lathe, machine off existing weld on seats on both body and

ball/cone.

5. Weld on new seat material, using no lead in process.


Addendum No. 1

6. Machine rough cut and grind new seats on cone/ball and body.

7. Repaint valve body, torque unit, and cylinder.

8. Reassemble valve, torque unit, and cylinder and test valve per AWWA

C507 requirements.

9. Provide for Witness Test and inspection at factory and record and submit

witness test for approval.

10. Provide final paint coat and ship to Pumping Station for Contractor to

reinstall.

H. Payment: Additional refurbishments so authorized in writing by the

Commissioner will be paid as a change order.

3.4 PAINTING AND COATING

A. General: Unless otherwise specified, coat the inside iron or steel surfaces of all

valves and exterior surfaces of valves and operators that are to be buried in the

ground or immersed in water with two coats of asphalt varnish. Paint exterior

surfaces of other valves and operators as specified in Section 09 96 00.


A. Manufacturer's Field Services: Furnish the services of a qualified representative of

each of the various manufacturers to provide instruction on the proper installation

of the equipment, inspect the completed installation, make any necessary

adjustments, participate in the startup of the equipment, participate in the field

testing of the equipment, and place the equipment in trouble-free operation, as

specified in Division 1.

B. Tests: After installation of the valves, control equipment and all appurtenances,

subject the units to a field running test, as specified in Division 1, under actual

operating conditions. Operate each valve through one complete open-close cycle

under the maximum pressure differential practical.

3.6 OPERATION DEMONSTRATION

A. Manufacturer's Field Services: Furnish the services of a qualified representative of

each of various manufacturer's to demonstrate the proper operation and instruct

pump station personnel in the equipment's operation and maintenance, as specified

in Division 1.

B. For the Water Hydraulic Actuation and Accumulator Systems, provide two (2)

days for startup and one (1) day for operator training. Provide training as specified

in Section 01 79 00.


Addendum No. 1

3.7 PAINTING

A. Paint the equipment in accordance with the requirements in Section 09 96 00.

3.8 SCHEDULE

A. Abbreviations used in the schedule are as follows:

Joints

B&S Bell and Spigot

F Flanged

G Grooved End

Lu Lug

MJ Mechanical Joint

Sc Screwed

Sd Soldered

SW Solvent Welded

W Welded

Operators

BS Bench Stand

D Diaphragm

E Electric Motor (Nonmodulating)

F Float

FS Floor Stand

H Handwheel

HC Hydraulic Cylinder (High Pressure)

L Lever

ME Modulating Electric Motor

N Nut

PC Pneumatic Cylinder

S Solenoid

WC Water Cylinder (Low Pressure Hydraulic Cylinder)


Addendum No. 1

VALVE SCHEDULE

Facility/Service

Valve Type Size

Inches Joint

Type Operator

Type

Remarks

PUMP ROOM

Hydraulic System

Ball/Globe

1/2 - 3

4 – 6

Sc

F

H

H

Hydraulic System Solenoid 3 Sc S Main Pump No. 1 Suction (SV-1B) Gate 36 F E Main Pump No. 2 Suction (SV-2B) Gate 36 F E

Main Pump No. 3 Suction (SV-3), No. 4

Suction (SV-4), and No. 5 Suction (SV-5) E

Provide only

operator. Main Pump No. 1 Discharge (DV-1), No.

2 Discharge (DV-2), No. 3 Discharge

(DV-3), No. 4 Discharge (DV-4), and No.

5 Discharge (DV-5)

E Provide only

operator.

Air Compressor Butterfly 6 or less Lu L Sump Discharge Eccentric Plug 2

2-1/2 - 3

4

Sc

F

F

L

L

L

Submerged

3-way

Natural Gas Lubricated Plug 1/2 - 2

2-1/2 - 4 Sc

F L

L

END OF SECTION


Addendum No. 1


CDWMCPPS 40 42 00-1 Mechanical Insulation – Process

Addendum No. 1

SECTION 40 42 00

MECHANICAL INSULATION - PROCESS

PART 1 GENERAL

1.1 SUMMARY

A. Section includes: Mechanical insulation for piping and equipment.


following:


2. Section 40 05 03 - Mechanical Identification

1.2 REFERENCES


1. ASTM C 195- - Mineral Fiber Thermal Insulation Cement

2. ASTM C 533 - Calcium Silicate Block and Pipe Thermal Insulation

3. ASTM C 552 - Cellular Glass Block and Pipe Thermal Insulation

4. ASTM C 553 - Mineral Fiber Blanket and Felt Insulation

5. ASTM C 547 - Mineral Fiber Pipe Insulation

6. ASTM C 612 - Mineral Fiber Block and Board Thermal Insulation

7. ASTM C 921 - Practice for Determining the Properties of Jacketing

Materials for Thermal Insulation

8. ASTM E 84 - Test Method for Surface Burning Characteristics of

Building Materials

9. NFPA 255 - Surface Burning Characteristics of Building Materials

10. UL 723 - Surface Burning Characteristics of Building Materials


Addendum No. 1

1.3 SUBMITTALS


Division 1.

B. Product Data: Submit the manufacturer's technical product data, insulation

materials, fire ratings, material safety data sheets and installation instructions for

each type of mechanical insulation. Submit a schedule showing the manufacturer's

product number, k-value, thickness, density, and furnished accessories for each

mechanical system requiring insulation.

C. Maintenance Data: Submit maintenance data and replacement material lists for

each type of mechanical insulation. Include this data and product data in the

maintenance manual.


A. Manufacturer's Qualifications: Substantial documented experience required for

company manufacturing the equipment of this Section

B. Installer's Qualifications: Substantial documented experience required for

company specializing in performing the Work if this Section.

C. Flame/Smoke Ratings: Provide composite mechanical insulation (insulation,

jackets, coverings, sealers, mastics and adhesives) with flame-spread index of 25

or less, and smoke-developed index of 50 or less, as tested by ASTM E 84 (NFPA

255) method.

1.5 DELIVERY, STORAGE, AND HANDLING

A. General: Deliver, store and handle all products and materials as specified in

Division 1 and as follows.

B. Labeling: Deliver the insulation, coverings, cements, adhesives, and coatings to

the site in containers with the manufacturer's stamp or label, affixed showing the

fire hazard indexes of products.

C. Protection: Protect the insulation against dirt, water, and chemical and mechanical

damage. Do not install damaged or wet insulation and remove damaged materials

from the project site.

1.6 SPARE PARTS

A. Not Used


Addendum No. 1

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. General: Acceptable manufacturers are listed below:

1. Armstrong World Industries, Inc.

2. Babcock and Wilcox; Insulating Products Div.

3. Certainteed Corp.

4. Knauf Fiber Glass GmbH.

5. Manville Products Corp.

6. Owens-Corning Fiberglas Corp.

7. Pittsburgh Corning Corp.

8. Rubatex Corp.

9. Raychem Corp. (Electric Heat Tracing)

10. Thermon Manufacturing Co. (Electric Heat Tracing)

11. Pipe Shields Inc. - "Thermal-Hanger Shields"

12. IMCOA (Refrigerant Piping)

2.2 MATERIALS

A. Piping Insulation: Provide fiberglass piping insulation meeting ASTM C 547,

Class 1 unless otherwise indicated.

1. Pipe insulation: Provide heavy duty bonded fibrous glass sectional pipe

insulation with a thermal conductivity not exceeding 0.26 BTU per hour per

square foot per degree F per inch thickness at 50 degrees F mean

temperature.

2. Jackets for Piping Insulation: Provide jackets meeting the requirements of

ASTM C 921, Type I for piping with temperatures below ambient, and Type

II for piping with temperatures above ambient. As an option Type I may be

used for all piping as approved by the Commissioner.

a. Encase pipe fitting insulation with one-piece premolded PVC fitting

covers, fastened as per the manufacturer's recommendations.

b. Encase exterior piping insulation with an aluminum jacket which is of

weather-proof construction.

3. Accessories: Provide the following accessories:

a. Provide staples, bands, wires and cement as recommended by the

insulation manufacturer for the applications indicated.

b. Provide adhesives, sealers, and protective finishes as recommended

by the insulation manufacturer for the applications indicated.


Addendum No. 1

B. Equipment Insulation

1. Rigid Fiberglass Equipment Insulation: Provide insulation that meets

ASTM C 612, Class 2, with "K" value of 0.24 at 200 degrees F, and 3

lb/cu.ft. density.

2. Jacketing Material for Equipment Insulation: Provide pre-sized glass cloth

jacketing material, not less than 7.8 ounces per square yard, or metal jacket

at the Contractor's option, except as otherwise indicated.

3. Accessories: Provide the following accessories:

a. Provide adhesives, cements, sealers, mastics and protective finishes as

recommended by the insulation manufacturer for the applications

indicated.

b. Provide staples, bands, wire, wire netting, tape, corner angles, anchors

and stud pins as recommended by the insulation manufacturer for the

applications indicated.

C. Thermal Hanger Shields: Provide insulated pipe protectors consisting of a 360-

degree high density, 100 psi, waterproofed calcium silicate inserts encased in 360-

degree sheet metal shields. On water pipes provide protectors with insulation

extended 1-inch beyond the sheet metal shield.

1. Provide the thickness of the insulation insert to be the same as the adjoining

pipe insulation, and sheet metal gauge in accordance with the manufacturer's

recommendations.

PART 3 EXECUTION

3.1 INSPECTION

A. General: Examine areas and conditions under which mechanical insulation is to be

installed. Do not proceed with Work until unsatisfactory conditions have been

corrected in manner acceptable for insulation installation.

3.2 PIPING SYSTEM INSULATION

A. Piping Application Requirements: Insulate the following piping systems:

1. Plant water.

2. Main pump suction and discharge.


Addendum No. 1

3. Insulate each piping system specified above with the following type and

thickness of insulation:

a. Fiberglass: 1-inch thickness.

B. Jackets for Piping Insulation: Install jacketing on all piping insulation.

C. Thermal Hanger Shields: Provide insulated pipe protectors at all support points.

3.3 EQUIPMENT INSULATION

A. Equipment Application Requirements: Insulate the following equipment:

1. Main pumps.

2. Main pump suction valves, discharge valves, and check valves.

3. Insulate each item of equipment specified above with the following types

and thicknesses of insulation:

a. Fiberglass: 2 inches thick.

B. Jackets for Equipment Insulation: Jacket equipment insulation.

3.4 INSTALLATION

A. General: Install piping and equipment thermal insulation in accordance with the

manufacturer's recommendations and approved shop drawings, and as specified in

Division 1. Install all products in accordance with the recognized industry

practices so that insulation serves its intended purpose.

B. Piping Insulation

1. Order of Installation: Install insulation on pipe systems subsequent to the

installation of testing, and acceptance tests.

2. Insulation Surfaces: Install the insulation materials with smooth and even

surfaces. Insulate each continuous run of piping with full-length units of

insulation, with a single cut piece to complete the run. Do not use cut pieces

or scraps abutting each other.

3. Cleaning and Drying: Clean and dry pipe surfaces prior to insulating. Butt

insulation joints firmly together to form a complete and tight fit over the

surfaces to be covered.

4. Integrity: Maintain integrity of the vapor-barrier jackets on pipe insulation,

and protect to prevent puncture or other damage.


Addendum No. 1

5. Insulating Fittings: Cover valves, fittings and similar items in each piping

system with an equivalent thickness and composition of insulation as

applied to the adjoining pipe run. Install factory molded, precut or job

fabricated units except where a specific form or type is indicated.

6. Penetrations: Extend piping insulation without interruption through walls,

floors and similar piping penetrations, except where otherwise indicated.

7. Pipe Hangers: Butt pipe insulation against pipe hanger insulation inserts.

For piping apply a wet coat of the vapor barrier lap cement on butt joints and

seal the joints with a 3 inch wide vapor barrier tape or band.

8. Pipe exposed to weather: Provide water tight aluminum jackets to protect

piping located outside.

C. Equipment Insulation:

1. Insulation Surfaces: Install the insulation materials with smooth and even

surfaces and on clean and dry surfaces. Redo poorly fitted joints. Do not

use mastic or joint sealer as a filler for gapping joints and excessive voids

resulting from poor workmanship.

2. Integrity: Maintain the integrity of the vapor-barrier on equipment

insulation and protect it to prevent puncture and other damage.

3. Hot Equipment: Do not apply insulation to equipment, breechings, or stacks

while they are hot.

4. Staggered Joint Method: Apply the insulation using the staggered joint

method for both single and double layer construction, where feasible. Apply

each layer of insulation separately.

5. Coating: Coat insulated surfaces with a layer of insulating cement, troweled

in a workmanlike manner, leaving a smooth continuous surface. Fill in

scored block, seams, chipped edges and depressions, and cover over wire

netting and joints with cement of sufficient thickness to remove surface

irregularities.

6. Jackets: Cover the insulated surfaces with all-service jacketing neatly fitted

and firmly secured. Lap the seams at least 2 inches. Apply over vapor

barrier where applicable.

7. Insulations Omitted: Do not insulate boiler manholes, handholes, cleanouts,

the ASME stamp, and the manufacturer's nameplate. Provide a neatly

beveled edge at interruptions of insulation.


Addendum No. 1

8. Removable Insulation: Provide removable insulation sections to cover parts

of equipment which must be opened periodically for maintenance, including

metal vessel covers, fasteners, flanges, frames and accessories.

9. Equipment Exposed to Weather: Protect outdoor insulation from weather

with the installation of a weather-barrier mastic protective finish, or

jacketing, as recommended by the manufacturer.

3.5 EXISTING INSULATION REPAIR

A. Repair:

1. Repair sections of existing mechanical insulation damaged during

construction. Use insulation of same thickness as the existing insulation.

Install a new jacket lapping and sealer over the existing insulation and paint

to match the existing surface color.

2. Repair sections of existing mechanical insulation damaged during

construction containing hazardous materials in accordance with Section 02

82 13 and/or 02 83 19 should damaged sections contain hazardous materials.

3.6 PROTECTION AND REPLACEMENT

A. Replacement: Replace damaged insulation which cannot be satisfactorily repaired,

including units with vapor barrier damage and moisture saturated units.

B. Protection: Follow methods which are required for protection of the insulation

Work during the remainder of construction period, to avoid damage and

deterioration.

END OF SECTION


Addendum No. 1


CDWMCPPS 40 80 50-1 Process Control System

Addendum No. 1 Commissioning

SECTION 40 80 50

PROCESS CONTROL SYSTEM COMMISSIONING

PART 1 GENERAL

1.1 SUMMARY

A. 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. Substantial documented experience required for company specializing in

performing the work of this section’ Retain the services of a System Integrator,

with substantial documented experience, to provide, supervise and perform check-

out and start-up of all Process Control System components. Provide the services of

an authorized manufacturer's representative to check the equipment installation and

place the equipment in operation. The manufacturer's representative shall be

thoroughly knowledgeable about the installation, operation and maintenance of the

equipment.

C. Relocate the existing SCADA monitoring cabinet to the new Server room for the

duration of the project. Remove and demolish the cabinet and associated wiring

after the last pump selected for electrification is taken out of service.

D. Related work specified in other sections includes, but is not limited to, the

following:

1. Section 01 33 00 - Submittals

2. Section 01 12 15 - Construction Work Sequence and Limitations

3. Section 01 79 00 - Training

4. Section 40 90 00 - Process Control System General Requirements

5. Section 40 90 50 - Process Control Descriptions

6. Section 40 91 00 - Process Control System Instruments

7. Section 40 94 13 - Process Control Systems Computer and Network

Hardware


9. Section 40 95 13 - Process Control System Panel Enclosure and Equipment

10. Section 40 96 15 - Process Control System Input and Output list

11. Section 40 98 00 - Process Control System Training

12. Section 40 98 50 - Process Control System Factory Testing

1.2 SUBMITTALS


01, Sections 01 33 00.



B. Submit the following

1. Test Plan

2. Test Schedule

3. Testing Tools

4. Test results

1.3 SYSTEM CHECKOUT AND START-UP

A. Perform the following:

1. Check and approve the installation of all Process Control System

components and all cable and wiring connections between the various

system components.

2. Conduct a complete system checkout and adjustment, including checking

each components functions, and testing of final process control system

instrument, device, computer, and network functions. Promptly correct any

problems encountered to prevent any delays in start-up of the process

control system network.

B. Provide all test equipment necessary to perform the testing during system checkout

and start-up.

C. Responsible for initial operation of the process control system. Make any required

changes, adjustment or replacements necessary to the system to perform the

intended functions.

D. Furnish The Commissioner 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 the Contractor, System Integrator, and

Packaged System Supplier.

1.4 INTEGRATED SYSTEM FIELD TEST

A. Perform a complete system test to verify that all process control system,

instrumentation and controls equipment, network hardware, and software are

operating properly as a fully integrated system, and that the intended network

functions are fully implemented and operational.

B. Correct any defects or problems found during the test and then retest to

demonstrate proper operation.



1.5 30-DAY TEST

A. The 30-Day Test is a period of time during which the control system shall be

utilized by the City in day-to-day operations. The purpose of the process control

system 30-day test is to test the control system stability and completeness over

time. This test shall occur in conjunction with all other systems included in the

project.

B. Start the 30-Day Test upon written approval from the Commissioner.

C. 30-Day Test shall continue until a time frame has been achieved wherein the

system (both hardware and software) availability meets or exceeds 99.7 percent for

30 consecutive days and no system failures have occurred which result in starting

the 30-Day Test over. During the 30-Day Test the system shall be available to

plant operating personnel for use in normal operation of the plant.

D. For the purpose of the 30-Day Test, the system will be defined as all new control

system work installed under this Contract, as well as any modifications made to

the existing control system.

E. Terminate the 30-Day Test if one or more of the following occur. Following

correction of the problem, a new 30 consecutive day 30-Day Test shall begin.

1. Failure to repair a hardware or software problem, causing one or more

processes to halt execution, within 72 consecutive hours from the time of

notification failure(s).

2. Recurrent hardware or software problems: If the same type of problem

occurs three times or more.

F. The following conditions shall constitute a system failure in determining the

system availability based on the equation specified in Paragraph 1.5.G, below and

shall precipitate a restart of the test:

1. Loss of communications between devices on the process control system

networks.

2. Failure of one or more network devices

3. Failures of any device impacting two or more process control system

components simultaneously.

4. Failure of Power Supply: Where redundant power supplies are provided,

failure of one power supply shall not constitute a system failure provided the

backup power supply operates properly and maintains power supply.

Failure of the backup supply to operate properly and maintain supply power

shall constitute a system failure.



5. The system shall be considered down if the system cannot generate the

periodic reports, alarm log or event log. The report and logs need not appear

on the printer originally selected for the report.

6. Downtime caused by primary utility power failure shall not count as

downtime.

7. Loss of any microprocessor shall be considered downtime.

8. Loss of more than 5 percent of the total inputs or outputs shall be considered

downtime.

9. The accuracy and precision of 90 percent of the analog inputs and outputs

must be within the limits specified, or the system shall be considered down.

10. The time between notifying the Contractor of a system failure and the time it

has been corrected and back on line.

11. Shutdown of the critical systems from a software fault shall be considered

downtime.

G. The system availability shall be calculated based on the following equation:

A = TTO x 100 percent

TTO + TTR

Where A = system availability in percent

TTO = total time in operation

TTR = total time to repair

H. Time to repair shall be the period between the time that Contractor is notified of a

system failure and the time that the system has been restored to proper operation in

terms of hours with an allowance for the following dead times which shall not be

counted as part of the time to repair period.

1. Actual travel time for service personnel to get to the Site up to four hours

per incident from the time Contractor is notified of a system failure.

2. Time for receipt of replacement parts to the Site once identified up to 24

hours per incident. Work done on the system while waiting for delivery of

replacement parts does not stop the failure clock.

3. Dead time shall not be counted as part of the system available period. The

dead time shall be logged and the duration of the 30-Day Test extended for

an amount of time equal to the total dead time. Dead time shall be totalized.



I. Supply all parts and maintenance materials required to repair the system prior to

completion of the 30-Day Test at no additional cost to THE CITY. Immediately

replace parts obtained from the Contract spare parts inventory.

1.6 SPARE PARTS

A. Not used.

PART 2 SOFTWARE SITE ACCEPTANCE TESTING

2.1 GENERAL

A. The Process Control System (PCS) Site Acceptance Test (SAT) is focused on

verifying that all instrumentation, equipment, SCADA and controller hardware and

software is working properly and that all software configurations match the

requirements identified in the Detailed Software Design, including the detailed

process narratives. Successful completion of the SAT is considered to be a critical

project milestone. Contractor shall test the software under all possible process

conditions in order to demonstrate the robustness of the software. The software test

shall be witnessed by Commissioner.

B. In general, the SAT consists of repeating of Section 40 98 50 Process Control

System Factory Testing using the actual field inputs/outputs once all field

equipment has been installed and successfully tested. Hence many of the

procedures are identical to the activities identified in the FAT procedures.

C. Carry out SAT testing for all SCADA and controller software including packaged

and vendor supplied products as a whole system.

2.2 PREREQUISITES

A. Equipment start-ups completed with manufacturer representatives including all

mechanical equipment required to fully test the operation of the software.

B. All required instrumentation to be installed, calibrated and tested prior to starting

SAT.

C. All required network equipment to be installed and tested prior to starting the first

converted pump SAT.

D. The SAT & Start-Up Test plan is to be submitted and approved by the

Commissioner no later than four (4) weeks in advance of the SAT.

E. All panel I/O must be wired up, tested and signed off 100% prior to commencing

SAT unless otherwise approved by Commissioner. Submit a request to defer I/O

testing until after the SAT for review and approval at the same time when the SAT

& Start Up test plan is submitted for review and I/O is not available. Identify the



reason for deferring I/O testing in the request along with a proposed date when the

I/O shall be tested.

2.3 START-UP TEAM

A. The Start-Up Team consisting of individuals from the Commissioner, Contractor

and System Integrator.

B. The Start-Up Team shall review the testing plan, SAT & Start-Up Plan and revise,

if necessary, at a pre-SAT & Start-Up meeting to be scheduled no later than six (6)

weeks in advance of the proposed SAT period.

C. Provide details for the SAT & Start Up Plan to clearly identify the proposed test

procedure for the equipment and software

D. The SAT testing shall be witnessed by the Start-Up Team.

E. Members of the Start-Up Team are to be identified at the pre-SAT & Start Up

meeting. These team members will be involved throughout the process and are to

be changed only with the approval of the Commissioner.

2.4 PURPOSE AND SCOPE

A. The goal of software testing is to verify that the system released for use by Station

Operators meets the contract requirements, and is error-free. Software installed or

modified under the project shall not adversely affect the operation of other systems

currently in operation at the Pumping Station. All functionality that is currently

available within the system must remain available at the completion of the testing.

B. Test all software installed on the project to confirm that the software developed,

tested and installed under the project conforms to the approved process control

narratives.

C. All software is to meet the requirements of the project specifications including all

operational control, monitoring and alarming, as well as integrates all vendor

packaged systems as defined within the contract documents.

D. Testing is intended to demonstrate that all software developed not only works

locally at the Pumping Station (CPPS) but that it is fully functional at the Jardine

WPP and all other eleven (11) pumping stations SCADA systems. All system-

wide testing is to be conducted concurrently with the local testing to confirm

operation throughout the system-wide system. Contractor must be aware that iFix

version at Jardine WPP and other stations may not be the same version as

implemented at CPPS and these other stations may require additional

programming and configuration to develop the SCADA screens for

implementation of remote operation at these contract required locations.



2.5 DEFINITIONS

A. Software testing is defined as the execution of a program to find its faults, not just

a process to verify its correctness.

B. Other definitions are:

1. Verification: The process of proving the program’s correctness.

2. Validation: An attempt to find errors by executing a program in the

controllers, SCADA Servers, Control nodes, and Monitoring nodes.

3. Debugging: Diagnosing the precise nature of a known error then correcting

it. Debugging is a “fix” activity, not strictly a testing activity.

4. Errors: Human mistakes; errors in design definition or interpretation of the

design by the programmer.

5. Defects: Improper program conditions that are generally the result of an

error. Not all errors produce defects (as with incorrect program comments,

for example).

6. Bugs: A fault that is a program defect found when the program is being

tested or is in operational use. Bugs result from defects, but all defects do

not necessarily produce bugs.

2.6 OBJECTIVES

A. The following identifies the overall objectives of the PCS Site Acceptance Test.

1. Confirm and document that the PLC I/O matches the panel shop drawings in

terms of input/output configuration, tagging and function;

2. Confirm and document that the individual device logic operates all field

equipment correctly and safely, as described in the detailed process control

narrative;

3. Confirm and document that the control logic operates the facility correctly

and safely, as reviewed at the FAT and also described in the detailed process

control narrative;

4. Confirm and document the data integration with Jardine WPP Historian as

described in the detailed process control narrative is correct;

5. SAT testing is to be conducted for both Pumping Station PLCs and network

connected vendor supplied PLCs.



2.7 APPROACH

A. As part of the testing process regression testing is to be incorporated into all test

plans to demonstrate that any changes made to the software do not impact other

areas of the logic. This approach shall ensure that corrections/modifications have

not adversely affected the previously tested (and debugged) systems and system

components.

B. Testing is to be both progressive and regressive. Progressive testing introduces

and tests new functions and uncovers problems in the newly added or modified

modules and in their interfaces. Regressive testing concerns the effects of newly

introduced changes or system components on all previously integrated (tested)

code.

C. The goal of software testing is to ensure that the system released for use by users

meets the contract requirements, is error-free and does not adversely affect other

systems.

2.8 TEST SUCCESS CRITERIA

A. Test success shall be based on the number of defects and the defect severity levels

encountered during the testing period. The Commissioner at their discretion shall

determine to restart a new SAT.

B. Refer to Section 1.5 above for additional details on defects and their impacts on the

testing period.

2.9 COMPLETION CRITERIA

A. Testing of software is deemed to be complete when all features, functions and

information required in accordance with the Process Control System Description,

Process and Instrumentation Drawings, and the complete functionality as described

in the contract documents has been verified as present and functioning, and

documented as accurate within the anticipated operating range for the process

being monitored and controlled

2.10 PARTICIPANT AND RESPONSIBILITIES

The roles and responsibilities for test planning and testing are summarized below.

A. SAT & Start-Up Test Planner (Contractor):

1. Develops the complete SAT & Start-Up test plan

2. Develops the schedule.

3. Coordinates all meetings identified in the contract documents to develop and

implement the test plan.



4. Coordinates the involvement of all team members and equipment

manufacturers required to be present during testing.

5. Develops/compiles the test data.

6. Oversees the test planning and test plan execution of the process control

system.

7. Obtains approval for test plan and schedule from Commissioner and City.

8. Documents test results

B. Commissioner:

1. Reviews and approves test plan.

2. Classifies defect severity.

3. Identifies system “design” defects (where the design does not match the

specification) and coding defects (where the system does not behave as

specified).

4. Reviews test results.

5. Assigns Level 1, 2 and 3 faults. Logs action required and taken in the

Software Action Log.

6. Assigns Level 4, 5 and 6 faults. Logs action required and taken in the

Software Action Log.

7. Maintains Software Action Log.

8. Maintains Deficiency Log related to other trades: electrical, instrumentation,

vendor packages, and others.

9. Presents Change Requests to the City for prioritization.

10. Schedules approved change request work.

11. Maintains Change Request Log.

12. Coordinate with City operations staff to avoid conflicts and minimize impact

to operations of construction activities.

13. Participate and assist in the acceptance testing.

14. Responsible for signing-off on the acceptance testing that the system is fully

functional as defined within the detailed process control narrative.



15. Oversee the integration of the software, including Historian, into the Jardine

WTP SCADA system.

C. System Integrator:

1. Responsible for defining the procedure required to complete the SAT &

Start-Up tests.

2. Responsible for directing the SAT and start-up testing and for providing

input to the Contractor as to which trades are required to complete the tests

identified within the test plan.

3. Installs and tests all software for functionality as per the detailed process

control narrative.

4. Fixes all defects.

5. Documents test results and forwards to Contractor.

PART 3 EXECUTION

3.1 GENERAL

This part provides an outline of the works to be carried out by the

Contractor/Commissioner/System Integrator as part of the PCS Site Acceptance

Test(s)

3.2 TEST SUB-PHASE

The types of software tests are:

1. Individual instruments, equipment, and process units: these sub-phases

test/verify that devices and their larger system parts (e.g. process units and

duty tables) perform as specified.

2. Intra-system Integration: tests/verifies the interfaces between units and the

associated process logic related to multiple units, and pumping station-wide

operating strategies.

3. Function: tests/verifies the functions the program is to perform as set out in

the detailed process control narratives.

4. Performance/Operational: tests/verifies the system’s performance under a

variety of conditions (normal/abnormal) and verifies these results against the

detailed process control narratives. Includes testing of the system’s

configuration, security, backup/recovery, and reliability in the planned

network architecture.



5. System Wide Integration: tests/verifies the operation of the CPPS facility

from Jardine WPP and eleven (11) other Pumping Stations.

3.3 DEFECT HANDLING

A. During testing, the need for changes to the system shall be identified. This shall be

as a result of a test failure or as a result of an incorrectly specified requirement

(test did not fail, but the requirement is incorrectly specified).

B. For test failures, the defect must be recorded in the SAT test document.

C. All defects shall documented by the System Integrator. All defects are to be

immediately reviewed and resolved during the SAT period.

D. The following “Fault Severity Index” is to be used for handling defects.

E. Testing cut-off points also need to be established in the test plan and reflected in

the testing schedule. Level 1, Level 2 and Level 3 faults shall be corrected as a

first priority and testing should not proceed to the next sub-phase until all Level 1,

2 and 3 faults are corrected.

F. The Commissioner determines the priority for correcting Level 4, 5 and 6 faults

and prioritizes all Change Orders.

G. Change Orders are prepared by the Commissioner. Possible implications of not

proceeding should also be identified. The City authorizes the work to be done

under any change Orders. The Contractor schedules change request work based on

the project priorities.

Defect

Severity

Level

Defect Description

1. Fault causes system to crash. System rendered unusable/non-functional.

2. Fault occurs in a critical function. Function is rendered unusable.

A critical function is defined as a function that is required to maintain operation

of the facility without manual intervention by the operations team.

3. Fault occurs in a critical function. A portion of the function is rendered

unusable.

4. Fault occurs in a non-critical function. Function is rendered unusable.

5. Fault occurs in a non-critical function. A portion of the function is rendered

unusable.

6. Cosmetic (e.g. typo) and would be unlikely to result in loss of confidence by

users.



3.4 SUCCESSFUL COMPLETION

A. The SAT is deemed successful when the following items have been completed:

1. SAT Test plan has been completed and signed-off.

2. All Level 1, 2 and 3 faults identified during the SAT have been corrected

and verified for correct operation.

3. The completed SAT plan has been reviewed and signed off by the

Contractor, System Integrator and The Commissioner.

3.5 FACILITY STARTUP PERIOD

A. Following successful completion of the SAT testing, the startup period may

commence. Contractor, Commissioner and System Integrator, are to be present

during the startup period.

B. Commissioner maintains a log of faults/deficiencies encountered during the startup

period. The Contractor/System Integrator is to immediately correct

faults/deficiencies at the request of the Commissioner. If any Level 1, 2 or 3 fault

occurs during the startup period, the test period shall be restarted from Day 1 after

completion of the software modifications and testing by the System Integrator.

C. Following completion of the startup period, the fault/deficiency log is submitted to

the Commissioner for review. Sign-off by Contractor, System Integrator, and the

Commissioner is required at the completion of the facility startup period.

3.6 TRAINING

A. Provide training in coordinated with and in accordance with the requirements

contained in Section 01 79 00 and detailed in Section 40 98 00, and related

sections.

END OF SECTION


Addendum No. 1 General Requirements

SECTION 40 90 00

PROCESS CONTROL SYSTEM GENERAL REQUIREMENTS

PART 1 GENERAL

1.1 SUMMARY

A. Section includes requirements for furnishing and installing process control system

(PCS) including all labor, materials, equipment and incidentals as shown, specified

and required to furnish, install, calibrate and place in operation a complete system

as illustrated on drawings, and as specified in the following related sections:

B. Related work specified in other sections includes, but is not limited to the

following:


2. Section 26 05 10 - Basic Electrical Material and Methods

3. Section 40 80 50 - Process Control System Commissioning

4. Section 40 90 50 - Process Control System General Requirements



Hardware



9. Section 40 96 15 - Process Control System Input and Output List



C. 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. The Contractor shall be responsible

for all elements specified and furnished as part of this section and related sections.

D. Substantial documented experience required for company specializing in

performing the work of this section. Assign complete responsibility for furnishing,

coordination, assembly, factory and field testing, installation supervision, training

and PLC services of all equipment to a qualified (as defined above) Systems

Integrator for manufacture, assembly, and production of systems of the type

specified. Provide a complete, satisfactory, and trouble-free operating installation.

1. System Integrator's Responsibilities

a. Engineering, furnishing, installation supervision, fabrication,

implementation and programming of the Process Control System and

all subsystems, including PLCs, instruments, field panels, networking

and network communication system, interface with the existing



Jardine WPP SCADA system and eleven other Pumping stations , and

all related instruments and controls in accordance with the Contract

Documents and all referenced standards and codes.

b. Preparation, assembly and correction of all submittals in accordance

with the Contract Documents.

c. Proper interfacing of the new equipment and panels, including

required interfacing with packaged control systems furnished by other

equipment suppliers, and integration with the existing Jardine WPP

control system and eleven other Pumping stations.

d. Supervision of the installation of all equipment required.

e. Calibration, testing and start up

f. Training of City personnel in operation and maintenance of the

process control system.

g. Handling of all warranty obligations for the system components.

h. Maintenance of two up-to-date reproducible copies of the complete

system and application software at the System Integrator's facility for

the duration of the warranty period. Software copies shall be

maintained and shall be directly loadable on the supplied system.

i. System Integrator shall retain the services of a certified Cisco

technician for programming of all switches, routers, and other Cisco

network devices.

1.2 REFERENCES

A. Section 01 42 00 – References.

B. Codes and Standards referred to in this Section are:

1. IEEE 802.3 10/100/1G Ethernet networks

2. ISA-S5.4 Instrument Loop Diagrams.

3. NFPA 70 National Electrical Code

4. UL Underwriter’s Laboratory

5. NEMA National Electrical Manufacturers Association

6. City of Chicago Electric Code



1.3 QUALITY CONTROL

A. General: Provide quality control, as specified in Section 01 45 00 – Quality

Control.


A. Pre-Submittal Conference:

1. Arrange and Conduct a pre-submittal conference on the process control

system (PCS) within 30 days of notification of preliminary acceptance of the

proposed supplier by the Commissioner.

2. The pre-submittal conference shall be attended by representatives of the

Contractor, System Integrator, and the Commissioner.

3. Allocate one full working day for the conference and that time shall be

included in the price of this Contract. The pre-submittal conference shall be

held at the job site or as located by the Commissioner.

4. The purpose of the pre-submittal conference is to review informally and

approve the manner in which System Integrator intends to respond to the

Contract requirements before any submittals are prepared.

5. Prepare the items listed below for presentation at the pre-submittal

conference. Submitted the information to the Commissioner three weeks

prior to the date of the conference.

a. A notarized letter signed by an Officer of System Integrator stating

that it has received a copy of all Contract Documents from the

Contractor including Specifications, all Division 1 Specifications, and

a complete set of Contract Drawings.

b. Resume of individual who shall be the Contractor’s coordinator for all

instrumentation and control issues furnished under all sections of the

Contract. Resume of the System Integrator Project Manager. Factory

Training certificates for all staff for programming and configuration.

c. List of equipment and materials required for the control system and

the brand and model which the Contractor proposes to use for each

item.

d. List of proposed exceptions to the plans and specifications along with

a brief explanation and justification of each, including cost impact.

Approval of the exceptions is not automatic and shall be subject to a

formal submittal review process.



e. Sample of each type of submittal specified herein. These may be

submittals prepared for other projects.

f. A flow chart showing the steps to be taken in preparing and

coordinating each control system submittal to the Commissioner, and

a list of proposed submittals.

g. Bar chart type schedule for all Process Control related activities from

the pre-submittal conference through start up and training. Particular

emphasis shall be given to dates relative to submittals, design,

fabrication, programming, factory testing, deliveries, installation and

field testing. The schedule shall be subdivided to show activities

relative to each major item or group of items when everything in a

given group is on the same schedule.

h. General outline of the type of tests to be performed to verify that all

sensors/transducers, instruments and digital processing equipment are

functioning properly. Tests shall include field calibration procedures,

field-testing, start-up procedures, and factory testing.

1.5 ABBREVIATIONS

A. EIA – Electronic Industries Association.

B. GUI –Graphical User Interface.

C. HIM – Human Machine Interface

D. IM – Instrumentation Manufacturer.

E. OAD – Operational Availability Demonstration.

F. OIT – Operator Interface Terminal.

G. OWS – Operator Workstation.

H. PCS – Process Control Systems.

I. PID – Proportional, Integral, Differential.

J. PLC – Programmable Logic Controller.

K. RAW – Remote Area Workstation.

L. RIO – Remote Input/Output.

M. SCADA – Supervisory Control and Data Acquisition.

N. UPS – Uninterruptable Power Supply.



1.6 SPARE PARTS

A. Not Used

1.7 DEFINITIONS

A. Process Instrumentation and Control Equipment (Equipment): Instrumentation and

control and monitoring components such as field elements, panels, process control

systems and associated electromechanical, electrical, and electronic accessories.

B. Process Instrumentation and Control System (System): Materials, equipment and

work required to implement a complete and operating system of instrumentation

and control equipment.

C. PLC: Programmable Logic Controller system, including power supply, central

processing unit (CPU), communication controller, interconnect cables, and input

and output interface.


A. Provide all materials and work necessary for implementation of a complete and

fully functional PCS as shown, specified, and described.

1. Provide instrumentation and control components as well as complete system

integration.

2. Provide all mounting hardware and supports. Work shall include panel

mounting and the completion of all wiring terminations within control

panels.

3. Coordinate work with all electrical, mechanical, and structural work

furnished in this Contract.

4. Install, make final connections, adjust, test, start-up systems per contract

documents and manufacturer’s instructions and recommendations.

B. Design Requirements

1. Provide complete instrumentation and control system design for

implementation of work shown and specified for the pumping station

additions and modifications as described in the contract documents.

2. The design documents detail minimum equipment requirements necessary

for the new process control system integration into the existing Jardine WPP

SCADA system and eleven other pumping stations, which include all work

performed in this Contract.



C. Network Communication Requirements

1. Provide Ethernet ready PLC systems.

2. Provide fiber optic connections where required.

3. Provide Network Access Panels and Network Core Panels with patch panels,

switches, routers, network switches, power supplies and associated

accessories where required.

D. Source Code Ownership

1. All developed control logic applications (along with source code) shall

become property of the Commissioner. This applies to all control logic

applications associated with package control systems.

2. All developed OIT and HMI applications (along with source code) shall

become property of the Commissioner. This applies to applications

associated with the package control systems.

1.9 SUBMITTALS


01, Sections 01 33 00.

B. Action Submittals

1. Product Data: Submit manufacturer’s official and published product data,

specifications, and installation recommendations for each item.

2. Shop Drawings: Submit shop drawings as per Section 01 33 00, and as

required below. Include the following information in each submittal:

a. Instrument index, including tag number, description, location, and

calibrated range for each instrument.

b. Individual instrument specification sheet, including manufacturer's

name and complete catalog number.

c. Panel construction drawings with dimensions, layout and bill of

materials.

d. Panel wiring diagrams

e. Loop diagrams

f. Communication and networks diagrams

g. Campus Network layout.



3. Include connections to Ethernet network identify cable, termination type,

termination location, and drop lengths for each segment.

a. Provide Network schematic for each different type of network.

b. Input and Output drawings, containing, but not limited to, the

following information:

(1) Line numbers and instrument tag numbers

(2) Individual component locations

(3) Actual equipment wiring terminal designations, point to point

wiring, and cable shield terminations

(4) Wire type, size and identification number

(5) Signal types (e.g., 120 Volt ac, 4-20 mAdc, pulse frequency,

etc.)

(6) Contact orientations (e.g., normally open, normally closed, etc.)

(7) Equipment grounding requirements

(8) Signal boosters, interposing relays, optical isolators, and shunt

resistors.

c. Completely developed process screens for OITs and HMI.

C. Information Submittals

1. Test Reports: Submit all loop field calibration reports.

2. Factory and Field Testing: Provide the following:

a. Test Results:

(1) Pass/fail status of all digital I/O.

(2) Results of analog I/O testing.

b. Miscellaneous:

(1) Detailed step-by-step in-factory and field test procedure at least

6-weeks in advance of scheduled test date. Include sign-off

sheets and punch list forms and description of configurations to

be tested.



(2) Complete inventory of equipment to be tested at factory

including make, model, and serial number. Label each piece of

equipment.

(3) Preventive maintenance schedule.

(4) Repair Report Forms.

(5) Spares and Consumables requirements.

3. Manufacturer’s Instructions: Submit manufacturer published installation

manuals and operations manuals for each instrument, device, or equipment.

D. Submittals for Closeout: Provide submittals as required below.

1. Project Record Documents: In addition to requirements described in Section

01 78 00, provide the following:

a. Program documentation: Provide paper copies of all software

development and configuration including listing of all register tables

and/or tags.

b. Include functional narrative description of the developed control logic

to describe each control system. Control logic is to be annotated as

specified in Section 40 94 43 to include functional alphanumeric

description of logic elements to assist the Commissioner in

understanding the control logic for troubleshooting and future

modification.

c. Program copies: Provide two digital copies of fully configured

systems. Digital copies shall be in CD-ROM format.

d. Operator interface program copies: Provide hard copy printouts and

digital copies of new or modified OIT and HMI screens and database

listings. Digital copies shall be in CD-ROM format.

2. Operation and Maintenance Data: Provide operation and maintenance

manuals as specified in Division 1. Include the following information:

a. Recommended spare parts list.

b. Manufacturer approved repair and service centers list.

c. Replacements part sources.

d. Recommended maintenance procedures and frequencies.

3. Warranty: Provide warranty certificate as described in, Section 01 78 90.



1.10 REFERENCES

A. Regulatory Requirements

1. Code Compliance: Comply with National Electrical Code (NFPA 70) and

any and all local codes including City of Chicago Electric Code, applicable

to construction and installation of electrical wiring, devices, material and

equipment.

2. NECA Standards: Comply with applicable portions of National Electrical

Contractor’s Association’s “Standard of Installation”.

3. UL Labels: Provide control panel components, power supplies, controllers,

relays, etc., which have been listed and labeled by Underwriter’s

Laboratories.

B. The purpose of Contract drawings and specifications is to convey information

required for complete and functioning systems. System Integrator is responsible

for all details necessary to properly install, adjust, and place in operation, intended

systems. “Instrument Schedule” and “Input and Output Lists” are provided for

convenience; their accuracy is not guaranteed.

1.11 SCOPE OF WORK

A. Provide application software programming as specified in Section 40 90 50

Process Control System Descriptions.

B. Provide Interconnecting Wiring Diagram Drawings for the Process and

Instrumentation Control System.

C. Immediately correct incomplete or deficient Work discovered during application

software programming, downloading, testing, troubleshooting, and System startup.

D. Detailed Design and Configuration of the Ethernet networks for the devices

specified herein and as shown on the Drawings.

E. For Process Control System control panels, components, and ancillaries specified

under this section.

1. Coordinate to ensure that: The proper size, type and number of Process

Control System related raceways and conductors are provided and installed.

2. Complete panel fabrication drawings.

3. Provide the specified submittals.

4. Provide panels, components and ancillaries.

5. Certify correctness of installation.



6. Verify final power and signal connections and labeling (lugging and

connecting).

7. Adjust and calibrate.

8. Starting up

9. Testing

10. Provide the required training per this, related sections including 40 98 00

and Division 1.

11. For systems, components, and ancillaries not provided under this Section but

that are directly connect to components provided under this Section.

a. Obtain manufacturers’ information regarding installation, interface,

function and adjustment.

b. For operation and control, verify that installations, interfacing signal

terminations and adjustments have been completed in accordance

with manufacture’s recommendations.

c. Test to demonstrate proper interface and operation with PCS.

1.12 APPLICATION SOFTWARE PROGRAMMING

A. Provide application software programming as required in this and related Sections.

Download and test application software programming after successful completion

of Process Control System Factory Testing specified in the related Section 40 98

50 and Process Control System Commissioning in Section 40 80 50.

B. Training Services specified in Section 40 98 00 in Section 01 79 00 shall not begin

until System Integrator has successfully completed application software

programming, downloading, and Site Acceptance Testing. See Section 01 12 16

for specified construction sequences and constraints that affect completion of

application software programming, downloading, and testing.

C. The Commissioner reserves the right to negotiate software license agreement

directly with the software supplier


A. Deliver, store, and handle all products and materials as specified in Section 01 60

00.

B. Packing and Shipping



C. Inspect all materials and equipment against approved shop drawings at time of

delivery. Immediately return for replacement or repair any equipment or materials

damaged or not meeting requirements of approved shop drawings.

D. Label all equipment and materials after they have been inspected. Store all

equipment and materials in dry, covered, ventilated location. Protect from harm in

accordance with manufacturer’s recommendations.

1.14 PROJECT/SITE CONDITIONS

A. Environmental Requirements: Protect all equipment and instruments specified

herein from all harmful elements such as moisture, dust, chemicals, rodents etc.

1.15 SEQUENCING AND SCHEDULING

A. Refer to Section 01 12 16 for Contractor’s scheduling requirements for

applications software testing.

B. Prerequisite Activities and Lead Times: Do not start following key Project

activities until prerequisite activities listed below have been completed and

satisfied:

1. Shop Drawing Reviews by Commissioner:

a. Prerequisite: Commissioner’s acceptance of Schedule of Values and

Progress Schedule.

2. Training

a. Prerequisite: Associated training plan submittal approved.

b. Prerequisite: Offsite Training plan submittal approved

PART 2 PRODUCTS

2.1 SERVICE CONDITIONS

A. Standard Service Conditions: The following defines certain types of environments.

Process Control subsections refer to these definitions by name to specify the

service conditions for individual equipment units. Design equipment for

continuous operation in these environments, :

1. Server Room, Air Conditioned:

a. Temperature: 60 degrees F to 80 degrees F.

b. Relative Humidity: 40 percent to 60 percent.



c. NEC Classification: Nonhazardous.

2. Inside, Air Conditioned:

a. Temperature:

(1) Normal: 60 degrees F to 80 degrees F.

(2) With Up to 4-Hour HVAC System Interruptions: 40 degrees F

to 105 degrees F.

b. Relative Humidity:

(1) Normal: 10 percent (winter) to 70 percent (summer).

(2) With Up to 4-Hour HVAC System Interruption: 10 percent to

100 percent.


3. Inside:

a. Temperature: 20 degrees F to 104 degrees F.

b. Relative Humidity: 10 percent to 100 percent.


4. Outside:

a. Temperature: Minus 20 degrees F to 104 degrees F.

b. Relative Humidity: 10 percent to 100 percent, rain, snow, freezing

rain.


2.2 SYSTEM ARCHITECTURE

A. Provide Campus layout drawings in a hierarchal order showing network access

panel locations, process control panels, connections types, and drops, for PLCs,

network devices and supervisory equipment. Network shall be redundant, fault

tolerant, self-healing.

2.3 MONITORING AND CONTROL – GENERAL

A. Functional descriptions of the processes and equipment to be monitored and

controlled by (or through) the Process Control System are specified in Sections 40

90 50 and related sections.



B. Configure the PLC system to meet the functional requirements specified in Section

40 94 43 and related sections.

C. Coordinate the HMI configuration programming with the configuration of the

SCADA Servers specified in Section 40 94 13.

D. I/O points (Hard and Virtual Points)

E. Examine status of operating mode input from each equipment item/group. PLC

control logic and outputs shall only be activated if the equipment is in the proper

operating mode (auto, remote, as applicable).

F. In general, all control discrete outputs for starting and stopping equipment are to

be configured as maintained “Run” signal commands which shall be released

during a power failure. Exceptions to this approach are noted in the respective

control strategy descriptions.

2.4 TYPICAL MONITORING AND CONTROL STRATEGIES

A. Continuous Process Signal Monitoring

1. Indicate each continuous process signal monitored on Operator Interface

systems in direct engineering units.

2. Allow programming of the following operator adjustable alarm points for

each process signal:

a. High High

b. High

c. Low

d. Low Low

e. High Rate of Change

Each of the above parameters shall be capable of being set, but the actual

number of alarm points configured is to be determined per signal.

3. Generate an alarm when process signal is out-of-range.

B. Typical Setpoint Control Adjustment

1. Each operator adjustable timer and process variable setpoint shall be

provided with minimum and maximum limits.

2. Provide numerical fields for setpoint entry. Do not use sliders. Setpoint

entries shall be in direct engineering units.



3. Provide out-of-range warning messages if attempts are made to set setpoints

less than the minimum limit, or greater than the maximum limit.

C. Equipment Runtime Totalizations

1. Configure PLCs to accumulate runtime totals from the running status inputs

for all motor driven equipment (pumps, fans, etc).

2. Display total runtime hours on each respective SCADA display screen

where shown.

D. Analog Data

1. The following data processing capabilities for analog points shall be

provided:

a. Engineering units conversion – Except as otherwise specified all

analog point raw values shall be converted to engineering units via a

linear transformation.

b. Rate-of-Change limit checking – Analog data shall be checked for

rate-of-change limit values. For each analog value, the total net

change in value since the last scan of the point shall be computed and

compared against a pre-defined limit value. An alarm shall be

generated if the limit is exceeded. A dead band value equal to a

percentage of this rate-of-change limit value shall also be used in

determining the return-to-normal condition.

c. Alarm checking- the following alarm conditions shall be checked

when enabled:

(1) Alarm limits (high-high and low-low)

(2) Caution limits (high and low)

(3) Rate of change

(4) The alarm limits are checked first and if not exceeded, caution

limits are checked. Return-to-normal of limit alarms shall be

filtered by a dead band. Each limit and dead band value shall

be adjustable by the operator and defined on a per point basis.

E. Control Strategy

1. Provide a self contained control system as specified in Sections 40 94 43.

2. Develop HMI and OIT screens, as listed below per City’s standards.

a. All pumping stations processes



b. HVAC status screens

c. Power system

d. Individual switchgear (showing breaker positions and power

monitoring)

e. Individual switchgear (showing breaker positions and power

monitoring)

2.5 DEVICE CONTROL

A. The control software shall recognize several control modes. The modes of control

reflect either field status of the equipment connected to the PLC/SCADA or

operator commands. Switching between control modes, such as auto/manual or

remote/local shall be bumpless. Equipment status shall be traced by the

PLC/SCADA and shall not change when modes are changed. The control modes

are organized in a hierarchical manner as follows:

1. CP0 (Local): A field operator controls the process equipment (gate) from the

Gate Actuator. In effect this mode is always a Manual Mode.

2. CP1: The equipment is controlled by the panel OIT via local PLC.

3. CP2: The equipment is controlled from the HMI in the Control Room of the

Pumping Station.

4. CP3: The Equipment is controlled from Jardine WPP.

5. Remote: The equipment is controlled by the PLC. The PLC has two

variations:

a. Manual: The equipment is controlled by an operator from the

OIT/HMI through Start/Stop or Open/Close commands or by issuing

set-points to the controllers.

b. Auto: An automatic control strategy executing in PLC controls the

equipment.

2.6 GRAPHIC DISPLAY REQUIREMENTS

The displays will include at a minimum all the equipment shown in the P&IDs and

described in the control narratives. All equipment shall be labeled as shown on the

drawing or as listed in the I/O list. The HMI and OIT graphics shall be based on

City standards as employed in other facilities.



PART 3 EXECUTION

3.1 INSTALLATION

A. General

1. Install all instruments and equipment in strict compliance with

manufacturer's instructions.

2. Mount all gages and indicators in upright position.

3. Provide sufficient space around equipment for maintenance and removal of

equipment without removal of adjacent equipment.

4. Cover front panels, gages and indicators during construction for protection

from dust, weld and paint splatter.

5. Unless otherwise impractical, mount all indicating instruments at eye level

(5 feet).

6. Unless otherwise impractical, support instruments independent of process

piping.

B. Hardware Installation

1. Provide aluminum or stainless steel support channels.

2. Provide 1/4-inch thick minimum, clear anodized aluminum equipment

mounting plates.

3. Provide gaskets to prevent galvanic reaction between dissimilar metal

surfaces.

C. Equipment Identification and Instrument Tags

1. Install embossed stainless steel tags for each device, instrument, and panel

meeting requirements as specified in Section 26 05 53.

2. Provide an engraved laminated plastic plate at each wall-mounted

instrument and panel, indicating panel and instrument function and tag.

3. Engraved laminated tag colors: Provide black lettering on white background.

Mount tags at eye level.



3.2 QUALITY CONTROL

A. Inspection: Demonstrate that instruments, panels, Network Access points and PLC

equipment,

1. Has not been damaged by transportation or installation,

2. Has been properly installed,

3. Has no mechanical defects,

4. Is in proper alignment, and

5. Has been properly connected.

B. Testing Process:

1. Test digital inputs and outputs by actual starting and stopping of equipment

when possible, or with jumpers at field equipment terminals.

2. Test analog inputs and outputs by a signal generator at 0, 50 and 100 percent

ranges.

3. Conduct all tests in presence of Commissioner.

C. Manufacturers Field Service: Provide manufacturer field service for calibration,

initial setup, programming and commissioning of each instrument.

END OF SECTION




CDWMCPPS 40 90 50-1 Process Control System Addendum No. 1 Description

SECTION 40 90 50

PROCESS CONTROL SYSTEM DESCRIPTION

PART 1 GENERAL

1.1 SUMMARY

A. Section includes requirements for furnishing and installing instrumentation and

control systems including all work and materials necessary to perform control and

monitoring functions as illustrated on drawings, and as specified in the following

sections.


following:


2. Section 26 13 11 – Medium-Voltage Switchgear Operational Sequence

3. Section 40 05 20 - Valves





Hardware


9. Section 40 96 15 - Process Control System Input and Output List




A. General Description of Work

1. Provide a complete process control system including networking and

software development for Central Park Pumping Station.

2. The Instrumentation and Control documents are guidelines to assist the

contractor with the detailed design of control system including the Ethernet

networks and communication with Jardine WPP and eleven other Pumping

stations.

3. Installation and commissioning of control system for individual pumps are

phased. Contractor shall install the control system backbone including the

network cabling, servers, switches, routers and network panels prior to

installation of PLC panel for the first scheduled pump.


4. The Site Acceptance Testing shall be performed for each pump individually

and with other converted pumps as a system. This process shall be

performed for all pumps and associated equipment due to phasing nature of

the work.

5. Relocate the existing monitoring system cabinet to the Server room when its

current location is scheduled for renovation.

6. Replace the SCADA servers furnished under this contract with new ones at

the completion of the construction at the discretion of Commissioner.

Furnish large screen monitors for SCADA system in the Control Room as

directed by Commissioner.

7. Develop IFix HMI screens at CPPS and replicate them at Jardine WPP and

eleven other Pumping Stations following City’s graphics used in similar

stations. Coordinate with the Commissioner to review the City’s existing

HMI screens.

B. The Control Descriptions specified herein provide the functional requirements of

the Control represented in the Contract Documents.

1. Descriptions will be provided as follows:

a. Control system overview and general description.

b. Equipment to be controlled.

c. Major Field mounted instruments (does not include local gauges).

d. Manual control functions.

e. Automatic control functions/interlocks.

f. Major indications provided at local control panels.

g. Remote indication and alarms.

C. The Control Descriptions are not intended to be an inclusive listing of all elements

and appurtenances required to execute loop functions, but are rather intended to

supplement and complement the Drawings and other Specification Sections. The

Control Descriptions shall be the base document for the Contractor creation of the

Control Strategies. Identification of required elements, documentation, and

coordination between loops are to be developed during shop drawings. Finalizing

and tuning of strategies, as required by process characteristics, are to be completed

during startup.


1.3 SUBMITTALS


01, Sections 01 33 00.

B. Action Submittals

1. Product Data: Submit manufacturer’s official and published product data,

specifications, and installation recommendations for each item.

2. Shop Drawings: Submit shop drawings as per Section 01 33 00, and as

required below. Include the following information in each submittal:

a. Complete control descriptions/strategies developed from the Control

Descriptions specified.

b. I/O List complete with Instrument Ranges and Alarm levels,

setpoints.

c. Each permissive detailed.

d. Provide complete control description for all areas of control.

Including sufficient detail for a complete understanding of each

operator controllable set point, failure modes, flow balancing and

pressure controls.

e. All screens for all control strategies shall be completed and included

in the submittal.

C. Contract Closeout Information Submittals: Provide submittals as required below.

1. Project Record Documents: In addition to requirements described in Section

01 78 00, Contract Close Out, provide the following:

a. Program documentation: Provide paper and electronic copies of all

software development and configuration including listing of all

register tables.

2. Operation and Maintenance Data: Provide operation and maintenance

manuals as specified in Division 1. Include the following information:

a. Recommended spare parts list.

b. Manufacturer approved repair and service centers list.

c. Replacements part sources.

d. Recommended maintenance procedures and frequencies.


3. Warranty: Provide one (1) year warranty. Warranty Period will begin as

defined I specifications Book1 – Terms and Conditions for Construction.


A. Provide Quality Assurance as specified in Section 01 40 00.

B. The purpose of contract drawings and specifications is to convey information

required for complete and functioning systems. System Suppliers are responsible

for all details necessary to properly install, adjust, and place in operation, intended

systems. “Instrument Schedule” and “Input and Output Lists” are provided for

convenience; their accuracy is not guaranteed.

C. Meetings

1. Schedule the following meetings:

a. Two (2) Process Control System Coordination Meetings and one (1)

I&C Coordination Meeting shall be held to review Project activities,

the submittal schedule, documentation requirements, and application

software programming requirements for the Process Instrumentation

and Control System. During the first coordination meeting, The

Commissioner will review the functional description for the System

and respond to initial questions raised by the System Integrator as to

design intent. The remaining two (2) meetings shall be conducted to

provide The Commissioner Review of programming effort and further

clarification of design intent for the functional description of the

System.

b. Process Control System Coordination Meetings shall be held

regularly at Pumping Station Site as required for the duration of the

contract. System Integrator’s Project Manager, lead designer

specifically assigned to Project, the Contractor and Commissioner,

shall attend each meeting.

c. Process control system testing coordination meetings shall be held in

advance of the SAT for each pump conversion.

d. Progress Meetings shall be held at the Pumping Station Site as

required during commissioning and testing of major equipment.

1.5 RESPONSIBILITY

A. System Integrator shall provide application software programming as specified

herein.


1.6 SPARE PARTS

A. Not used

1.7 APPLICATION SOFTWARE PROGRAMMING

A. Provide application software programming as specified in this and related

Sections. Download and test application software programming after successful

completion of:

1. Process Control System Factory Testing, as specified in Section 40 98 50,

2. Process Control System Commissioning as specified in Section 40 80 50.

B. Training services, as specified in Sections 01 79 00 and 40 98 00, Training; and

equipment testing and start-up, as specified in Section 01 12 16, Equipment

Testing and Start-Up shall not begin until System Integrator has successfully

completed application software programming, downloading, and testing.

C. Refer to Section 01 12 16, Construction Limitations and Constraints, for specified

construction limitations and constraints that affect completion of application

software programming, downloading, and testing.


A. Not Required

1.9 PROJECT/SITE CONDITIONS

A. The project is at the Central Park Pumping Station, Jardine WPP, and 11 related

pumping stations and the equipment is subject to humidity, dust, noise, elevated

and reduced temperatures.

1.10 SEQUENCING AND SCHEDULING

A. Refer to Section 01 14 00.

1.11 ACRONYMS

ANSI: American National Standards Institute

CPPS: Central Park Pumping Station

GUI: Graphical User Interface

HMI: Human Machine Interface

IEC: International Engineering Consortium


OIT: Operator Interface Terminal

OS: Operating System

PDC: Power Distribution Center

PID: Proportional, Integral, Differential

PLC: Programmable Logic Controller

SCADA: Supervisory Control and Data Acquisition

UL: Underwriters Laboratories

PART 2 PRODUCTS

2.1 GENERAL

A. Local Pressure or Curb Pressure or Station Pressure are interchangeable terms and

refers to the same ‘Curb Pressure’.

B. All pump status, alarms and controls input/output points shall be transmitted to

SCADA, Specification Section 40 94 13. The input/output points are listed on

Contract Drawings.

C. Dewatering alarms YH-920C and YHH-920D (HI and HIHI level alarms as

indicated by the Float switches FS-920C and FS-920D) shall inhibit ALL other

alarms in the SCADA system.

2.2 PUMPING SYSTEM OPERATIONAL SEQUENCES

A. Introduction

1. The intent of this document is to provide a detailed description of the control

strategies for the Central Park Pumping Station. This document is used by

the system integrator to design the process control system to meet the

intended design requirements. The Process Control Narrative also serves as

a guide to Operators to provide a better level of understanding for the way in

which CPPS is intended to function.

2. This Process Control Narrative describes the control logic for the following

process components:

a. Monitoring Instruments

b. Main Pump Control

c. Stand-by Generator


B. Operating Levels

1. Individual pump operation and station operation are defined by the four

operating levels listed below. Each level is described in detail in this

specification.

a. Pump Designation

b. Selection of Station Mode

c. Selection of Control Scheme

d. Selection of Control Point

2. Pump Designation

a. The pump SCADA Screens must show all pumps at the station

assigned to one of the following two designations at all times:

(1) UNAVAILABLE

(2) AVAILABLE

b. Operator must select Pump Designation for each pump.

3. Station Mode

a. The station must be either in MANUAL or AUTO mode.

b. MANUAL: The MANUAL mode shall operate CPPS with

intervention from the Operators. The control systems shall provide the

decisions and Operators shall take the actions.

c. AUTO: The AUTO mode shall operate CPPS with very few inputs

from the Operating Staff. The initial conditions shall be set by the

operators, but as long as “AUTO” mode is active all the decision

makings and actions shall be performed by the control systems. In

AUTO mode pumps will only run in Proportional Control pump

control scheme. This mode shall be programmed and tested.

d. Operator must select Station Mode.

4. Control Scheme

a. The Operator shall select one of the following pump control schemes:

(1) Flow Control – Pump speed is automatically adjusted to

provide the desired flow depending on the operator-entered

flow setpoint for that pump.


(2) Pressure Control - Pump speed is automatically adjusted to

provide the desired pressure depending on the pressure setpoint

for the station. That setpoint is operator entered “Local

Pressure” which is also referred as “Curb Pressure” or “Station

Pressure”.

(3) Manual Control - Pump speed is automatically adjusted to the

desired speed depending on the operator-entered speed set point

for that pump.

(4) Proportional Control – This control is for station operation and

require minimum two pumps running in this control scheme.

Individual pump speed is automatically adjusted based on the

flow and relative pump capacity to provide the desired pressure

depending on the pressure set point for the station. That set

point is operator-entered and is either “Station Pressure” or

Remote Sensor Point (RSP) modulated. The details about the

RSP are provided later in this section. Proportional Control is

the only available control scheme when the pumping station is

in AUTO Station Mode.

b. Control schemes may be changed while pumps are running only if the

pumping station is operating in MANUAL Station Mode.

5. Control Point

a. Each pump will be operated at either at CP-1, CP-2, or CP-3.

(1) CP-1: The local control panel located at the pump’s VFD. CP-1

can only be selected from the local control panel. When CP-1

control point is selected, control of the pump from CP-2 or CP-

3 shall be disabled.

(2) CP-2: The HMI in the Control Room. CP-2 can only be

selected from the local control panel at the VFD. When the CP-

2 control point is selected from the CP-1 level, control of the

pump from CP-1 shall be disabled.

(3) CP-3: The existing operator station located in the Pumping

Station Control Center at the Jardine Water Purification Plant

(JWPP) control room. CP-3 can only be selected from the

Control Room HMI. When CP-3 control point is selected at

CP-2 (when the selector switch at CP-1 is set to CP-2), control

of the pump from CP-1 or CP-2 shall be disabled.

b. When the pump control is transferred from one level to another (i.e.

CP-2 to CP-3) the transfer shall be bumpless and without interruption

to each pump’s operation.


C. Pump start-up pre-check

1. The pump SCADA Screens must show all pumps at the station assigned to

one of the following two designations at all times:

a. UNAVAILABLE

b. AVAILABLE

2. The pump SCADA Screen also has a Pump Status indicator, and all pumps

at the station must have one of the following four statuses at all times

assigned by control system:

a. NOT READY

b. READY

c. IN SERVICE

d. ONLINE

3. The following conditions must be met in order for a pump to be ready for

startup:

a. Pump must be designated as AVAILABLE.

b. Pump must be fully primed as indicated by the pump priming valve

float switch.

c. Pump must not be rotating as indicated by the motor shaft speed

optical sensor.

d. Pump Suction Valve must be fully opened as indicated by the suction

valve limit switch.

e. Pump Check Valve must be fully closed as indicated by the check

valve limit switch.

f. Pump Discharge Valve must be fully closed as indicated by the

discharge valve limit switch.

g. Hydraulic pressure must be available at Pump Check Valve as

indicated by the check valve control panel.

h. Pump Oil Lubrication system must have the required flow, pressure

and temperature as indicated by the lube oil system control panel.

i. Pump seals must have the required flow and pressure as indicated by

the seal water flow switches and pressure switches.


j. No other pump is starting up.

k. Bus voltage must be within limits at the medium voltage switchgear.

l. VFD must not be failed.

m. VFD circuit breaker in the main switchgear must be closed.

n. If above conditions are met, pump will be in READY status. If any of

the above conditions are not met, pump will be in NOT READY

status.

D. Pump Start up

Following successful pre-check, the Pump will be in READY status.

1. Station Mode, Control Scheme, and Control Point are selected.

2. In MANUAL Station Mode, Operator will issue a “START” command. In

AUTO Station Mode, control system will issue “START” command. Upon

receiving a “START” command, the pump is sequenced as below.

3. VFD starts the motor at the minimum speed and slowly ramps up.

4. After the pump discharge pressure exceeds the curb pressure, the control

logic must initiate opening of the pump check valve.

5. Pump check valve must open fully.

6. When the pump check valve reaches the full open position, control logic

activates a “DISCHARGE VALVE READY” signal. In MANUAL Station

Mode, Operator will issue the “OPEN” command to the discharge valve. In

AUTO Station Mode, the control logic will issue the “OPEN” command to

the discharge valve.

7. The discharge valve opens and water must begin to flow as indicated by the

Venturi flow meter.

8. Based on the pump running, check valve open, discharge valve not closed,

and discharge flow above minimum limit indications the pump is designated

as ONLINE.

E. Station Operation

1. The 60MGD and 80MGD pumps are capable of 55MGD and 90MGD,

respectively.


2. It is assumed that at least two pumps must run at all times, with each of the

pumps fed from a different ComEd substation. Normally the two running

pumps are Pump No. 1 and 2.

3. A third pump must be in READY state for start-up in case of a power

problem with one of the electric lines or when demand exceeds a

predetermined value.

4. In MANUAL Station Mode, selection of which pump(s) to bring online is

the Operator’s decision. In AUTO station mode, the PLC program will

choose the pump(s) as selected by the Operator through the HMI “DUTY

TABLE” (Shown in a later section of this specification).

5. In MANUAL Station Mode, when the pumping station demand increases

and the ONLINE pumps reach their maximum speed without meeting their

respective setpoints, the control logic issues a warning annunciating the need

for an additional pump.

6. In MANUAL Station Mode, when the pumping station demand decreases

and the ONLINE pumps reach their minimum speed without meeting their

respective setpoints, the control logic issues a warning annunciating the need

to stop an ONLINE pump.

7. Individual pumps at CPPS operate within set motor speed, pressure, and

flow limits, as measured by local devices.

F. Station Operation under Proportion Control Control Scheme

1. Pumps can be operated in Proportional Control control scheme only when all

pumps are set to run in the Proportional Control control scheme.

2. The total required flow from all the ONLINE pumps running in Proportional

Control control scheme, as determined by the SCADA system, must be

shared proportionally according to each pump’s rated capacity, i.e. 90MGD

flow requirement, two pumps would be required to run, assume one 80

MGD pump and one 60MGD pump: the load would be split 51.4MGD and

38.6MGD, respectively.

3. Proportional Control control scheme will use a PID control instruction in the

PLCs. It will have the station curb pressure or a Remote Sensing Point

(described below) for its input process variable, and have the pump speed

setpoint as the output controlled variable. This method should allow the

required proportional flow distribution based on relative pump capacity as

well as automatic, quick, and appropriate response to changes in station

pressure when a pump is started, normally stopped, or emergency stopped.

4. Selecting Proportional Control will be allowed only if individual pumps are

in CP-2 or CP-3. When Proportional Control control scheme is selected for


an ONLINE pump, it will then adjust to distribute the flow proportionately

with other pumps in Proportional Control control scheme, according to

pump capacity.

5. The Proportional Control PID logic will be kept in manual mode when not in

control, with its output set equal to a normal speed percentage, to prevent

windup and allow a relatively bump-less transfer to Proportional Control.

6. Proportional Control can be selected at CP-2 or CP-3, and will be indicated

at all control points. Switching out of Proportional Control control scheme

would leave a pump in Manual Control control scheme. It would then be up

to an operator to select an appropriate control scheme for the pump.

7. The cascaded PID control method outlined above is essential to maintain the

specified proportional division of flow and operation within set parameters

under all conditions.

G. Remote Sensing Point (RSP) Pressure Setpoint:

1. In Proportional Control control scheme the pressure setpoint is operator

entered and is compared to either the Station Pressure or Remote Sensor

Point (RSP) control variable.

2. The station's output flow / delivery pressure is modulated in order to meet

minimum pressure setpoints as measured by existing continuously

monitored RSPs throughout the distribution system. The pressure setpoints

are modified by user interface.

3. Each RSP is given a unique designation.

4. Each RSP is assigned a status by the operator.

a. LIVE - the SCADA System is using that point to determine pump

speed.

b. INACTIVE - the SCADA System is not using the RSP as a parameter

to determine pump speed.

5. Input from up to 20 RSP’s can be monitored by the SCADA System at one

time. RSP’s values are obtained from Jardine WPP through communication

system.

6. While in Proportional Control, if an operator has selected any RSP as "Live,"

it will automatically step the station pressure set-point up or down, in small

steps and at an appropriate rate, if needed to keep the remote site pressure

within its normal range. Step size and rate, remote site pressure ranges, and

the allowed station pressure set-point range will be operator adjustable. The


number of RSP's chosen as live will be indicated as "No. of RSP's Enabled”

at all control points.

7. An operator at CP-2 or CP-3 is able to manually adjust a range of set points

for each RSP. That range is to be considered the "deadband” for that RSP,

meaning no action will be called for while the pressure remains within that

range.

8. The master pressure set point range for the station is read from the RSP

(RSP-M) located directly outside the CPPS.

9. If the pressure at any of the designated RSP’s moves outside of its deadband,

and remains outside of the deadband for more than 120 seconds, the

SCADA system commands modulation of the speed of the pump motor(s),

by incrementally changing the pressure setpoint of the station, until the

pressure at that RSP is back within the deadband.

a. Should the changing of the motor speed push any of the other RSP's

outside of their respective deadbands (except RSP-M) for more than

10 seconds, the SCADA system commands the speed modulation of

the motor.

b. At that time the SCADA system requests an operator input to which

RSP signal to discard

c. If operator input is not received within 1 minute, the SCADA System

discards the other RPS’s that have gone outside of their respective

deadbands, change their status to inactive, and send an alarm to CP-1,

CP-2 and CP-3

d. At that point modulation continues until the deadband of the original

RSP is reached.

e. If the modulation of the VFD speed in response to an RSP falling out

of its deadband causes the Station Pressure to reach the high or low

limit of its allowed range, modulation of the speed of the VFD stops

immediately, the SCADA System discards the RSP’s that have fallen

out of their respective deadbands, changes their status to inactive, and

sends an alarm to CP-1, CP-2 and CP-3.

10. If pressure at any of the RSP's drops more than 20% in under 1 minute, the

SCADA System disregards that RSP, change its status to inactive, and send

an alarm to CP-1, CP-2 and CP-3.

H. Pump Shut Down

1. When an operating pump is set to stop (either by an operator or if in AUTO

mode by the PLC logic) the following steps must occur consecutively.


2. Check Valve Closes.

3. VFD reduces the pump speed to minimum.

4. VFD Output contactor opens and pump motor stops.

5. The discharge valve closes.

I. Station Operation Under Fault Conditions:

1. Fault Conditions are defined as:

a. ComEd power is not available.

b. Less than three pumps are available.

c. All Ancillary systems are not available.

d. The SCADA Network functions have communication errors.

e. At least CP-1 or CP-2 control points are not available.

2. The fault condition could be Pumps or their ancillary systems or partial

failure in the SCADA system. The following describes various possible

faults and the methods to deal with them to eliminate or minimize their

impact on the Pumping Station Operations.

a. The Station has Five (5) pumps. The number of pumps in operations

simultaneously is two (2). Upon rising system demand a third pump

may be required to meet the demand.

b. The status of the Motors and Pumps are monitored in real-time by

various field instruments as part of the Motor Management System

(refer to electrical specifications, P&IDs and Instrument index

drawings).

c. The Motor Management System functions independently of SCADA

system. However SCADA system will display all the data received

from the Motor Management system including Alarms and status

points. The Motor Management system is configured to stop a pump

if serious malfunction occur. Refer to Electrical Specification for

more details.

d. Additionally the SCADA system generates alarms based on the

operating parameter of measuring devices. Any major deviations

(selectable by the operating staff) shall cause the SCADA system to

issue alarms detailing the reason.


e. If a major alarm is issued by the SCADA system and no action is

taken by the operating staff within a pre-set time, the SCADA system

shall take appropriate steps to prevent any damage to equipment or

personnel.

f. The redundancy of the equipment in the pumping station will prevent

any major operation disruption to occur. The number of pumps is

sufficient to withstand losing one or even two pumps at one time. The

management of the failures is mostly done through SCADA system

which issues “Alert”, “Caution” or “Alarm” assisting operating staff

with decision making.

3. Pumping System

a. When a Motor/Pump fails during operation the control system will

issue a major “Alarm”. The major Alarm initiates the shutdown

sequence of the failed pump and its associated equipment, such as

valves. There is the possibility that a device such as Discharge Valve

will not properly operate during a fault. The SCADA shall bypass the

failed step after a preset time and proceed to next shutdown step.

b. When a non- major failure occurs the SCADA system will alert the

Operating staff for decision making.

c. The following are the alarms generated by the SCADA system based

on deviations of operating parameters. If a pump is in “Auto” mode

then the SCADA system will initiate the shutdown of the pump and

issues a major “Alarm”.

d. If the pump is in “Manual” mode SCADA will issue the “Alarm” and

operation staff are responsible for initiation of proper response.

(1) Pump Running but No Flow or Pressure detected

(2) Pump Discharge Pressure Low/High

(3) Pump Failed to Start/Stop

(4) Discharge Valve Failed to Open/Close

(5) Check Valve Failed to Open/Close

(6) VFD failed to reach speed setpoint

(7) Pump Un-commanded Start/Stop

(8) Discharge Valve Un-Commanded Open/Close


(9) Check Valve Un-Commanded Open/Close

4. Control System and Local Area Network

a. Control system and its backbone network system have been designed

based on multi-level redundancy and backups. In addition the

modularity of the control system provides an important level of safety

against major failures. All devices and cabling, from PLCs, power

sources to Fiber Optic network have hot backups which make the

system “Fault Tolerant”. When a device fails or a cable is

disconnected the backup systems will seamlessly replace them. The

network topology is a ring system. This allows communication

flexibility between devices. If a communication pathway is blocked at

any point on the network the system automatically reverses the

communication path. However no system is totally immune to

failures.

b. Below describe the options available to the operation staff if part of

control system fails.

(1) Pump Control Operation and Monitoring relies on

communication between CP-1, CP-2 and CP-3. The Pumping

Operation shall be monitored from all levels at the same time.

The Control location of the pumps depends on the operation

staff decision.

(2) If Communication between CP-3 and CP-2 fails while CP-3 is

selected as main control point then SCADA system shall:

(a) Transfer the control to CP-2 and issue a Communication

Failed alarm. All the parameter entered from CP-3 shall

be retained.

(b) If the alarm is not acknowledged at CP-2 after a pre-set

time. The pumps control shall be set to “Auto”.

(c) The station operational data shall be stored in the local

storage rather than transmitted to CP-3.

(d) Upon restoration of communication system between CP-

2 and CP-3 the control point shall be returned to CP-3.

The “Auto” mode shall not change unless commanded

by the operating staff at CP-3.

(3) Communication failure between CP-1 and CP-2 requires

immediate action by the operating staff. The operating staff at

CP-2 and CP-3 will not be able to monitor the Pumps


operation. The control system shall take the following

precautionary steps until the communication is restored:

(a) The controlling level will be transferred to CP-1.

(b) The Pump control mode shall be changed to “Auto” if

communication failure continues for a pre-set time.

(c) Alarms shall be issued at CP-2 and CP-3

(d) Upon restoration of communication system the pump

control shall remain with CP-1 in Auto mode.

(e) The operation staff shall make the decision to change

control mode and parameter.

5. Power failure (Standby Generators)

a. There are four electrical Generator sets which will provide enough

power to CPPS to prevent the shutdown of the station

b. Three Generator sets suffice to run the station the fourth is the

backup.

c. If less than three Generator sets are available, the AUTO Station

Mode shall not be available and transition from AUTO to MANUAL

Station Mode shall be seamless.

d. Generator Paralleling Controller (GPC) shall not allow Pump to start,

if it would overload the Standby Generators as described in 40 90 50.

e. When ComEd power fails the generator sets will start within thirty

seconds.

f. The process control system power is provided by a central UPS with 2

hour backup capacity.

g. Control System Actions during a power failure

(1) The intent of the Control System is to minimize the down time

of the station and ensure pumping operation starts as soon as

possible after a power failure.

(2) Notify lube oil system that power failure has occurred and

allow continued operation of lube oil system on UPS for

designated period, followed by shutdown of lube oil pumps.


(3) The pumps that were running during power failure shall go

through Stop sequence. It takes approximately 10 minutes for a

pump to go through the stop sequence and be ready for a

restart.

(4) The Check valve operating on Hydraulic Accumulator shall

close when power fails

(5) When the control system receives the closed signal from the

last Check valve it shall begin the process to start the third

pump in automatic.

(6) Operating Staff shall make decision to allow the third pump to

continue running during power failure until ComEd services are

back on line or to start the pumps that were running prior to the

power failure.

(7) The transition from Generators to normal power is seamless.

No action is required from the control system.

6. Servers and Network Devices

a. All devices and cables are redundant. The failure of any individual

device may not impact the operation of the Network.

b. HMI and RSlogix PLC programming tool reside in the SCADA

Servers. A redundancy software creates a Virtual Server allowing the

mirroring of operation of the two servers. If a servers fails the other

will seamlessly take over. An alarm will be issued. The Virtual Server

software shall automatically configure the replacement software

c. The network diagnostic software shall monitor all network devices.

Display the status of the network on the HMI screen. Any failure will

be “Alarmed”.

J. Emergency Stop

1. Fault conditions of either an electrical or mechanical nature must initiate

“Emergency-Stop” operation of an associated pump and must initiate an

alarm.

2. The emergency stop sequence for each pump must be initiated by a fault

condition as described and must be as follows:

a. The pump adjustable speed contactor must trip and the pump must

stop.


b. Simultaneous with the above, the pump check valve must close at an

adjustable preset speed.

3. The electrical fault sensing devices, malfunction systems, and emergency

push button action that must trip the pump adjustable speed contactor and

initiate the “Emergency Stop” sequence must be as follows:

a. Station flooding trip, as indicated by the Emergency Dewatering

System.

b. The VFD multi-function motor management relay trip command at

the VFD.

c. Check Valve fails to open on pump start or closes when pump is

running.

d. Emergency stop push button operation at CP-1.

e. Emergency stop command sent from CP-2 or CP-3, no matter which

control point is currently selected.

f. Emergency stop push button operation at the motor.

g. Breaker trip operation at the switchgear.

h. Discharge valve remains closed for a set time at start up.

4. The following failure sensing systems and malfunctioning devices for each

pumping unit must be “Alarm Only”, in nature and must not trip the pump

circuit breaker:

a. Motor management relay alarm command.

b. Pump check valve fails to open on pump start or closes when pump is

running.

K. AUTO Station Mode

1. The AUTO Station Mode shall operate CPPS with very few inputs from the

Operating Staff. The initial conditions shall be set by the operators

(described below) but as long as AUTO Station Mode is active all the

decision makings shall be performed by the control systems.

2. The AUTO Station Mode shall be activated/deactivated from CP-2 or CP-3.

3. In AUTO Station Mode start or stop commands from the operators shall start

the appropriate procedures automatically. Steps are monitored and advanced

by the SCADA System based on pre-set parameters.


4. All control Modes detailed above shall be available in AUTO Station Mode.

The fundamentals of operating CPPS, specifically the concept of running 2

pumps at all times shall be observed.

5. The Operators shall select the operating mode and set points described above

before activating the AUTO Station Mode. The transition to/from AUTO to

MANUAL Station Mode shall be seamless. The following Duty table shall

be activated to enable the Operators to select pumps hierarchy in operating

the station.

DUTY TABLE

Pump

Rank 1 2 3 4 5

Duty 1

Duty 2

Lag 1

Lag 2

Lag 3

6. The AUTO Station Mode program shall start pumps based on selected duty

and shall operate them based on the setpoints and operation mode set by the

operating staff. If a pump should fail the program will substitute the failed

pump with the next available pump.

7. All “Alarms”, “Cautions” and “Warnings” shall be issued by the control

system regardless of the mode of operation.

8. If a pump is not “Ranked” in the duty table the program shall assume that the

pump is not available.

9. If 2 or more pumps are ranked the same the program shall reject the

selections and shall prompt the operating staff to enter different values for

each pump.

PART 3 EXECUTION

Not Used

END OF SECTION


Addendum No. 1 Instruments

SECTION 40 91 00

PROCESS CONTROL SYSTEM INSTRUMENTS

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing process control system instruments

as detailed in the Instruments’ Specification herein.


following:

1. Section 01 32 50 - Project Management System (Constructware)


3. Section 01 79 00 - Training

4. Division 26 - Electrical

5. Section 40 90 00- Process Control System General Requirements



1.2 REFERENCES

A. International Society of Automation (ISA).

B. Underwriters Laboratories (UL): Applicable listings.

C. All electrical work shall comply with the requirements of the National Electric

Code (NEC) – Latest Revision.

1.3 SUBMITTALS


01, Sections 01 33 00 and 01 32 50.

1. Provide Shop Drawings as required below.

2. Complete and detailed system schematic drawings showing all components

with electrical point to point connections of each system (wiring and piping

diagrams). Include a description of the operation of the system and

equipment.

3. Instrumentation equipment specifications: Include manufacturer’s catalog

information showing product data, outlines, dimensional drawings and



instructions for installation, storage, handling, and protection. Duplicate

equipment may be covered by one set of literature.

4. Instrument Data Sheets showing actual manufacturer and devices selected,

with all fields completed.

5. The submittal shall be organized in a logical manner and have a schematic

diagram and a loop diagram for each system.

1.4 SUBMITTALS FOR CLOSEOUT

A. Instruction Manuals:

1. Refer to Section 01 78 23.

2. Operation and maintenance information – complete descriptive

literature/shop drawings for each piece of equipment, including a list and

description of all parts of each piece of equipment and instructions for

calibration, testing and maintenance requirements.

3. Project Record Documents: Revisions from the “As-awarded” design and

previous submittals. This includes as built records such as instrument

ranges and actual component/instrumentation locations, including sources of

control power.

4. Revised or updated P&IDs (IC series drawings), and process flow diagrams

showing location of instrumentation and equipment including calibration

data.

5. Submittals of Data Sheets shall be electronic and editable with file naming

based on the device tag.

PART 2 PRODUCTS

2.1 SIGNAL LINE TRANSIENT PROTECTION

A. All signal lines for solid state electronic equipment shall be equipped with line

voltage surge suppressors to protect the equipment from damage due to electrical

transients induced in the interconnecting lines from lightning discharges or nearby

equipment.

B. This shall include, but is not be limited to digital inputs, analog inputs, analog

outputs, flow transmitters and level transmitters. .

C. The signal line transient protection shall include gas discharge tubes, varistors and

suppressor diodes.



D. Terminal block shall be DIN rail type, mounted in the vertical position.

E. Provide lightning protection termination for all digital and analog signals, plus a

minimum of 10 percent spares per panels.

F. Acceptable Manufacturers are

1. Phoenix Contacts

2. Allen-Bradley

3. Square D

G. Field instruments, for 24V DC analog signals:

1. Conduit Mounted: Protection circuit mounted inside ¾ inch stainless steel

conduit.

2. Provide surge protection for analog and digital I/O designed to withstand a

10kA test current of a (8/20) microseconds waveform according to IEC 1024

Application Guide A and ANSI/IEEE C62.41 Category C Area.

3. Surge protection shall consist of a multistage hybrid circuit utilizing only

diodes and gas discharge tubes but no Metal Oxide Varistors (MOVs).

4. Resistance: Less than 10 ohms of series resistance.

5. Surge protection shall have a response time less than 1 microsecond.

6. Maximum Continuous Operating Voltage: Not to exceed 28V DC.

7. Cutoff Frequency: Less than 400 kHz (for a 600 ohm system) to allow

HART protocol and other superimposed smart digital signals to function.

8. Operating Temperature Range: Minus 40 to 65 degrees C, minimum.

9. Acceptable Manufacturer

a. Phoenix Contact

b. Allen-Bradley

c. Rosemount

2.2 DC LOOP POWER SUPPLIES

A. Each power supply shall be enclosed in a NEMA type 1 enclosure, vertical surface

mounting type, with surface barrier screw terminals for load connection. Each

power supply shall be equipped with a power on/off circuit breaker.



B. Power supplies shall meet the following specifications:

1. Input Power: 115V AC plus or minus 10 percent, 60 Hz.

2. Output Voltage: 24V DC.

3. Output Voltage Adjustment: 5 percent.

4. Line Regulation: 0.05 percent for 10 percent line change.

5. Load Regulation: 0.15 percent no load to full load.

6. Ripple: less than 3 millivolt RMS.

7. Operating Temperature: 32 to 140 degrees F.

C. Size power supplies to accommodate present load plus 25 percent spare capacity.

D. Provide a relay contact to indicate the on/off status of the power supply.

E. Provide power supply output overvoltage and overcurrent protective devices to

protect the instruments from damage due to power supply failure and to protect the

power supply from damage due to external failures.

F. Mount power supplies such that dissipated heat does not adversely affect other

components.

2.3 TERMINAL BLOCKS

A. Manufacturers:

1. Phoenix Contact

2. Weidmuler

3. Rockwell

B. Terminal Blocks: ANSI/NEMA ICS 4.

C. Power Terminals: Unit construction type with closed back and tubular pressure

screw connectors, rated 600 volts.

D. Signal and Control Terminals: Modular construction type, suitable for channel

mounting, with tubular pressure screw connectors, rated 600 volts.

E. Provide intrinsically safe barriers for signal and control conductors going to

explosion proof areas.



F. Provide ground bus terminal block, with each connector bonded to enclosure.

2.4 PRESSURE AND DIFFERENTIAL PRESSURE TRANSMITTERS

A. Differential capacitance cell type. Two-wire, 4-20 mAdc output signal. Loop

powered from 24 vDC nominal. Output load impedance of at least 550 ohms.

B. Microprocessor based "smart" electronics. HART protocol compatible.

C. Accuracy: +\- 0.10 percent of calibrated span.

D. Span and zero continuously adjustable, either locally or via hand-held digital

interface.

E. FM approved for installation in Class l, Division l hazardous areas.

F. NEMA 4 housing. Suitable for operation over ambient temperature range of 20 to

120 degrees F.

G. Ceramic or stainless steel wetted parts. Stainless steel bleed and drain fittings. All

metal external parts.

H. Integral 4-digit LCD output indicator graduated 0-100%. Provide integral

mounting bracket suitable for wall or pipestand mounting.

I. 1/2-inch NPT process connections.

J. Manufacturers: Provide products of one of the following:

1. Endress and Hauser Cerabar/Deltabar S

2. Rosemount 3051

2.5 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 or as required by

process.

2. Setpoint: As specified in the Instrument schedule.

3. Setpoint Repeatability: ± 1 percent of range.



4. Output: Snap action switch, DPDT 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: maximum full scale, minimum

10% of scale.

7. Ambient Temperature Limits: -4°F to 140°F.

D. Construction Features

1. Pressure Transducer Housing and Diaphragm Materials:

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; provide covers threaded and seated on

Buna-N O-rings; NEMA 4X rating.

c. Process Wetted Parts: 316 stainless steel.

d. Water Service with Copper Pipe: Brass housing with Buna-N

diaphragm.

e. Other Services: 316 stainless steel.

2. Set and Reset Point Adjustments: Adjustable external adjusting nuts and

pressure setting scales in psi.

3. Process Connection: 1/2-inch NPT.

4. Housing: Copper-free die cast aluminum, NEMA 4X.

5. External Mounting Lugs.

6. Electrical Connection: 3/4-inch NPT.

7. Diaphragm seal.

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

1. Automatic Switch Company, Tri-point SA Series.

2. United Electric Controls Series 400 (non hazardous areas, series 120 for

hazardous).



2.6 GAUGES – PRESSURE AND VACUMM

A. General: Provide gauges to include pressure, vacuum and compound gauges of the

dial-indicating bourdon tube type. Provide gauges to the requirements of ASME

B40.100 except as modified herein. Locate gauges as shown or specified. Wall

mount or independently support gauges.

B. Pressure Gauges: Provide Grade 2A pressure gauge with a range of 0 to 100 psig,

with an accuracy of 0.5 percent of the maximum scale reading.

C. Compound Vacuum and Pressure Gauges: Provide Grade 2A compound vacuum

and pressure gauges a vacuum renage of 0 to 30 inches of mercury and pressure

range of 0 to 60 psig with accuracy of 0.5 percent of maximum scale reading.

2.7 DIAPHRAGM SEAL

A. General: Furnish diaphragm seals for pressure gauges and switches at locations

shown and as specified.

B. Required Features

1. Provide fill/bleed screw to permit filling of instrument and diaphragm seal.

2. Instrument Connection: 1/2-inch NPT.

3. Process Connection: 1/2-inch NPT.

4. Working Pressure Rating: Equal to or greater than the attached gauge or

switch operating pressure specified.

5. Bolting Materials: Type 304 for non-wetted exposed parts (typ.) stainless

steel.

6. Provide a clean-out ring which holds the diaphragm captive in the upper

housing to allow the upper housing assembly to be removed for recalibration

or cleaning of the process side housing without the loss of filling liquid or

change in calibration. Flushing connection ¼” NPT.

C. Construction Features

1. Top Housing: Type 316 stainless steel.

2. Diaphragms, O-rings and Gaskets:

3. Process Side Housing Material: 316 SS for metallic piping; CPVC to match

non-metallic piping.



4. Sensing Liquid: Use silicone except for process fluids containing chlorine.

When the process fluid contains chlorine, provide Halocarbon 63 or

Flurolube 63 for the filling liquid.

5. Working Pressure Rating: Equal to or greater than the attached instrument,

and the operating pressure specified in the Exposed Piping Installation,

section 15109, whichever is greater.

D. Assembly and Calibration

1. Provide complete diaphragm seal assembly, including gauge, switch or

transmitter, shall be factory assembled, filled and calibrated to the ranges

and switch setpoints specified prior to shipment.

2. Coordinate location and orientation of the gauges, switches and seal

assemblies with the actual piping and equipment installations so that gauges

and indicators can be easily read and accessed for maintenance by OWNER

personnel.

3. Where field mounting and orientation conflicts arise due to incomplete

coordination with field changes in the process piping and equipment

installation, relocate, re-orient, re-assemble, and re-calibrate as directed by

the Commissioner at no cost to the OWNER.

E. Product and Manufacturer

1. Type 100 HCF, as manufactured by Bristol Babcock/Helicoid.

2. Type 101 as manufactured by Ashcroft.

2.8 FLOW SWITCH - THERMAL DISPERSION

A. Technical Requirements:

1. Type: Thermal Dispersion

2. Process Connection: 3/4 inch male NPT standard.

3. Insertion Length: 1.2 inches. See installation detail.

4. Sensor Wetted Material: 316 stainless steel with all-welded construction.

5. Operating Temperature: Sensing Element: -40 to 350 Deg F.

6. Control Circuit: Ambient: -40 to 140 Deg F.

7. Operating Pressure: 3500 psig at 70 Deg F.

8. Set point Range: Water-based liquids: 0.01 to 3.0 sfps, 3 watt heater power.



9. Electrical Enclosure: NEMA 4X, 300 Series Stainless Steel, Class 1,

Division 1.

10. Factory Calibrated Switch Point Accuracy: ±2% of set point velocity over

operating temperature range of ±50 Deg F. See instrument list for set point.

Switch shall be set at factory for decreasing flow. Set point shall also be

field adjustable.

11. Monitoring Accuracy: Liquids: ±5% reading based on a measured output

voltage over the entire flow range, an operating temperature range of ±50

Deg F, and an operating pressure range of ±100 psig.

12. Repeatability: ±0.5% reading.

13. Response Time: 5 to 10 seconds.

14. Input Power: 120 VAC, 60 Hz.

15. Power Consumption: 13VA maximum (AC units), 7 watts maximum (DC

units).

16. Relay Rating: Single DPDT field configurable 6 amp resistive at 115VAC or

24 VDC.

17. Tagging: See instrument index. SS engraved tag required.

2.9 FLOW SWITCH – LOW FLOW

A. Technical Requirements:

1. Type: Insertion

2. Process Connection: 3/4 inch male NPT standard.

3. Insertion Length: 1.2 inches. See installation detail.

4. Sensor Wetted Material: 316 stainless steel with all-welded construction.

5. Operating Temperature: Sensing Element: -40 to 350 Deg F.

6. Control Circuit: Ambient: -40 to 140 Deg F.

7. Operating Pressure: 160 psig at 70 Deg F.

8. Set point Range: Water-based liquids: 0.01 to 3.0 gpm.

9. Electrical Enclosure: NEMA 4X, 300 Series Stainless Steel, Class 1,

Division 1.



10. Factory Calibrated Switch Point Accuracy: ±2% of set point velocity over

operating temperature range of ±50 Deg F.

11. Monitoring Accuracy: Liquids: ±5% reading based on a measured output

voltage over the entire flow range, an operating temperature range of ±50

Deg F, and an operating pressure range of ±100 psig.

12. Repeatability: ±0.5% reading.

13. Response Time: 5 to 10 seconds.

14. Input Power: 120 VAC, 60 Hz.

15. Power Consumption: 13VA maximum (AC units), 7 watts maximum (DC

units).

16. Relay Rating: Single DPDT field configurable 6 amp resistive at 115VAC or

24 VDC.

17. Tagging: See instrument index and drawings. SS engraved tag required.

2.10 CONDITION MONITORING SYSTEM

A. Furnish a condition monitoring system for each Pump in its Control Panel.

1. Provide Shaft Speed and Vibration monitoring modules as shown on the

Process and Instrumentation Diagram (P&ID).

2. Condition monitoring system shall be Allen Bradley Dynamix 1444 Series

for Vibration and Motor shaft speed. Provide Allen Bradley 1443 Sensors

for vibration sensors and Allen Bradley 1442 sensors for motor shaft speed

sensor.

2.11 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 16 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:

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.

5. Float must be rated to meet the electrical hazard classification.

C. Manufacturers – Provide one of the following:

1. Flygt.

2. Rotofloat

PART 3 EXECUTION

3.1 INTERFACE WITH OTHER PRODUCTS

A. Coordinate installation of, transmitters, and pressure switches with piping and

equipment installers.

3.2 INSTALLATION

A. Install all devices as specified and shown on the Contract drawings and in

accordance with manufacturer’s requirements.

3.3 TRAINING

A. Perform training in accordance with the requirements contained in Section 01 82

00 of these specifications and as specified in the Equipment Datasheets.

3.4 MANUFACTURER’S FIELD SERVICES

A. On-site start up assistance and/or training for operating and maintenance

personnel, calibration, and system testing.

1. Test Schedule

2. Testing Tools

3. Test results

END OF SECTION




CDWMCPPS 40 93 50-1 Fiber Optic Cable and Addendum No. 1 Accessories

SECTION 40 93 50

FIBER OPTIC CABLE AND ACCESSORIES

PART 1 GENERAL

1.1 SUMMARY

A. Section Includes: Requirements for providing and placing into successful

operation the fiber optic data highway and appurtenances for the FACILITY

PROCESS Control System network specified. The system includes, but is not

limited to the following:

1. Fiber Optic Patch Cables,

2. Terminal Connectors,

3. Fiber Optic to Copper Converters,

4. Fiber Optic Trunk Cables.


following:


2. Section 01 45 00 - Quality Control.

3. Section 01 42 00 - References.



Hardware


7. Section 40 95 13 - Process Control System Panel Enclosures and

Equipment.

1.2 REFERENCES

A. Standard for Installing Commercial Building Telecommunications Cabling

(ANSI/NECA/BICSI 568).

B. International Society of Automation (ISA).

C. Electronics Industry Association (EIA).

D. Color Coding of Fiber Optic Cables (TIA-598).


E. Fiber Optic Test Procedures (FOTP):

1. FOTP-25 - Impact Testing of Fiber Optic Cables and Cable Assemblies.

2. FOTP-33 - Fiber Optic Cable Tensile Loading and Bending Test.

3. FOTP-41 - Compressive Loading Resistance of Fiber Optic Cable.

4. FOTP-81 - Compound Flow (Drip) Test for Filled Fiber Optic Cable.

5. FOTP-82 - Fluid Penetration Test for Filled Fiber Optic Cable.

6. FOTP-104 - Fiber Optic Cable Cyclic Flexing Test.

7. FOTP-181 - Lighting Damage Susceptibility Test for Optic Cables with

Metallic Components.

8. Flammability requirements per NEC 770-51(b) and NEC 770-53(b) OFNR

rated.

F. National Electrical Contractors Association (NECA), Building Industry Consulting

Service International (BICSI):

1. ANSI/NECA/BICSI 586 – Standard for Installing Commercial Building

Telecommunications Cabling.

1.3 DEFINITIONS

A. The following definitions shall apply throughout this Section:

1. “Structured Cabling System (SCS)” refers to the campus

telecommunications cabling infrastructure which consists of the following

subsystems: network room, fiber-optic backbone cabling, horizontal cabling

system, and work-area outlets.

2. “Fiber-Optic Backbone Cabling” refers to the backbone cabling providing

interconnection between either the Network Access Panels (NAC) or the

Network Core Switches. It consists of the backbone cables, mechanical

terminations, and patch cords or jumpers used for backbone-to-backbone

cross-connection.

3. “Horizontal Cabling System” refers to the horizontal cabling (copper

Ethernet cables).The system consists of horizontal cabling, work-area

outlets, cable terminations, and cross-connections.


4. “Station Cable” refers to the connection between the Work-Area Outlet and

the end field device (e.g., PLC, OIT, etc.). It consists of cords, adapters, and

other transmission electronics.

5. “Work-Area Outlet” provides the cross-connect between the horizontal

cabling system and the station cable.

6. “Pathways” are designed for installation of data communications media.

7. “Spaces” are the rooms and areas where media is terminated and/or

communications equipment is installed.

8. “Network Core Panel”: A 19” rack enclosure constructed to support the

termination of cables (fiber-optic, CAT6aUTP, and power) and the

installation of Ethernet Switch(es) (core switch(es). .

9. “Network Access Panel”: An enclosure constructed to support the

termination of cables (fiber-optic, CAT6aUTP, power) and the installation

of Ethernet Switch(es). Network Access Panels are installed in the process

areas and provide connectivity of the end field devices (e.g., PLC, OIT, etc.)

to the Network Core Switch.

10. “Network Core Fiber Patch Panel”: An enclosure constructed to support the

termination of the fiber-optic backbone cables. . Fiber-optic patch cables

are used to interconnect the CISCO core switch in the Network Core Panel

with the fiber-optic patch enclosures in the Network Core Fiber Patch Panel.

11. “SCADA Server Panel”: An enclosure constructed to support the

installation of computer servers and associated hardware.

1.4 CONSTRUCTION

A. This section applies to construction of control system communication networks.

1. The fiber allocation within each fiber optic backbone cable is as follows: LAN – 12 multimode fibers (MMF) active, LAN – 12 MMF fibers reserved.

All fibers of each backbone cable shall be terminated and tested.

2. Horizontal cables shall always be collated as a group of four (4) cables.

Each group of horizontal cables shall be associated with a single 4-port

work-area outlet.

3. All network components of a single type shall be from the same

manufacturer and the same manufacturer’s catalog number.

4. All network sub-system components shall be from the same manufacturer.


1.5 SUBMITTALS

A. General: Provide submittals as specified in Division 01, Section 01 32 50 and

Section 01 33 00.

B. Include the following information in the submittal for this section:

1. Manufacturer’s product data sheets and complete construction details

including physical characteristics of optical fiber, strength members, and

jackets.

2. Overall dimension of cable.

3. Provide an optical link analysis for each fiber optic link. Calculate point-to-

point (transmit/receive) optical power loss of each fiber link using proposed

installed cable lengths. Include all losses through connectors.

C. Provide end-to-end connection drawings for the fiber optic system affected by the

work. The drawings shall uniquely identify each cable from the trunk line to patch

panel, and from the patch panel to the end user or device.

D. Provide printouts of the Optical Time Domain Reflectometer (OTDR) tests

conducted on all fiber cables provided under this Contract.

1.6 SPARE PARTS

A. The following shall constitute the minimum spare parts of each connection type:

ST-LC and ST-ST

a. Twenty (20) duplex fiber patching cables, twelve foot length.

b. Twenty (20) duplex fiber patching cables, three foot length.

c. Four (4) fiber optic media converters of each type used in the

Contract.

PART 2 PRODUCTS

2.1 GENERAL

A. Fiber optic patch cable and hardware provided under this section shall be

compatible for use indoor and outdoor. The fiber optic patch cables shall be

provided with ST connectors on each end, and in suitable lengths to accommodate

terminations as indicated on the Drawings.


2.2 FIBER-OPTIC BACKBONE CABLE

A. Provide fiber-optic cable, connectors, and appurtenances that make up the

backbone cable segments.

B. The fiber-optic backbone cable segments shall meet the requirements of the

TIA/EIA-568-B specification for multi-mode fiber.

C. Fiber-optic backbone cable shall meet or exceed the following minimum

requirements:

1. 24 Fibers per Cable.

2. Quantity 24 – 8 to 9 micron multi-mode fiber strands.

3. Indoor/Outdoor Rating.

4. Core-locked, Tight-buffered.

5. Riser-Rated (FT4) inner and outer PVC jackets (DX series).

6. Fiberglass wrapped in locations where rodents are a known issue.

D. The fiber-optic cable shall be:

1. Optical Cable Corp

2. Belden

3. Timbercon

E. Attenuation losses shall be 3.5dB/km or less at a wavelength of 850 nm and

1.5dB/km or less at a wavelength of 1300 nm.

F. Do not use cable with plastic fiber core construction.

G. Jacketing to include dry waterblock.

H. Indoor Use:

1. Tight buffer design.

2. Individual fiber tubes to be stranded around a dielectric strength member

made of Kevlar.

3. A rip cord for ease of access to individual fiber tubes.

4. Outer jacket of blue flame retardant PVC.


5. Operating Temperature Range: minus -4 to +116 degrees F.

I. Indoor/Outdoor Use:

1. Loose buffer design.

2. Individual buffer tubes to be stranded around a fiberglass epoxy rod

stabilization member.

3. Inner jacket of PVC.

4. Kevlar braid.

5. Outer jacket of black PVC.

6. Operating Temperature Range: minus -40 to +116 degrees F.

2.3 FIBER-OPTIC ADAPTOR PANELS

A. All connectors for the termination of the fiber-optic backbone or horizontal cable

shall be ST connectors.

B. For multi-mode fiber optic terminations inside Network Access Panels and Fiber

Patch Panels, the connectors shall be preloaded adapters configured with 4 ST

duplex multi-mode adapters fitted with a zirconia ceramic split sleeve. ST

connectors shall be Panduit catalog no. FAP4WBUDSCZ.

C. For multi-mode fiber-optic terminations inside Network Fiber Core Patch Panels

the connectors shall be preloaded adapters configured with 8 ST duplex multi-

mode adapters filled with a zirconia ceramic split sleeve.

D. Acceptable Manufacturers

1. Panduit

2. Amphenol

3. 3M

2.4 FIBER-OPTIC CONNECTORS

A. All connectors for the termination of the fiber-optic backbone or horizontal cable

shall be simplex ST connectors.

B. For multi-mode fiber-optic terminations the connectors shall be for 900um tight-

buffered fiber installation..


C. Acceptable Manufacturers

1. Panduit

2. Amphenol

3. 3M

2.5 FIBER OPTIC PATCH CABLE

A. Provide multi-mode, buffered, optical glass fiber cores, compatible with laser-

based transmission systems and suitable for fiber optic Ethernet LAN standards,

including the point-to-point Fiber Optic Inter-Repeater Link (FOIRL) network, and

ANSI standard Fiber Distributed Data Interface (FDDI) networks.

B. Attenuation losses shall be 3.5dB/km or less at a wavelength of 850 nm and

1.5dB/km or less at a wavelength of 1300 nm.

C. Do not use cable with plastic fiber core construction.

D. Connection on patch cables shall be ST for patch panels for equipment, or as

required.

E. Manufacturers:

1. Hubbel,

2. Ortronics,

3. Leviton

4. Belden,

5. Corning,

6. Prysmian Group

2.6 FIBER OPTIC CABLE PATCH PANELS

A. All fiber optic patch panels shall be provided in wall mounted NEMA 12

enclosures. Patch panels may be located inside network cabinets as shown.

B. Provide fiber optic cable patch panels are referenced on the drawings and which

meet the following requirements:

1. Furnish panels with the following accessories:

a. Sliding tray with tray glides


b. Cable strain relief,

c. Bend radius protectors,

d. Routing guides,

e. Grommetted cable entries,

f. ST simplex adapters and adapter plates,

g. Sufficient working space for removal of connectors,

h. Identification label,

i. All cable management hardware required to accomplish the

installation.

2. It is acceptable for the accessories to be installed in a separate enclosure

inside the NEMA 12 enclosure.

3. Furnish each cabinet with a keylock and two (2) keys for each cabinet.

4. Furnish cabinets with internal space to store, organize, and strain relieve

incoming and outgoing cables.

5. Grounding lug for cable support member and routing supports to maintain

allowable cable bend radius.

C. When the required number of terminations exceeds the capacity of a single patch

panel, multiple patch panels shall be provided. These multiple patch panels shall

be enclosed in a single NEMA 12 enclosure.

D. Patch panel features and qualities shall be the same for multimode and single mode

cable.

E. Manufacturers:

1. Hubbell Premises Wiring,

2. Aria Technologies,

3. Leviton,

2.7 TERMINAL CONNECTORS

A. Provide fiber optic ST simplex connectors; multimode and single mode versions.

Fusion splice, epoxy or hot-melt is acceptable. Provide polymer body with a

precision zirconia ferrule.


1. Connector specifications:

a. Insertion Loss: 0.15 / 0.30dB (typical/maximum).

b. Durability Delta: 0.1 dB (1,000 matings).

c. Cable Retention: 40 pounds.

d. Operating Temperature: -40 to +80 degrees C.

2. Manufacturers:

a. 3M,

b. Siemon,

c. Stratos Lightwave,

d. Leviton

2.8 WIRE MANAGEMENT LOOPS

A. Wire management loops shall be used to route wiring near patch panels and

electronics. Loops shall support and protect wiring and terminations within panel.

All cables and fibers must be supported from loops and not from the termination

B. Manufacturer and Product: To match patch panel / network rack supplier

2.9 COPPER TO FIBER MEDIA CONVERTERS

A. Where required for proper operation, show or specified provide media converters to

convert copper signals to fiber optic.

B. Acceptable Manufacturers

1. BlackBox

2. Metrobility

PART 3 EXECUTION

3.1 FIBER-OPTIC INSTALLATION

A. Installation of the fiber-optic backbone cable shall comply with EIA/TIA-568-B

Telecommunications Building Standard.


B. Each fiber backbone segment shall be a continuous run (no splices) from the

Network Panels to the target Network Access Panel or Fiber Wall Mount

Enclosure.

C. As a minimum, a one Ft loop for every 300 Ft of cable length shall be left at the

end of each fiber-optic backbone cable and housed in the Network Core Panel and

either the Network Access Panel or Fiber Wall Mount Enclosure. If the cable

length is less than 600 Ft, then a 6 Ft loop of cable shall be left at the end of each

fiber-optic backbone cable and housed in the Network Core Panel and either the

Network Access Panel or Fiber Wall Mount Enclosure.

D. The bend radius for fiber-optic backbone cable shall not be less than the

manufacturer’s recommended minimum bend radius.

E. The tensile load for fiber-optic backbone cable shall not exceed the manufacturer’s

recommended maximum tensile load.

F. Do not use nylon cable-ties to prevent micro-bends. Use hook and loop straps to

secure or collate fiber-optic backbone cable.

G. Field-verify cable lengths.

H. Provide full circle and half circle coil formers at each end to coil excess fiber

strands and excess fiber patch cords.

I. Labeling

1. Use durable non-fading sleeve-type wire markers to identify network cables.

2. Apply the tagging convention described in this Specification for Fiber-Optic

cables.

3. As a minimum, label both ends of the fiber-optic backbone cable.

4. In addition, label the fiber-optic cable every 60 Ft from the Network Core

Panel and at major transitions. Major transitions are defined as: the

entrance and exit of a wall or floor, a change in method of ducting, or a

change in direction of more than 45 degrees.

3.2 IDENTIFICATION

A. Label each termination point.

B. Tag each cable in junction boxes and enclosures.

1. Tags shall indicate the cable number, date installed, type of cable, and

manufacturer.


2. Attach tags to cable with non-ferrous metal wire.

3. Tagging and labeling shall meet the requirements of Div 26


A. Provide the services of the fiber optic cable manufacturer to inspect the installation

of each cable. Test each fiber between its patch panel bulkhead connectors for

optical power loss and frequency response. All fibers shall be verified to meet

manufacturer’s advertised specifications.

B. Fibers shall be tested both directions

3.4 TESTING TOOL

A. Provide one set of fiber optic test tools.

1. Optical Power Meter (OPM)

a. Accuracy/Linearity +/-0.2dB

b. Amplifier design: Linear

c. Calibrated wavelength: 850nm, 1300nm

d. Calibration period: 12 months

e. Display resolution: 0.01dB

f. Dynamic range (Power): +3dB to -55dB

g. Optical adapter: Universal

h. Photodiode: Germanium

i. Power Source: 2 AA batteries

j. Battery Life: 100 hours

2. Optical Light Source

a. Source type: LED

b. Wavelength: 850nm, 1300nm

c. Power launched into 62.5/125nm fiber @850nm: -13dBm and

@1300nm: -12dBm

d. Power output accuracy: +/-2dB @ 850nm and +0.5dB @ 1300nm


e. Optical adapter: Universal

f. Power Source: 2AA batteries

g. Battery life: 8 hours

3. Splice/connectorization kit: Provide a splice and termination kit with the

following minimum equipment.

a. Fiber cleaver

b. 50 multimode connectors of each type used. Connectors shall be of

the mechanical type with a pre-polished factory stub with mechanical

splice with index matching gel.

4. Additional items as recommended by equipment manufacturers or as

described elsewhere in the Specifications.

5. Provide special tools necessary for normal operation, maintenance and

diagnostic aids.

END OF SECTION

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