GAS MANAGEMENT SYSTEM REHABILITATION AND … · 01 41 26 permit requirements 01 45 00 quality...

Matthew Pagendarm Dan Gagne

Michael Harrison John Pepper Robinette

CONTRACT DOCUMENTS FOR THE CONSTRUCTION OF

SACRAMENTO REGIONAL WASTEWATER TREATMENT PLANT

GAS MANAGEMENT SYSTEM REHABILITATION AND IMPROVEMENTS

CONTRACT NUMBER

BID SET

VOLUME 2 OF 3 PART A – CONTRACT REQUIREMENTS (DIV 00 AND DIV 01) PART B – TECHNICAL SPECIFICATIONS (DIV 02 THROUGH DIV 43)

January 2019

Version: 10

BOARD OF DIRECTORS J. Bruins L. Carr S. Frost E. Guerra J. Harris K. Howell P. Hume P. Kennedy S. Ly R. McGarvey D. Nottoli Q. Orozco S. Peters P. Serna O. Villegas A. Warren

8295

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01/28/19 Gas Management System Rehabilitation and Improvements

00 01 10 - 1

SECTION 00 01 10

TABLE OF CONTENTS

VOLUME 1

PART A - CONTRACT REQUIREMENTS DIVISION 00 – PROCUREMENT AND CONTRACTING REQUIREMENTS RFB REQUEST FOR BID (RFB) Document including appendices 00 62 05 00 73 19

PROPRIETARY INFORMATION AGREEMENT HEALTH AND SAFETY REQUIREMENTS

00 73 83 DISPUTE RESOLUTION DIVISION 01 – GENERAL REQUIREMENTS 01 12 16 WORK SEQUENCE 01 14 13 ACCESS TO SITE 01 14 16 COORDINATION WITH OCCUPANTS 01 14 19 USE OF SITE 01 14 20 CONTRACT TIME 01 26 00 CONTRACT MODIFICATION PROCEDURES 01 26 13 REQUESTS FOR INTERPRETATION 01 29 76 PROGRESS PAYMENT PROCEDURES 01 31 19 PROJECT MEETINGS 01 31 26 ELECTRONIC COMMUNICATION PROTOCOLS 01 32 16 CONSTRUCTION PROGRESS SCHEDULE 01 32 23 SURVEY AND LAYOUT DATA 01 32 33 PHOTOGRAPHIC DOCUMENTATION 01 33 00 SUBMITTAL PROCEDURES 01 33 16 DESIGN DATA 01 41 26 PERMIT REQUIREMENTS 01 45 00 QUALITY CONTROL 01 51 00 TEMPORARY UTILITIES 01 52 00 CONSTRUCTION FACILITIES 01 55 26 TRAFFIC CONTROL 01 56 00 TEMPORARY BARRIERS AND ENCLOSURES 01 57 19 TEMPORARY ENVIRONMENTAL CONTROLS 01 57 23 TEMPORARY STORM WATER POLLUTION CONTROL 01 64 00 OWNER-FURNISHED PRODUCTS 01 65 00 PRODUCT DELIVERY REQUIREMENTS


00 01 10 - 2

DIVISION 01 – GENERAL REQUIREMENTS 01 73 24 DESIGN REQUIREMENTS FOR NON-STRUCTURAL

COMPONENTS AND NON-BUILDING STRUCTURES 01 73 33 RESTORATION OF IMPROVEMENTS 01 74 23 FINAL CLEANING 01 78 23 OPERATION AND MAINTENANCE DATA 01 78 39 PROJECT RECORD DOCUMENTS 01 78 43 SPARE PARTS 01 79 10 TRAINING 01 91 00 COMMISSIONING 01 91 10 REFERENCE FORMS

DIVISION 02 – EXISTING CONDITIONS 02 41 13 SELECTIVE SITE DEMOLITION

PART B – TECHNICAL SPECIFICATIONS

DIVISION 03 – CONCRETE 03 11 00 CONCRETE FORMING 03 11 32 CONCRETE CRACK REPAIR 03 20 00 CONCRETE REINFORCING 03 30 00 CAST-IN-PLACE CONCRETE 03 34 13 CONTORLLED LOW STRENGTH CONCRETE 03 40 00 PRECAST CONCRETE 03 60 00 GROUTING

DIVISION 05 – METALS 05 05 14 HOT-DIP GALVANIZING 05 05 20 ANCHOR BOLTS 05 10 00 STRUCTURAL METAL FRAMING 05 59 00 METAL SPECIALTIES

DIVISION 09 – FINISHES 09 06 90 SCHEDULES FOR PAINTING AND COATING 09 90 00 PAINTING AND COATING

DIVISION 13 – SPECIAL CONSTRUCTION 13 34 19 PRE-ENGINEERED METAL STRUCTURES


00 01 10 - 3

VOLUME 2 DIVISION 26 – ELECTRICAL 26 05 00 COMMON WORK RESULTS FOR ELECTRICAL 26 05 21 ELECTRICAL POWER CONDUCTORS AND CABLES 26 05 26 GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS 26 05 34 RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR

ELECTRICAL SYSTEMS 26 06 20.21 ELECTRICAL RACEWAY SCHEDULE 26 06 20.25 ELECTRICAL CABLE SCHEDULE 26 08 10 ACCEPTANCE TESTING OF ELECTRICAL SYSTEMS 26 09 16 ELECTRICAL CONTROLS AND RELAYS

DIVISION 31 – EARTHWORK 31 10 00 SITE CLEARING 31 20 00 EARTH MOVING 31 41 00 SHORING

DIVISION 32 – EXTERIOR IMPROVEMENTS 32 12 16 ASPHALT PAVING

DIVISION 40 – PROCESS INTERCONNECTIONS 40 05 03 COMMON WORK RESULTS FOR PIPING SYSTEMS 40 05 07 HANGERS AND SUPPORTS FOR PROCESS PIPING 40 05 23 STAINLESS STEEL PROCESS PIPE AND TUBING 40 05 24 STEEL PROCESS PIPE 40 05 32 POLYETHYLENE PROCESS PIPE 40 05 57 ACTUATORS FOR PROCESS VALVES AND GATES 40 05 63 BALL VALVES 40 05 64 40 05 66

BUTTERFLY VALVES FIRE-RATED FIRE ISOLATION VALVES

40 06 60.13 POWER ACTUATED VALVE AND GATE SCHEDULES 40 06 70 SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS 40 61 13 PROCESS CONTROL SYSTEM GENERAL PROVISIONS 40 61 21 PROCESS CONTROL SYSTEM TESTING 40 61 26 PROCESS CONTROL SYSTEM TRAINING 40 61 93.20 PROGRAMMABLE LOGIC CONTROLLER INPUT/OUTPUT 40 61 96.10 PLANT COMPUTER CONTROL SYSTEM CONTROL

STRATEGIES


00 01 10 - 4

DIVISION 40 – PROCESS INTERCONNECTIONS 40 61 96.20 PROGRAMMABLE LOGIC CONTROLLER CONTROL

NARRATIVES 40 63 43 PROGRAMMABLE LOGIC CONTROLLERS 40 66 35 FIBER OPTIC CABLE, CONNECTORS, AND PANELS 40 67 00 CONTROL SYSTEM EQUIPMENT PANELS AND RACKS 40 70 00 INSTRUMENTATION FOR PROCESS SYSTEMS 40 79 00 MISCELLANEOUS INSTRUMENTS, CALIBRATION

EQUIPMENT, INSTRUMENTATION VALVES, AND FITTINGS DIVISION 43 – PROCESS GAS AND LIQUID HANDLING PURIFICATION, AND STORAGE EQUIPMENT 43 05 10 COMMON WORK RESULTSFOR GAS HANDLING EQUIPMENT 43 13 43 WASTE GAS BURNER SYSTEM 43 13 43.01 GROUND FLARE REFURBISHMENT 43 41 23.01 43 41 23.03

50” WC WATER SEAL CONDENSATE TANK FSG CONDENSATE TANK

DIVISION 46 – WATER AND WASTEWATER EQUIPMENT (NOT USED) APPENDICES APPENDIX A EQUIPMENT DATA FORMS APPENDIX B SIT, SAT, COMMISSIONING PLAN, REFERENCE FORMS

DIVISION 26 - ELECTRICAL 26 05 00 COMMON WORK RESULTS FOR ELECTRICAL 26 05 21 ELECTRICAL POWER CONDUCTORS AND CABLES 26 05 26 GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS 26 05 34 RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR

ELECTRICAL SYSTEMS26 06 20.21 ELECTRICAL RACEWAY SCHEDULE26 06 20.25 ELECTRICAL CABLE SCHEDULE26 08 10 ACCEPTANCE TESTING OF ELECTRICAL SYSTEMS 26 09 16 ELECTRICAL CONTROLS AND RELAYS

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26 05 00 - 1

SECTION 26 05 00

COMMON WORK RESULTS FOR ELECTRICAL

PART 1 -- GENERAL

1.01 GENERAL REQUIREMENTS

A. OVERALL SCOPE: Install new air operated control valves and instruments for the Gas Management System. New ground flare control panels and waste gas burner control panel to be provided by Contractor. Control valves, pressure transmitters and flow meters to be connected to existing PLC panel located in the gas compressor building.

B. SCOPE:

1. This section specifies general requirements for electrical work. Detailed requirements for specific electrical items are specified in other sections but are subject to the general requirements of this section.

2. The electrical drawings and schedules included in the contract documents are based upon field conditions and indicate a constructible approach to installation of electrical systems. Existing raceway and/or cables shall be removed or identified as spare as specified in the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21) and the ELECTRICAL CABLE SCHEDULE Section (26 06 20.25) or as shown on the drawings. Not all existing cables shown on the drawings have unique documented identification.

3. Demolition plan drawings show electrical equipment, raceways & cables to be either removed or retained for spare. Remaining segments of empty raceway shall be retagged in accordance with the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21). Demolition Interconnection Diagrams show the termination points in existing equipment. Unless otherwise noted on the drawings or in the cable or raceway schedule, cables shall be identified as spare.

4. Cables & Raceways are shown on the plan drawings and/or specified in the ELECTRICAL CABLE SCHEDULE Section (26 06 20.25) and the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21). Other routes are reserved for future expansions. Raceway routing is shown on the plan drawings except for lighting and receptacle circuits. If the lighting or receptacle raceways are going to be embedded, submit and obtain approval of the embedded raceway and cable schedules prior to starting the work. Not all cable routes required for installation are shown on the drawings. The drawings do not show cables in trenches, or trays, unscheduled cables, or unscheduled raceways.


26 05 00 - 2

5. Do not shut down existing electrical equipment except as specified in the approved Outage Plan in accordance with the WORK RESTRICTIONS Section (01 14 00).

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed references, the requirements of this section shall prevail.

Reference Title

NFPA-70 National Electrical Code (NEC) CBC California Building Code CSC Canadian Standards Association (CSA) UL Underwriters Laboratories Inc. (UL) ETL Electrical Testing Laboratories (ETL)

1.03 SUBMITTALS

A. The following information shall be submitted for review in accordance with the SUBMITTAL PROCEDURES Section (01 33 00):

1. A copy of this specification section, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations.

2. Electrical test results.

3. Interconnection wiring diagrams.

4. Electrical equipment nameplate engraving schedules.

5. Electrical equipment seismic calculations.

B. GENERAL:

1. When required in the individual specification sections attend a pre-submittal meeting prior to preparing the submittals for work described in this division.

2. The shop drawings or data required by the SUBMITTAL PROCEDURES Section (01 33 00) shall be submitted in one complete package for each electrical equipment or group of related equipment in accordance with the SUBMITTAL PROCEDURES Section (01 33 00). Submittals shall consist of the data hereinafter specified and under individual specification sections.


26 05 00 - 3

C. SUBSTITUTIONS:

1. Substitution for specified equipment requires a written application in accordance with the GENERAL CONDITIONS Section (00 72 00) and the SUBMITTAL PROCEDURES Section (01 33 00). Where standardized equipment is specified, it shall be provided in accordance with the GENERAL CONDITIONS Section (00 72 00).

2. CATALOG CUTS

a. Catalog information shall include technical specifications and application information, including ratings, range, weight, accuracy, etc. Catalog cuts shall be marked with bold arrows to identify the items, model numbers, and information that apply.

b. Catalog cuts shall be assembled in a folder. Each folder shall contain a cover sheet, item index, equipment numbers, and reference to the specification section and paragraph that describes the item being submitted.

D. TEST RESULTS:

1. Provide the test results in accordance with the ACCEPTANCE TESTING OF ELECTRICAL SYSTEMS Section (26 08 10) for motors and electrical systems on the forms specified.

E. PROJECT RECORD DOCUMENTS:

1. Where required to provide information on the drawings as part of the specified work, such drawings shall be prepared in accordance with the SUBMITTAL PROCEDURES Section (01 33 00). Provide project record documents (also known as “as-built drawings”) in accordance with the PROJECT RECORD DOCUMENTS Section (01 78 39).

F. INTERCONNECTION WIRING DIAGRAMS:

1. GENERAL: Prepare interconnection diagrams in accordance with the SUBMITTAL PROCEDURES Section (01 33 00). Cable shall not be pulled into raceway until the interconnection diagrams depicting the cable are approved.

2. DESCRIPTION: The conductor numbering shall consist of the equipment number, equipment designation letters, and a unique wire number; for example: P42318-B-C-1 where:

P42318 is the served equipment number (WAS pump 5)

B-C are equipment designation letters on the interconnection diagram

1 is a unique wire number for the equipment number


26 05 00 - 4

3. USAGE NOTES:

a. Conductors common to two or more pieces of equipment shall, for simple interlocks, take on the number of the equipment controlled (not the one doing the controlling). For complex interlocking, the conductor’s common to two or more pieces of equipment shall take on the number of the first piece of equipment in the series.

b. Wherever possible, the conductor number shall be the same as the terminal to which it connects. The conductor numbering sequence shall start at and use the MCC terminal numbers.

c. When factory wired equipment has terminal numbers different than the terminal numbers shown on the control and logic diagrams, use the factory numbers on the interconnection diagram and modify the control and logic diagram to show as-built conditions.

1.04 OPERATION AND MAINTENANCE INSTRUCTIONS (NOT USED)

PART 2 -- PRODUCTS

2.01 IDENTIFICATION OF LISTED PRODUCTS

A. Electrical equipment and materials shall be listed for the intended purposes by one or more of the following organizations: Underwriters Laboratories Inc. (UL), Canadian Standards Association (CSA), and Electrical Testing Laboratories (ETL). Other approved independent testing laboratories may be acceptable upon approval by the District Representative.

2.02 PROJECT/SITE CONDITIONS

A. Equipment and materials shall be sized and rated for operation at full load in an ambient temperature of 40 degrees C at an elevation ranging from sea level to 1000 feet, or other ambient conditions as specified, without exceeding the manufacturer's stated tolerances and without failure.

2.03 MATERIALS/EQUIPMENT

A. GENERAL:

1. Equipment and materials shall be new and free from defects. All material and equipment of the same or a similar type shall be of the same manufacturer throughout the work. Standard production materials shall be used wherever possible.


26 05 00 - 5

B. EQUIPMENT FINISH:

1. Unless otherwise specified in the particular equipment section, electrical equipment shall be finished using the manufacturer’s standard factory finishing procedures. Hot-dipped galvanizing shall be in accordance with the HOT DIP ZINC COATING Section (05 05 14).

C. PHASE ARRANGEMENT:

1. The phase arrangement on three-phase buses on electrical distribution equipment shall be A, B, C (1,2,3) from front to back, top to bottom, or left to right, as viewed from the front of the equipment.

PART 3 -- EXECUTION

3.01 GENERAL

A. CONSTRUCTION:

1. The work under Division 26 shall be performed in accordance with these specifications and California Electrical Code.

2. Electrical plan drawings of existing areas, equipment location and sizes, routing and space on conduit racks, tray routing and locations of existing conduit are in reasonable agreement with actual field conditions. Plan drawings are based upon equipment sizes and configuration of the first specified equipment. Coordinate the location of electrical material and equipment with equipment pad sizes, other process equipment, piping or structures. Coordination shall be based upon the actual approved equipment and the material being provided. Equipment shall be located to accommodate access requirements identified in the manufacture’s installations instructions. Minor adjustments and changes in location of electrical material or equipment made to suit the installation shall be made at no cost to the District.

B. NAMEPLATES:

1. Nameplates shall be provided for all electrical equipment, including boxes, and shall be made from laminated phenolic plastic. The nominal size of the nameplates shall be 3/4 inch high by 2 inches long. Nameplates shall have black backgrounds with 3/16-inch white letters. If abbreviations are required because of space limita-tions, abbreviations shall be submitted to the District Representative prior to manufacture. The nameplate shall be engraved with the equipment number and description as shown on the drawings and specification schedules.


26 05 00 - 6

C. HOUSEKEEPING:

1. All electrical equipment including panels shall be kept dry, protected from dust, water, condensation and physical damage. Motor control centers, switchgear, and bus ducts shall be wiped free of dust and dirt on the outside, and shall be vacuumed on the inside before acceptance of the work.

2. Before final acceptance, touch up any scratches on equipment with factory supplied touchup paint of matching color.

3.02 INSTALLATION (NOT USED)

3.03 CORROSIVE AREAS AND HAZARDOUS AREAS

A. CORROSIVE AREAS:

1. The following areas are designated as corrosive:

a. All sumps.

b. Manholes and handholes.

B. HAZARDOUS (CLASSIFIED) AREAS:

1. The following areas are designated as hazardous (classified) areas:

Refer to the Drawings for Regional San hazardous area designations and boundaries.

3.04 SEISMIC

A. Electrical equipment and supports shall be braced in accordance with CBC for Risk Category III, Site Class D, and Seismic Design Category D.

B. Provide seismic calculations for anchoring all floor mounted electrical equipment. Load and seismic calculations shall be provided for all suspended supports for bus ducts, wireways and cable trays. Load and seismic calculations shall also be provided for suspended conduit racks if they have more than 12 conduits or are different in any way from the “Typical Trapeze Pipe Support” detail shown on the drawings. All calculations shall be stamped and signed by a registered civil or structural engineer who is licensed to practice in the State of California.

3.05 WET AREAS

All outdoor and indoor areas except architecturally finished, HVAC, switchgear and motor control center rooms shall be defined as wet areas and are subject to wash down by high pressure water.


26 05 00 - 7

3.06 STORAGE OF MATERIALS AND EQUIPMENT

A. Equipment and materials shall be stored as specified in the PRODUCT DELIVERY REQUIREMENTS Section (01 65 00).

B. Equipment and materials to be located indoors shall be stored indoors and protected with plastic film wrap.

3.07 ELECTRICAL NUMBERING SYSTEMS

A. RACEWAY AND CABLE NUMBERS:

1. All raceways and cables are identified in the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21) shall be tagged, even if not identified as such on the drawings. Conflicts between the drawings and the raceway schedule shall be brought to the attention of the District Representative. Raceways shall be tagged at each segment end point and within 3 feet of each floor, ceiling or wall penetration. Where raceway numbers have not been assigned in the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21), the Contractor shall assign raceway numbers in accordance with the following system.

2. Cables in scheduled raceway are identified in the ELECTRICAL CABLE SCHEDULE Section (26 06 20.25). The Contractor shall assign cable numbers in accordance with the following system:

40 A NN NNNNNNNN A N

Contract sequence number

Cable or raceway prefix*

Area number (0-99) or Nominal Voltage in KV for High Voltage Raceways

Cable or raceway number (99999999)** or Switchgear Breaker Designation for High Voltage Raceways

Cable or raceway suffix

Parallel path number

Where "NN" represents a numerical value and

"A" represents an alphanumeric value. *In the case of raceway, prefixes can be "A" or "AA." **Each character in an alphanumeric field ranges from 0 through Z.


26 05 00 - 8

B. DEFINITIONS:

1. CONTRACT SEQUENCE NUMBER: Assigned by the District. This contract sequence = 64.

2. CABLE OR RACEWAY PREFIX: to identify class of service as follows:

Cable Class of Service

C Control 120 VAC F Fiber optic D Data H High voltage power, 601 to 15,000 VAC L Lighting P Power, 120 to 600 VAC S Signal, PA, Fire, 24 VDC and less N Pneumatic (considered cable for routing purposes) X Spare (extra)

Raceway Class of Service

C Control 120 VAC F Fiber optic D Data H High voltage power, 601 to 15,000 VAC L Lighting P Power, 120 to 600 VAC

PC Power and Control, 120 to 600 VAC S Signal, PA, Fire, 24 VDC and less T Telephone N Pneumatic X Spare (extra)

Special Raceways Class of Service

CT Cable Tray WW Wireway


26 05 00 - 9

3. AREA NUMBER OR NOMINAL VOLTAGE:

a. Numerical area assignment

b. Nominal voltage in KV

4. CABLE OR RACEWAY NUMBERS:

a. Raceway numbers: Assign a number from 10 to 999999999 or a combination of alphanumeric characters ranging from 0 to ZZZ for unique identification. Cable numbers: Assign a number from 0 to 9999 or a combination of alphanumeric characters ranging from O to ZZZZ for a unique identification. To avoid confusion, letter characters are restricted to upper case only. Cable or raceway numbers can be arbitrarily selected or follow a similar pattern to related equipment, instruments, devices, or electrical circuits Circuit identification numbers start from the power source.

b. The following are examples of numbers generated using the cable and raceway numbering system:

1) EQUIPMENT NUMBER: Equipment P83102 is in area 8, with number 3102. Similarly, all the cables and raceways associated with P83102 will use number 3102. Example: 9P83102A.

2) INSTRUMENT NUMBER: Instrument LIT8143 is in area 8, with loop number 143. Similarly, all the cables and raceways associated with LIT8143 will use number 143. Example: 9S8143A.

3) MAIN SWITCHGEAR FEEDER: Main switchgear SWR12KV circuit B10 feeds 12kV/480 volt switchgear. Cables and raceways associated with SWR12KV, circuit B10 will use number 12 for nominal voltage in KV and B10. Example: 9H12B10A.

4) SWITCHGEAR FEEDER: Switchgear SWR8L circuit 1 feeds 480 volt MCC. Cables and raceways associated with SWR8L, circuit 1 will use number L01. Example: 9P8L01A.

5) LIGHTING CIRCUIT: Lighting panel PNL8LG circuit 6 feeds a run of lighting fixtures and the raceway and cable is required to be rescheduled (normally they are shown by home run only and are not scheduled). Cables and raceways associated with PNL8LG, circuit 6 will use number LG06. Example: 9L8LG06A.

5. CABLE OR RACEWAY SUFFICE:

a. Assign an alphanumeric character to retain unique identification of cable or raceway.


26 05 00 - 10

6. PARALLEL PATH NUMBER:

a. Assign a numeric character when parallel runs are required. Example: switchgear 8L circuit 01, a feeder to an MCC, requires two feeds of 3-500 Kcmil Cu cable in parallel. First run will be assigned "1"; second parallel run will be assigned "2," i.e., 9P8L01A1, 9P8L01A2.

b. NOTE: When assigning cable or raceway numbers to instruments connected in parallel, e.g., SD88115S11, parallel path number may be an alphanumeric combination although the circuit may be "series" in nature.

C. INDIVIDUAL CONDUCTOR NUMBERS:

1. MEDIUM VOLTAGE CIRCUITS: Conductor numbering shall be the same as the cable schedule number.

2. UNSCHEDULED CIRCUITS: The Contractor shall follow the conductor numbering system for identifying unscheduled lighting and receptacle circuits.

3. SIGNAL CIRCUITS: Conductor numbering is defined in the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00).

3.08 TORQUEING ELECTRICAL CONNECTIONS

A. All bolts and screws associated with electrical equipment for electrical connections shall be torqued in accordance with the manufacturer's instructions and in compliance with NEC Article 110. A torque wrench shall be used. The torque mechanism shall be the sensing type that automatically limits the torque to a preset value until it clicks. Beam type torque indicating wrenches are not acceptable. Torque wrenches shall be supplied in the following three ranges: a low range of 5 to 75 foot-pound, a medium range of 30 to 150 foot-pound, and a high range of 50 to 250 foot-pound, Klein 57000/57005/57010, or equal. Torque wrenches shall be available for each crew making connections.

3.09 DEMOLITION OF RACEWAY AND CABLES

A. CABLES:

1. Remove all wiring disconnected on this contract unless identified as spare on the plans or schedules. Spare cables shall not be removed from raceways containing active cables. Cables shall be coiled up at the nearest junction or pull box and retagged "SPARE" at both ends. Demolition schedules shall be annotated to indicate the demolished cables not removed and tagged spare. Conduits vacated by demolished cables shall be provided with a nylon pull cord fastened at each end.


26 05 00 - 11

B. RACEWAYS:

1. Unless otherwise specified or shown, leave in place all vacated raceways as "spares." Retag as indicated. Where exposed vacated conduit conflicts with new work, remove and cap at nearest coupling. Where embedded vacated conduit conflicts with new work, cut off, grind, and dam; plug with grout flush with building surface. Dam and grout the alternate end. Grout shall be nonshrink per the GROUTING Section (03 60 00). Plug all spaces left by removed conduits in panels, boxes, equipment, devices, fixtures, etc. The type of plug shall maintain the NEMA integrity (i.e., NEMA 12, NEMA 4X) of the equipment.

3.10 PROJECT RECORD DOCUMENTS

A. Maintain an annotated set of contract shop drawings and a set of redline mark-ups of the contract documents in according with the PROJECT RECORD DOCUMENTS Section (01 78 39). These documents shall be available on-site for review by the District on request.

3.11 TESTING

A. GENERAL:

1. Equipment acceptance testing shall be performed in accordance with the requirements of the COMMISSIONING Section (01 91 00). Installation acceptance testing shall be performed in accordance with the requirements of the ACCEPTANCE TESTING OF ELECTRICAL SYSTEMS Section (26 08 10).

B. CONDUCTOR & CABLE TEST:

1. Continuity and insulation resistance measurements shall be made on conductors. The test specified herein shall be performed prior to energizing. Conductor to conductor and conductor to ground insulation resistance shall be measured for all circuits 120V and above except lighting and receptacle circuits. Measurements shall be made after wire pulling and prior to connecting equipment. Insulation with a resistance of less than 50 megohms is not acceptable.

C. NETWORK CABLE CERTIFICATION:

Not used.

D. MOTOR TESTS:

1. All motors shall have their insulation resistance measured before they are connected. Motors 50 HP and larger shall have their insulation resistance measured at the time of delivery as well as when they are connected. Insulation resistance values less than 100 megohms are not acceptable.


26 05 00 - 12

E. PRE-OPERATIONAL TESTING:

1. Prior to operational testing, all protective devices shall be adjusted and made operative. Prior to energizing of equipment, perform pre-operational testing of each device and control circuit. Pre-operational testing shall consist of energizing each control circuit and operating each control, alarm or malfunction device and each interlock in turn to verify that the specified action occurs. Submit pre-operational tests procedures and results in accordance with the COMMISSIONING Section (01 91 00).

2. Verify that all fixtures and devices operate and are correctly polarized, that motors have correct rotation, and that all three-phase receptacles have correct phase sequence and polarity. Verification may be accomplished by momentarily energizing the motor, provided that neither the motor nor the driven equipment will be damaged by reverse operation.

**END OF SECTION**

01/28/19

Gas Management System Rehabilitation and Improvements

26 05 21 - 1

SECTION 26 05 21

ELECTRICAL POWER CONDUCTORS AND CABLES

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies conductors and cables rated 300 to 600 volts used for power, lighting, receptacle, data, signal, and control circuits.

1.02 REFERENCES


Reference Title

AEIC CS6 Ethylene Propylene Rubber Insulated Shielded Power Cables Rated 5 Through 69 kV

ANSI/IEEE 386 Separable Insulated Connector Systems for Power Distribution Systems Above 600V

ASTM B3 Soft or Annealed Copper Wire

ASTM B8 Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

ASTM D 1248 Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and Cable

ASTM D 3349 Standard Test Method for Absorption Coefficient of Ethylene Polymer Material Pigmented with Carbon Black

BELLCORE GR-409-CORE Generic Requirements for Premises Fiber Optic Cable

ICEA S-58-679 Standard for Control Cable Conductor Identification

IEEE 802 series Local and Metropolitan Area Networks

IEEE 1202 Standard for Flame Propagation Testing of Wire and Cable

01/28/19


26 05 21 - 2

Reference Title

NEMA WC5 Thermoplastic-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy

NEMA WC8 Ethylene-Propylene-Rubber-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy

NEMA/ICEA WC 57/S-73-532 Standard for Control Cables

NEMA/ICEA WC 70/S-95-658 Non-Shielded Power Cables Rated 2000 Volts or Less for the Distribution of Electrical Energy

NFPA 70 National Electrical Code (NEC)

NFPA 262 Standard Method of Test for Flame Travel and Smoke of Wires and Cables for Use in Air-Handling Spaces

TIA/EIA 568A Commercial Building Telecommunications Cabling Standard

UL 44 Rubber-Insulated Wires and Cables

UL 83 Thermoplastic-Insulated Wires and Cables

UL 486A Wire connectors and Soldering Lugs for Use with Copper Conductors

UL 486C Splicing Wire Connectors

UL 486D Insulated Wire Connectors for Use with Underground Conductors

UL510 PVC and Rubber insulating Tape

UL 758 Appliance Wiring Methods

UL 910 Test Method of Fire and Smoke Characteristics of Electrical and Optical Cables Used in Air Handling Spaces

UL 1072 2001-8000 Volt Nonshielded Solid-Dielectric Single Conductor Power Cable

UL 1277 Electrical Power and Control Tray Cables with Optional Optical Fiber Members

UL 1666 Test for Flame Propagation Height of Electrical and Optical-Fiber Cables Installed Vertically in Shafts

UL 1685 Vertical-Tray Fire-Propagation and Smoke-Release Test for Electrical and Optical Fiber Cables

01/28/19


26 05 21 - 3

SUBMITTALS

B. The following information shall be submitted for review in accordance with the SUBMITTAL PROCEDURES Section (01 33 00)

1. GENERAL:

a. A copy of this specification section, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations.

b. Manufacturers catalog data showing manufacturer's general information on the conductors and cable to be supplied.

c. Manufacturers catalog data on terminations, taps, splices, tapes, insulation type, insulation voltage, American Wire Gauge (AWG) size, conductor material, pulling compound, and compression tools.

d. SHOP DRAWINGS: Show splice locations for each proposed splice. Provide written justification describing why the splice is necessary.

e. TEST REPORTS: Submit test reports for meg-ohm tests.

f. CALCULATIONS:

1) Submit cable pulling calculations to the Engineer for review and comment for all cables that will be installed using mechanical pulling equipment. Show that the maximum cable tension and sidewall pressure will not exceed manufacturer recommended values:

2) Provide a table showing the manufacturer’s recommended maximum cable tension and sidewall pressure for each cable type and size included in the calculations.

3) Submit the calculations to the Engineer a minimum of 2 weeks before conduit installation.

1.03 STORAGE OF MATERIALS AND EQUIPMENT

A. As specified in COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00).

1.04 QUALITY ASSURANCE

A. As specified in COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00).


01/28/19


26 05 21 - 4

PART 2 -- PRODUCTS

2.01 GENERAL

A. Provide the type, size and number of conductors as shown and as specified in the raceway and cable schedule included in the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21). Unscheduled lighting system and receptacle circuit conductors shall be provided.

2.02 COLOR CODING

A. CONTROL CONDUCTORS:

1. SINGLE CONDUCTOR: Single conductor No. 14 AWG control cable shall be violet except neutrals which shall be white.

2. MULTICONDUCTOR: Multi-conductor No. 14 or No. 16 AWG control cable shall be color coded per WC8, Part 5, Method 1, Table K-2.

B. POWER CONDUCTORS:

1. Power conductors shall have the following colors for the indicated voltage:

120/208V 277/480V 5kV to 15 kV

Phase A Black Brown Red Phase B Red Orange White Phase C Blue Yellow Blue Ground Green Green Neutral White White/Red Tracer

2. Cables sized No. 4 AWG and larger shall be black with phase colored 3/4-inch vinyl plastic tape.

2.03 LIGHTING AND RECEPTACLE CONDUCTORS

A. Lighting and receptacle conductors shall be stranded. Minimum size conductor shall be No. 12 AWG.

B. Conductors shall be provided with the following characteristics:

VOLTAGE: 600 volts.

CONDUCTOR: Bare annealed copper; stranded, annealed copper per ASTM B8.

INSULATION: THHN/THWN, 90 degree C dry, 75 degree C wet, polyvinylchloride (PVC) per UL 83.

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JACKET: Nylon

FLAME RESISTANCE: UL 83

MANUFACTURER: Houston Wire & Cable type THHW/THWN: Southwire, Type THHN/THWN, or equal.

2.04 POWER AND CONTROL CONDUCTORS AND CABLE, 600 VOLT

A. SINGLE CONDUCTOR (P&C SC):

1. Single conductor cable shall be stranded and shall be used in conduits for power and control circuits above grade.

a. Conductors shall be provided with the following characteristics:

VOLTAGE: 600 volts. CONDUCTOR: Coated, Class B, stranded, annealed copper per

ASTM B8. INSULATION: THWN/THHN, 90 degrees C dry, 75 degrees C

wet, polyvinylchloride (PVC), per UL 83. JACKET: Nylon FLAME RESISTANCE: UL 83 MANUFACTURER: Houston Wire & Cable type THHW/THWN;

Southwire type THHN/THWN, or equal.

2. Single conductor cable shall be stranded and shall be used in conduits for power and control circuits below grade.

a. Conductors shall be provided with the following characteristics:

VOLTAGE: 600 volts.

CONDUCTOR: Coated, Class B, stranded, annealed copper per ASTM B8.

INSULATION: XHHW-2, 90 degrees C dry, 90 degrees C wet, cross-linked polyethylene (XLP), per UL 44.

JACKET: Nylon

FLAME RESISTANCE: UL 44

MANUFACTURER: Houston Wire & Cable type XHHW-2; Southwire type XHHW-2, or equal.

B. MULTICONDUCTOR CABLE (P&C MC):

1. Multiconductor cable shall be used for control circuits routed in conduit and wireway. Cables shall be UL labeled, Type TC, designated for cable tray installation in accordance with NEC Article 340. The type of insulation, number of conductors, and size of conductor shall be as specified.

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a. CONTROL CABLE (PVC): Unless otherwise specified multiconductor control cable above grade shall be sized No. 16 AWG.

VOLTAGE: 600 volts.


INSULATION: THHN/THWN, 90 degree C dry, 75 degree C wet, polyvinylchloride (PVC) per UL 83 and UL 1277.

JACKET: Nylon

OVERALL JACKET: Heat, moisture and sunlight-resistant polyvinyl-chloride (PVC).

FLAME RESISTANCE: UL 1685,IEEE 1202

MANUFACTURER: Houston Wire & Cable type THHW/THWN: Southwire, Type THHN/THWN, or equal

b. CONTROL CABLE (XLC): Unless otherwise specified multiconductor control cable below grade shall be sized No. 16 AWG.

VOLTAGE: 600 volts.


INSULATION: XHHW-2, 90 degrees C dry, 90 degrees C wet, cross-linked polyethylene (XLP), per UL 44 and UL1277.

JACKET: Nylon


FLAME RESISTANCE: UL 1685, IEEE 1202


2. Multiconductor cable shall be used for power circuits routed in conduit and wireway. Cables shall be UL labeled, Type TC, designated for cable tray installation in accordance with NEC Article 340. The type of insulation, number of conductors, and size of conductor shall be as specified.

a. POWER CABLE (PVC): Unless otherwise specified multiconductor power cable above grade shall be sized No. 12 AWG.

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VOLTAGE: 600 volts.


INSULATION: THHN/THWN, 90 degree C dry, 75 degree C wet, polyvinylchloride (PVC) per UL 83 and UL 1277.

JACKET: Nylon



MANUFACTURER: Houston Wire & Cable type THHW/THWN: Southwire, Type THHN/THWN, or equal

b. POWER CABLE (XLC): Unless otherwise specified multiconductor control cable below grade shall be sized No. 12 AWG.

VOLTAGE: 600 volts.


INSULATION: XHHW-2, 90 degrees C dry, 90 degrees C wet, cross-linked polyethylene (XLP), per UL 44 and UL1277.

JACKET: Nylon




2.05 MEDIUM VOLTAGE POWER CONDUCTORS AND CABLE (5 KV-15 KV)

Not used.

2.06 SIGNAL CABLES (SC)

A. GENERAL:

1. Cables shall be UL labeled, Type TC, designed for cable tray installation in accordance with NEC Article 340. Cable shall be rated 600V, 90 degrees C, and be suitable for wet or dry locations. Circuits shall be shielded twisted stranded copper conductor construction, color-coded black and white for pairs, or black, white and red for triads. Circuit shielding shall be provided in addition to cable shielding.

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B. SINGLE CIRCUIT (SC SPR AND SC STR):

1. Cable shall consist of 600 volt rated, one pair (PR) or triad (TR), No. 16 AWG stranded conductors with 15 mils PVC/4 mils nylon insulation rated 90 degree C, twisted with a nominal 2-inch lay, covered with a 0.85 mil aluminum mylar 100 percent coverage tape shield having a bare No. 18 AWG stranded tinned copper shield drain wire, and a 45 mil PVC outer jacket. Overall maximum diameter shall be 0.325 inch for pairs and 0.342 inch for triads. Cable shall be manufactured by Furon Dekoron, Part No. 1C52-67000 or 1C62-67000; or equal.

a. 1PR#16 = Twisted shielded pair

C. MULTIPLE SHIELDED PAIR OR TRIAD CABLES (SC MPR AND SC MTR):

1. Cable shall consist of 600 volt rated, multiple pair (MPR) or triad (MTR), No. 18 AWG stranded conductors 15 mils PVC/4 mils nylon insulation rated 90 degree C, twisted on a nominal 2-inch lay. Each pair or triad shall be covered with a 0.85 mil aluminum- mylar 100 percent coverage tape shield having a bare No. 20 AWG stranded tinned copper shield drain wire. The overall shield shall be 2.35 mil aluminum-mylar 100 percent coverage tape shield with a bare No. 18 stranded tinned copper drain wire. Cable shall be manufactured by Furon Dekoron, Part No. 1C74-8xxxx or 1C84-8xxxx; or equal.

2.07 DATA CABLE

A. RS-485 SERIAL COMMUNICATION CABLE (SP-1):

1. The twisted pair data link cable for EIA-RS485 communication shall be UL listed, Type CM. The conductors shall be No. 24 (7x32 strand) tinned copper. The insulation shall be polyethylene with an overall 100 percent shield of aluminum mylar with a 90 percent tinned copper braid. The jacket shall be polyvinyl chloride. The cable shall be Belden No. 9841, or equal.

B. TWINAXIAL SHIELDED COMPUTER CABLE (SP-2):

1. The twin axial-shielded cable shall be two conductor, 20 strand, tinned copper, 78 ohm, with 100 percent shield coverage. The cable shall pass the VW-1 vertical wire flame test and shall be classified in accordance with the NEC as Type "CM." The PVC jacket shall be colored blue. The overall diameter shall be 0.243 inch. The cable shall be Belden 9463, or equal.

C. CATEGORY 6 CABLE (CAT- 6):

1. Category 6 cable shall be suitable for high-speed LAN applications (100mb/s) as well as any EIA/TIA 568A Level 1 through Level 4 applications. Cat-6 cable shall meet regulation for 100 BaseT per IEEE 802 series. Cat-6 cable shall have 100 ohms nominal impedance and nominal capacitance between conductors of 15 pF/ft.

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Cat-6 cable shall be third party verified to conform to the requirements of TIA/EIA 568B.2.1 for Level 6 attenuation limits and near end cross talk (NEXT) as follows:

Signal frequency MHz

Maximum attenuation dB/100m

Minimum NEXT

1 1.9 82.3 10 5.7 67.3 31.25 10.2 59.9 62.5 14.7 55.4 100 18.9 52.3

2. Cat-6 cable shall contain four twisted pairs of Polyolefin insulated 23 AWG solid copper conductors and rip cord. Cat-6 cable shall be AWM style in conformance with UL 758. Jacket shall be sunlight and oil resistant rated. Cat-6 cable shall be Belden 7927A or equal.

2.08 600V CONNECTORS, TAPS AND SPLICES

A. One- and two-way connectors shall be tool applied compression types for stranded conductors conforming to UL 486A. The compression tool shall be designed to prevent the tool from releasing until the proper compression force is reached. The tool and connectors shall be of the same manufacture. Connectors shall be constructed with tin-plated high conductivity wrought copper. Connectors for wire sizes #8 AWG and larger shall be long barrel. One-way connectors shall be one-hole lugs up to size #3/0 AWG, and two-hole or four-hole lugs for size #4/0 and larger. Furnish T&B #549xxBE, #548xxBE, and #548xx series with hydraulic TBM tools, or equal. Mechanical clamp, dimple, screw-type one and two-way connectors are not acceptable.

B. Tap connectors shall be split-bolt with spacer type conforming to UL 486A. Hex-head split-bolt and pressure bar shall be constructed of copper alloy. Spacer shall be contoured and constructed of electrolytic copper or bronze alloy. All pieces shall be tin-plated. Furnish T&B Blackburn xxHPS series, or equal.

C. Connectors for wire sizes #10 AWG and smaller shall be nylon self-insulated locking forks or rings of high conductivity electrolytic copper conforming to UL 486A. Crimping tool shall be of the same manufacture as the connector. Furnish T&B RB22xx & RB14xx series with ERG tools, or equal. Standard spring connectors for #10 AWG and smaller conductors shall be flame-retardant winged nylon shells with a fixed square-wire plated steel spring conforming to UL 486C. Furnish 3M Ranger 512 series, or equal. Waterproof spring connectors shall be the same as the standard type, except filled with silicone sealant. Furnish King Safety Inc. King 3, 4, 5 sealed pro line series, or equal.

D. Insulating tapes shall be weather resistant, flame retardant, rated for 80 C and 600 volts conforming to UL 510. Electrical tape shall be 7-mil vinyl plastic black. Phase tape shall be 7-mil vinyl plastic color code as specified herein. Furnish 3M

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Scotch 33, 35, or equal. Varnished cambric shall be 9-mil cotton tape impregnated with yellow insulating varnish and adhesive backed. Furnish 3M Scotch 2520, or equal. High temperature tape shall be rated for 130 C temperatures, linerless rubber, suitable for 1kV through 69kV. Furnish 3M Scotch 130C, or equal. Heat shrinkable insulators shall be rated 600v and 90 C conforming to UL 486D. Heat shrinkable tape, tubing, boots, and end caps shall be made of thermally stabilized cross-linked polyolefin with internal moisture sealant. Furnish T&B Shrink-konHSxx series, or equal.

2.09 FIREPROOFING MATERIALS

A. Fireproofing tape shall be 3M Scotch 77, or equal. Tape shall be held in place with 3M Scotch 69, or equal, glass cloth tape.

PART 3 -- EXECUTION

3.01 GENERAL

A. Each power, control, signal, data and fiber optic conductor shall be identified at each terminal to which it is connected. The marking system shall comply with the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00).

B. Wire and cable shall not be pulled into conduits until conduits have been cleaned, and the associated interconnection diagrams have been approved.

C. Pulling wire and cable into conduit or trays shall be completed without damaging or putting undue stress on the cable insulation. UL listed pulling compounds, American Polywater J or Ideal Yellow 77, are acceptable lubricants for pulling wire and cable. Grease is not acceptable. Raceway construction shall be complete and protected from the weather before cable is placed.

D. Whenever a cable leaves a raceway, a cable support shall be provided such that no cable weight is transferred on the termination point.

E. When flat bus bar connections are made with unplated bar, the contact areas shall be cleaned to a smooth bright metal. Bolts shall be torqued to the bus manufacturer's recommendations.

F. Each field connection shall be connected to an individual terminal block, except for signal circuits where no more than two conductors shall be inserted into a terminal.

G. Spare power and control conductors shall be identified with wire markers as "spare". A minimum of 12 inches of conductor length shall be coiled inside electrical equipment or pull boxes. Spare conductors shall be insulated with half lapped vinyl plastic tape on each end.

H. Install cables and conductors so that the radius of bends is larger than the manufacturer’s recommended minimum bending radius.

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3.02 600 VOLT CONDUCTOR AND CABLE

A. ELECTRICAL PANELS:

1. Conductors in panels and electrical equipment, No. 6 AWG and smaller, shall be bundled and laced at intervals not greater than 6 inches, spread into trees and connected to their respective terminals. Lacing shall be made up with plastic cable ties. Lacing is not necessary in plastic panel wiring duct.

2. Conductors crossing hinges shall be bundled into groups not exceeding 12. Groups shall be so arranged that they will be protected from chafing and rotate instead of bend when the hinged member is moved.

3. Stranded conductors shall be terminated using connectors and tools described in herein. Where terminals will not accept such terminations, conductors shall be terminated directly on the terminal block.

4. Conductors landing on current transformers shall be terminated with ring lugs.

B. JUNCTION AND PULL BOXES, HANDHOLES AND MANHOLES:

1. Slack shall be provided in junction and pull boxes, handholes and manholes. Slack shall be sufficient to allow cables or conductors to be routed along the walls of the box.

2. Cable racks shall be placed at 2-foot intervals along the walls of large pull boxes, handholes, and manholes. Cables shall be secured to the racks by plastic cable ties arranged in three phase circuits or control groups.

3. Splices shall be installed only in junction boxes, pull boxes, outlets, or cabinets. Splices shall not be permitted in conduit bodies except for connecting solenoid valves where the conduit body is rigidly supported.

4. Indoor lighting fixtures, 120v receptacles, and solenoid pigtails shall be terminated with standard spring connectors. Outdoor lighting fixtures, 120v receptacles, and solenoid pigtails shall be terminated with waterproof spring connectors.

5. Two-way and split-bolt taps in manholes, handholes, and outdoor boxes shall be insulated and waterproofed with heat shrink tubing or heat shrink boots. Two-way and split-bolt taps in indoor boxes shall be insulated with heat shrink tubing, heat shrink boots, or hand wrapped. Hand wrapping shall be varnished cambric first layer, high temperature tape second layer, and vinyl-plastic tape top layer.

C. MOTORS AND TRANSFORMERS:

1. Terminations at transformers and motors with conductors #8 and larger shall be made by bolting together the lugs to the cable compression connectors. Terminations shall be insulated with varnished cambric first layer, high temperature

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tape second layer, and vinyl-plastic tape top layer. Terminations at motors with conductors #10 and smaller shall be made by installing two-piece motor connectors, slip-on insulators, and tyraps.

2. When necessary to correct 3-phase rotation, it shall be accomplished by leaving the phase tape in place and reversing two terminations at the motor or transformer.

D. MOTOR CONTROL CENTERS:

1. Cables entering MCCs shall be bundled into groups of power and control for each starter or feeder unit with plastic cable ties. Each group shall also be supported within the vertical and horizontal wire troughs with plastic cable ties to the trough sides.

3.03 SIGNAL CABLE AND DATA CABLE

A. GENERAL:

1. Signal wiring shall be carried in raceways in compliance with RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS Section (26 05 34) and the following paragraphs. Circuits shall be run as individually shielded twisted pairs or triads. In no case shall a single circuit be made up using conductors from different pairs or triads. Triads shall be used wherever 3-wire circuits are required. Triads shall not be formed by using two pairs. Terminal blocks shall be provided at instrument cable junctions for each wire and shield, and circuits shall be identified at such junctions. All return current paths shall be confined to the same signal cable. Common return conductors for two or more analog circuits are not acceptable. Shields shall not be used for a signal path. The signal cable shield shall be maintained at a fixed potential with respect to the circuit being protected. Cables shall be protected from physical damage during all phases of construction. Tie wraps shall not deform cable twist patterns or shields.

B. CABLE PULLING AND TERMINATION:

1. Manufacturer’s recommended pulling tensions shall not be exceeded. The maximum pulling tension for Cat 6 cable shall not exceed 25lbs. All cables shall be free of tension at both ends, as well as over the total length of each run.

2. Minimum extra cable length requirements are 6-feet for equipment closets, 3-feet for panels, and 10-inches for outlets.

3. Install cables so that the radius of bends is larger than the manufacturer’s minimum bending radius.

C. SIGNAL CONNECTIONS:

1. Electric signal connections to equipment shall be made on terminal blocks, unless

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the product specified in the Contract Documents is only available with suitable locking plug and receptacle cable assemblies, in which case cable assemblies may be used. When flexible cable assemblies are provided with the instrument, the cable assemblies may be used without conduit provided the installation meets all requirements of the NEC, conforms to the RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS Section (26 05 34) requirements and is not subject to mechanical damage.

D. SHIELD TERMINATIONS:

1. Signal cable shields shall be grounded at only one end. Unless otherwise specified, shields shall be bonded to the panel ground bus at the location where the signal common is grounded. The total length of exposed drain signal conductors shall not exceed three inches. Terminals for landing the shield drain wires shall be located immediately adjacent to the signal conductors for that cable.

E. SPARE CIRCUITS:

1. Spare circuit conductors in multiple pair or triad cable and shield drain wires shall be individually terminated on terminal blocks at both ends of cable runs and be electrically continuous through terminal boxes.

F. SIGNAL WIRE TAGGING:

1. All signal wires, whether field wiring or panel wiring, shall be tagged in accordance with the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00), the LOAD INTERRUPTING AIR SWITCHES Section (26 36 15), and the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13). Circuits shall be tagged at all terminations and terminal blocks shall be labeled.

G. SIGNAL CIRCUIT SEPARATION:

1. Low level analog, digital code, pulse frequency, and modulated signal circuits shall be run in enclosed metallic raceways separate from each other and from other circuit types. Low-level analog and digital code signal cables shall be terminated with the shortest practical, untwisted lengths of wire, which expose a minimum area to inductive pickup.

2. High level analog, discrete events, low voltage control, and high level audio signals may be run together in any type raceway complying with RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS Section (26 05 34), as long as each cable is shielded. If individual cable shielding is not provided, high level analog and discrete events signals must be run in separate raceways from low voltage control and high level audio signals.

3. High level analog, low voltage control, and high level audio signals may be run in a

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common cable, as long as individual circuit shielding is provided. Discrete events signals shall not be run in a common cable with other signal types.

4. Any signals operating at greater than 80 volts AC or DC shall be classed as power or control and shall be located separate from any signal circuits and in compliance with RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS Section (26 05 34). Separation for signals shall be 12 inches minimum if either the power/control or the signal circuits are in metallic conduit, except for circuits crossing at a 90-degree angle. Separation for signals shall be 24 inches minimum if both signal and power/control circuits are not in metallic conduit, except for circuits crossing at a 90-degree angle.

5. Reduce exposed circuit area by connecting all signal pairs to adjacent pins in connectors. Cable shields shall be carried through the connector on pins adjacent to the signal pairs.

H. GROUNDING AND SIGNAL COMMON:

1. POWER SUPPLY GROUNDING:

a. Each 24V DC power supply and all circuits powered from it shall be connected to electrical ground at a single location. In the ACCs, connect the 24V DC common bus bar to the panel ground bus at a single location. Unless otherwise shown or specified, other 24V DC power supplies shall be connected to electrical ground by connecting the negative terminal directly to the closest point of the building electrical ground grid.

2. CIRCUIT CONNECTION TO 24V DC COMMON AND ELECTRICAL GROUND:

a. Each analog signal circuit shall be connected to electrical ground at only one location. For circuits that are powered from the ACC 24V DC power supplies, connection to electrical ground shall be accomplished by connecting the circuit to the 24V DC signal common bus bars in the ACC control panel cabinets. Connections to the signal common bus bar shall be made as shown on the drawings. Also, each new instrument shall be provided with an independent connection to the 24V DC signal common bus bar. Field powered signal circuits shall be isolated from electrical ground or be isolated from the 24V DC common bus bars in the ACCs.

I. MULTI-CONDUCTOR CABLE TERMINATION:

1. Insulate the foil shielding and exposed drain wires from each individual signal cable which emerge from the multi-conductor cable that terminates in any cabinet or panel. Insulation tubing shall be installed over the drain conductor to cover the area from the end of the individual cable to just inside the foil shield, allowing room on the end of the cable for termination. Insulate the exposed end of the foil

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shielding, with heat shrink tubing to ensure that the foil shields and drain wires for each cable remain isolated from each other and ground. Fold back and insulate the drain wire from the multi-conductor cable overall shield.

3.04 PHASE INSTALLATION AND IDENTIFICATION

A. The phase installation on three-phase buses or terminals shall be A,B,C from front to back, top to bottom, or left to right, as viewed from the front of the electrical power distribution equipment.

3.05 UNSCHEDULED CONDUCTORS

A. The unscheduled conductors shall be sized by the Contractor to limit voltage drop to 3 percent and shall be sized in accordance with the NEC. The wire shall not be sized less than No. 12 AWG.

3.06 CONDUCTOR CODE COLOR

A. Control conductors shall have violet colored insulation except neutrals that shall be white and ground conductors that shall be green. Control conductors shall include all wires inside "C" conduits. Control conductors shall include 120v power conductors switched inside control panels and routed to motors, valves, etc. Control conductors shall also include 120v power derived from control power transformers inside MCCs, starters, and control panels.

B. Multiconductor cables used for controls shall utilize the manufacturer's color code, except install white phase tape on neutrals and green phase tape on ground conductors. Multiconductor cables used for power shall have phase tape installed as necessary for the 120/208v and 277/480v color codes specified herein.

C. Power conductors #6 AWG and smaller shall have the specified colored insulation throughout the circuit. Power conductors #4 AWG and larger shall have phase colored tape installed at the feeder termination and all utilization equipment terminations.

D. Phase tape shall be half lapped approximately 3 inches long near each termination. Phase tape shall not be removed. Devices shall be re-terminated as necessary for correct three-phase rotation.

3.07 TESTING

A. GENERAL:

1. Test all conductors and cable unless otherwise specified herein. Test results shall be submitted under the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00) for power, control, signal and data conductors.

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B. CONDUCTORS:

1. Conductor-to-conductor and conductor-to-ground insulation resistance shall be measured for all circuits, 120 volts and above, except lighting and receptacle circuits. Measurements shall be made after the wire has been pulled and prior to connecting the equipment.

3.08 TRAINING (NOT USED)

**END OF SECTION**

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SECTION 26 05 26

GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies the system for grounding electrical equipment, exposed metal surfaces of equipment that could possibly become energized and metal structures. The grounding and bonding system is intended to minimize touch potential and to provide a safe and effective path for dissipation of lightning and fault currents. The grounding system is intended to provide a low resistance path (less than or equal to 2 ohms) to earth ground.

1.02 REFERENCES

A. REFERENCE STANDARDS: The publication referred to hereinafter forms a part of this specification to the extent referenced. The publication is referred to in the text by the basic designation only. The latest edition of the referenced publication in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed reference, the requirements of this section shall prevail.

Reference Title

ASTM Standard specification for Concentric-Lay Copper Conductors, Hard, Medium-Hard, or Soft

NFPA 70 National Electrical Code (NEC) NEC 250 National Electrical Code (NEC) Grounding UL 467 Grounding and Bonding Equipment

1.03 SUBMITTALS

A. The following information shall be submitted for review in accordance with the SUBMITTAL PROCEDURES Sections (01 33 00):

1. A copy of this specification section, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations shall be submitted.

2. Manufacturer's catalog and application data for each material shall be submitted in accordance with this specification.

3. Manufacturer's installation instructions shall be submitted.

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PART 2 -- PRODUCTS

2.01 GROUND RODS AND CLAMPS

A. Ground rods shall be copper-clad steel, 5/8-inch diameter and 10 feet long conforming to UL 467. Electrolytic copper 10-mils thick shall be mechanically bonded to the rigid steel core. Each ground rod shall be supplied with a steel driving stud. Ground rod clamps shall be cast high strength copper alloy with hex head screw. Furnish T&B Blackburn 6260, 60DSNT, JAB34C, JAB58H or equal. Ground rod clamps shall be Burndy YGHC Series or equal.

2.02 EXOTHERMIC CONNECTORS

A. Exothermic connections shall consist of a molecular weld utilizing the reaction of copper oxide and aluminum powder in a semi-permanent graphite mold. Exothermic connectors shall be as manufactured by Erico Products Cadweld, Thermoweld, or equal.

2.03 COMPRESSION CONNECTORS

A. Compression connectors shall be the irreversible type and be constructed with tin-plated high conductivity wrought copper conforming to the ELECTRICAL POWER CONDUCTORS AND CABLES Section (26 05 21). Burndy YSCM Series, or equal.

2.04 GROUND PLATES

A. Ground plates shall be a cast copper alloy with four 1/2inch-13 threaded holes, 1/2-inch deep, and plastic plugs, Cadweld B164-2Q Series, or equal.

2.05 GROUND WELL

A. Provide a 13-inch inside diameter, 9-inch nominal throat, concrete ground rod box, minimum 12 inches deep, with a cast iron traffic cover embossed or engraved "GROUND." Ground rod box shall be Oldcastle Christy G08T box with G05CT lid with grade ring and extensions as required, or equal.

PART 3 -- EXECUTION

3.01 GENERAL

A. The grounding electrode system consists of the bonding together of the ground ring conductors with the ground rods, duct bank grounding conductors, foundation rebar, metal frame of the building(s), metal underground water pipes and other made electrodes. The ground ring conductors shall be buried a minimum of 30 inches deep.

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3.02 INSTALLATION

A. CONNECTIONS:

1. Embedded or buried ground connections shall be made by exothermic weld type connectors. Conductors and molds shall be prepared in accordance with manufacturer's instructions. Exposed connections between grounding conductors shall be made by either exothermic or compression connectors. Compression connections will be made utilizing diamond or hexagon dies and a hand compression tool for wire sizes 2 AWG and smaller and a hydraulic pump and compression head for wire sizes larger than 2 AWG. Tools and dies shall be approved for this purpose; dimple compressions are not acceptable. Compression connections shall be prepared in accordance with the manufacturer's instructions.

2. Accessible connections to structural members shall be made by exothermic or bolted connection. Exposed ground connections to equipment shall be made by bolted connections torqued in accordance with the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00). No solder shall be used in any part of the ground circuits.

3. Where the ground cables cross the top of tunnels and cannot be buried to the required 30 inches, the cable shall be buried as deep as possible.

4. Where the grounding system is required to be connected to the existing grounding system, the connection shall be made accessible. Underground connections shall be enclosed in a concrete junction box. Grounding connections to existing concrete structures shall be made by chipping into the structure and installing a ground plate connection which shall be exothermically connected to the rebar. The plate shall be mounted on the surface of the structure. The surface of the structure shall be repaired to the original condition.

5. District shall inspect exothermic process molds before starting first exothermic connection. Molds shall be replaced at intervals recommended by the manufacturer.

B. EMBEDDED GROUND CABLES:

1. Ground cables embedded in slabs or pads shall be laid underneath the top layer of reinforcing steel. Ground cables shall be securely attached to reinforcing steel with tie wires to prevent displacement from the steel during concrete placement. Ground cables shall be bonded by exothermic welds to the reinforcing steel at 40-foot intervals but in two places at a minimum.

2. Ground cables embedded in duct banks shall be bonded together in manholes and handholes. Duct bank ground cables shall also be bonded to distribution equipment served by the duct bank. Manhole ground cables shall be connected by exothermic weld.

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3. The District shall be notified 24 hours prior to backfilling or encasing in concrete any part of a ground system.

C. EXPOSED GROUNDING CONDUCTORS:

1. Grounding conductors which extend beyond concrete surfaces for connection to equipment shall be extended a sufficient length to reach the final connection point without splicing. The minimum extension shall be 6 feet. Grounding conductors which project from a concrete surface shall be located as close as possible to the equipment grounding pad and shall be protected from mechanical damage by a conduit sleeve. Exposed grounding conductors shall be supported by noncorrosive metallic hardware at 4-foot intervals or less. Grounding conductors for substation transformers and future equipment shall be terminated using a four-hole copper flush mounted grounding plate.

D. ELECTRICAL EQUIPMENT GROUNDING:

1. Ground conductors, except signal conductor shields, entering metallic enclosures shall be bonded together to the enclosure or ground bus. Prior to making ground connections or bonds, the metal surface at the point of connection shall be cleaned to a smooth bright metal.

2. Lightning arresters shall be directly connected to the ground system using copper conductors.

3. Metal device boxes shall be drilled and tapped and fitted with a grounding screw for the terminating of the equipment grounding conductor.

4. Metallic sheaths or shields of shielded power cable shall be terminated by connecting the cable sheath or shield grounding strap (provided with the cable termination or splice kit or connector) to the grounding system.

5. All motors shall be grounded by bonding the grounding conductor within the raceway to the motor frame. Motors 100 HP and larger shall also have a supple-mental grounding conductor bonded to the reinforcing steel in the immediate area of the motor.

6. Nonmetallic liquid tight conduit shall be provided with a bonding jumper sized in compliance with NFPA 70.

E. RACEWAY GROUND:

1. Metallic conduits shall be assembled to provide a continuous ground path from the point of supply to the utilization equipment. Metallic conduits shall be bonded to the ground system using insulated grounding bushings and conductors sized in compliance with NFPA 70.

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2. An insulated (green) stranded copper equipment grounding conductor shall be installed in conduits that contain circuits operating above 50 volts. The equipment grounding conductor shall provide a continuous ground path from the point of supply to the utilization equipment. When the size of the equipment grounding conductor is not shown on the drawings or cable schedules, the equipment grounding conductor shall be sized in accordance with Table 250-95 of NFPA 70.

3. Metal parts of nonmetallic boxes and plastic coated boxes shall be bonded to the conduit system.

4. Cable trays shall have No. 2/0 AWG bare copper bonding jumper looped on the outside of each tray. The ground conductor shall be connected to each section or fitting.

F. EQUIPMENT AND ENCLOSURE GROUND:

1. Nonelectrical equipment shall be connected to the grounding system as specified by NEC 250 and as shown on the drawings. Cables shall be sized as specified in the Cable Schedule.

2. Metal fences shall be grounded where they are as shown on the drawings. Use flexible connections at each gate.

3.03 CABLE SIZES

A. Ground cable shall be annealed bare or insulated copper, concentric stranded as shown on the drawings. If ground cable sizes are not shown on the drawings, the minimum sizes shall be in accordance with NEC Article 250 and as follows:

Item Ground Cable Size

Duct banks (low voltage) #2/0 AWG Duct banks (signal/communication) #2/0 AWG 480V MCCs #2/0 AWG Lighting panels #2 AWG Exposed metal (possibly energized) #2 AWG 480V motors(100 HP and larger) #2 AWG

3.04 TESTING

A. GROUNDING SYSTEM TESTS:

1. The grounding system shall be tested in accordance with the ACCEPTANCE TESTING OF ELECTRICAL SYSTEMS Section (26 08 10). The measurements shall be recorded on appropriate forms.

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**END OF SECTION**

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SECTION 26 05 34

RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies raceways, fittings and supports, manholes, handholes and boxes for electrical conductors and cables.

1.02 REFERENCES


Reference TitleANSI/NFPA 70 National Electric Code (NEC)ANSI C80.1 Electric Rigid Steel Conduit-Zinc Coated (ERSC) ASTM A123 Zinc (Hot Dipped Galvanized) Coatings on Iron and Steel

ProductsASTM 153 Zinc (Hot Dipped) Coating on Iron and Steel HardwareASTM A240 Heat-Resisting Chromium and Chromium-Nickel Stainless

Plate, Steel and StripASTM A570 Hot-Rolled Carbon Steel Sheet and Strip, Structural QualityASTM A576 Steel Bars, Carbon, Hot-Wrought, Special Quality ASTM A193 Alloy-Steel and Stainless Steel Bolting Materials for High

Temperature ServiceASTM B633 Electrodeposited Coating of Zinc and Iron and SteelASTM C857 Minimum Structural Design Loading for Underground

Precast Concrete Utility StructuresASTM D2564 Solvent Cements for Polyvinyl Chloride (PVC) Plastic

Piping SystemsASTM E814 Methods for Fire Tests of Through-Penetration Fire StopsNEMA ICS-6 Enclosures for Industrial Controls and Systems NEMA RN-1 Polyvinyl Chloride (PVC) Externally Coated Galvanized

Rigid Steel ConduitNEMA TC2 Electrical Plastic Tubing (EPT) and Conduit (EPC 40 and

EPC 80)

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Reference TitleNEMA TC3 Polyvinyl Chloride (PVC) Fittings for Use with Rigid PVC

Conduit and TubingNEMA VE1 Cable Tray SystemsUL 6 UL Standard for Safety, Rigid Metal Conduit, 10th EditionUL 50 Enclosures for Electrical Equipment, Non0Environmental

ConsiderationsUL 360 Liquidtight Flexible Steel ConduitUL 467 Grounding and Bonding EquipmentUL 514A Metallic Outlet BoxesUL 514B Fittings for Conduit and Outlet BoxesUL 651 Schedule 40 and 80 Rigid PVC Conduit UL 870 Wireways, Auxiliary Gutters, and Associated FittingsUL 886 Outlet Boxes and Fittings for Use in Hazardous LocationsUL 1479 Fire Tests of Through-Penetration Fire stops

B. DEFINITIONS: (Not Used)

1.03 SUBMITTALS



2. Shop drawings for all large fabricated pull boxes.

3. Raceway support seismic and safety factor calculations

4. MANUFACTURERS CATALOG DATA:

a. Galvanized rigid steel conduit, conduit bodies, seals, and fittings.

b. PVC coated rigid steel conduit, fittings, and accessories.

c. Liquidtight flexible conduit, explosion proof flexible conduit, and fittings.

d. Rigid nonmetallic conduit, elbows, end bells, adapters, and duct bank spacers.

e. Wireways, wireway fittings, cable trays, and cable tray fittings. Cable tray deflection data.

f. Boxes grouped by NEMA classification and size.

g. Wiring trough.

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h. Expansion, wall, and roof fittings.

i. Handholes and manholes.

j. Individual, embedded and suspended raceway supports.

k. Raceway markers, fire stops, and duct cable seals.

l. Raceway plaque engraving material, adhesive and double sided tape.

5. Handholes and manhole schedule, sizes, construction details, and cable racks.

6. Manhole penetration details and waterproofing system.

7. Manhole structural details and calculations stamped by registered Civil engineer.

8. Manhole and handhole raceway plaque schedule.

PART 2 -- PRODUCTS

2.01 STEEL CONDUIT, BODIES AND FITTINGS

A. GALVANIZED RIGID STEEL CONDUIT:

1. Galvanized rigid steel conduit and elbows shall comply with ANSI C80.1 and UL 6; minimum size shall be 3/4 inch. Zinc coating shall be applied after fabrication and then coated with a chromate finish. Conduit shall be as manufactured by Allied Tube and Conduit, Type GRC; Western Tube, Type GRS; or equal.

B. CONDUIT OUTLET BODIES:

1. Conduit outlet bodies shall be oversized type and shall conform to ANSI C80.1 and UL 514B. They shall be fabricated from cast iron alloy with zinc electroplate. The finish shall be aluminum acrylic paint. The covers shall be the same materials as the body material with neoprene gasket and stainless steel screws. Manufacturer shall be Cooper Crouse-Hinds, Form 8 Condulets, or equal.

C. FITTINGS:

1. Locknuts shall be extra heavy electro galvanized steel for sizes up to 2 inches. Locknuts larger than 2 inches shall be electro galvanized malleable iron. Bonding and grounding bushings shall be threaded, insulated locking type (set screw) and shall be provided with a feed-through compression lug for securing the ground cables. Unions 3/4 inch to 1 inch shall be steel, zinc plated three piece types. Unions 1 1/4 inch and larger shall be malleable iron; zinc plated three piece types. Furnish Emerson O-Z Gedney type UNF/UNY series, or equal. Threaded hubs for

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connection of conduit to junction, device or terminal boxes shall be made of zinc electroplated cast ferrous alloy or nickel chrome-plated zinc and shall have insulated liner with a grounding locknut. The hubs shall utilize a neoprene O-ring and shall provide a watertight connection. Manufacturers shall be Emerson O.Z. Gedney, Type CHM-T, or Thomas & Betts 370/106 series, Cooper Crouse-Hinds STG series.

2.02 PVC COATED RIGID STEEL CONDUIT, FITTINGS AND ACCESSORIES

A. PVC-coated conduit shall be rigid steel conduit as specified herein to which a 40-mil thick polyvinylchloride coating has been bonded to the exterior and shall conform to NEMA RN-1. A urethane coating of 2-mil thickness minimum shall be applied to the interior of all conduits and fittings plus all threads. Coating shall be free of pinholes. Bond strength shall exceed the tensile strength of the plastic coat. Conduit bodies, junction bodies, elbows and fittings shall be factory made and coated to the same thickness as the conduit. Minimum size shall be 3/4 inch. PVC coating patching material shall be as provided by the manufacturer. Manufacturers shall be Robroy Industries; Plasti-Bond Red; Thomas & Betts; Ocal-Blue; or equal.

2.03 FLEXIBLE CONDUIT

A. LIQUIDTIGHT TYPE:

1. Liquidtight flexible steel conduit shall be formed from spirally wound galvanized steel strip with successive convolutions securely interlocked with integral copper ground wire and jacketed with ultraviolet resistant liquidtight plastic cover. Fittings for liquidtight conduit shall have cadmium-plated malleable iron body and gland nut with cast-in lug, steel grounding ferrule threaded to engage conduit spiral and O-ring seals around the conduit and box connection and insulated throat. Straight, 45- and 90-degree fittings shall be used where applicable. Liquidtight flexible conduit shall be Type U.A. in conformance with UL 360. Manufacturers shall be Anaconda Sealtite, Emerson Appleton Type STB, Emerson O.Z. Gedney Series 4QT, or equal.

2.04 RIGID NONMETALLIC CONDUIT

A. Rigid nonmetallic conduit, endbells and fittings shall conform to requirement of UL 651 and NEMA TC2, type EPC-40-PVC, high impact, polyvinylchloride (PVC). Duct bank spacers shall high impact plastic interlocked 2-inch spacers for PVC ducts. Joint glue shall be medium grade gray, solvent cement. Minimum size shall be 1 inch. Manufacturer shall be Thomas & Betts Carlon 49000 (Sch. 40) or 49400 (Sch. 80) series, Thomas & Betts Carlon Snap-Loc Spacers series, or equal. All rigid nonmetallic 2-inch and larger elbows and bends (22.5- through 90-degree) shall be factory made with a 48-inch radius minimum and shall be Thomas & Betts Carlon UA/BxHx series, or equal.

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2.05 WIREWAYS

A. NEMA 12:

1. Feed-through wireways shall conform to UL 870 and NEMA ISC6, type 12.Wireways shall be hinged, oiltight, with flanged connectors constructed of and 14-gauge steel with 10-gauge end flanges. All bolted connections shall be gasketed. Finish shall be ANSI 61 gray inside and outside. Manufacturers shall be Schneider electric Square D Type LJ; Hoffman, Bulletin F-20; or equal.

B. NEMA 4X:

1. Feed-through wireways shall conform to UL 870 and NEMA ICS6, type 4X. Wireways shall be constructed of 304 stainless steel, 14-gauge body, 14-gauge hinged cover, and 10-gauge flanges. All bolted connections shall have oil-resistant gaskets. All fasteners shall be stainless steel. The manufacturer shall be Hoffman, Bulletin F-22, or equal.

2.06 CABLE TRAYS

A. Cable trays shall be of heavy-duty, 6063-T6 aluminum alloy construction, NEMA load Class 12C, in accordance with NEMA VE1.

B. Cable trays shall be ladder type with rungs and side rails. Interior loading depth shall be 4 inches nominal. Exterior height shall be 5 inches nominal. Tray loading width shall be as indicated on the drawings with a maximum rung spacing of 6 inches between centers. The trays shall be designed and constructed to support a uniformly distributed minimum load of 50 pounds per linear foot with a maximum deflection of 0.57 inch for 12-inch-wide trays; and 100 pounds per linear foot with a maximum deflection of 0.62 inch for 18-inch and 24-inch-wide trays, when tested as a single 10-foot span, simple beam.

C. Cable tray components shall be fabricated to a 1/16-inch tolerance. Bottom to side rail connections shall be a positive mechanical joint to assure lateral and longitudinal stability. Wall and floor penetration sleeves shall be two pieces, 14-gauge hot-dipped galvanized steel with 304 stainless steel hardware. Furnish Legrand PW Industries Cablofil 4G05-0424-xx-S4 series, or equal.

D. Fittings, barriers, expansion fittings, and covers shall be of the same materials, finish and construction as the straight trays. The minimum radius of side rails on horizontal elbows, inside and outside vertical risers, tees and crosses, shall be 12 inches except where shown otherwise on the drawings. Furnish Legrand PW Industries Cablofil 06-4G05 series (flange out system), or equal.

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2.07 NEMA 3R CAST FERROUS ALLOY BOXES

A. Boxes shall conform to NEMA ICS6 type 3R, fabricated from cast ferrous alloy finished with zinc electroplate and aluminum polymer paint. Integrally cast threaded hubs or bosses shall be provided for conduit entrances and shall provide for full 5-thread contact on tightening. Drilling and threading shall be done before galvanizing. Cover plates shall be of similar hot-dip galvanized cast ferrous alloy material. A full-body neoprene gasket shall be provided with the cover. Type 316 stainless steel screws shall be provided for covers. Exposed boxes requiring surface mounting shall have integrally cast mounting tabs. Embedded boxes shall have a bonded PVC jacket. Device boxes shall be Emerson O.Z. Gedney FD series, Cooper Crouse-Hinds FD series, Emerson Appleton FD series, or equal.

B. Outlet and device boxes shall be gang type where two or more devices are located together. Device covers shall be suitable for gang boxes with neoprene gaskets to fit the devices and boxes used. Device plates shall be provided in accordance with the WIRING DEVICES Section (26 27 26). Exposed multiple gang boxes requiring surface mounting shall have integrally cast mounting tabs and shall be furnished with drilled and tapped raintight hubs. Manufacturer shall be Cooper Crouse-Hinds FDOXX/HUBX series, or equal. Embedded multiple gang boxes shall be FD type as manufactured by Cooper Crouse-Hinds, Emerson Appleton, Emerson O.Z. Gedney, or equal.

2.08 NEMA 12 BOXES

A. MID-SIZE BOXES:

1. Boxes larger than FD boxes shall be fabricated from welded 14/16-gauge steel. Finish shall be ANSI 61 light gray enamel over phosphate pretreatment. Fasteners, screws and hardware shall be 316 stainless steel and hinged doors shall be provided with gaskets. Boxes shall conform to NEMA ICS6 type 12 requirements. All screws shall be captive. Where a grounding pad is not available, a bronze service post connector shall be provided. Manufacturer shall be Hoffman Bulletin A-51 and A-12, or equal.

B. LARGE CUSTOM FABRICATED PULL BOXES:

1. Large custom fabricated pull boxes shall be fabricated to NEMA ICS6 type 12 gasketed standards with removable cover plates. The pull box shall consist of a welded frame constructed of 3/16-inch by 2-inch by 2-inch angle iron and 10-gauge steel fabricated to the size specified. End, top and bottom covers as required shall be constructed of 10-gauge stretcher leveled steel plate. Access covers shall be supplied with handles. Cover plates shall be held in place with 1/4-24, type 316 stainless steel cap screws on a maximum spacing of 12 inches. Cover plates shall be sized so that each access plate does not weigh more than 35 pounds. Before finish is applied, a grounding pad drilled for two bolted grounding lugs or a

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½-inch x 2-inch grounding stud shall be welded to the inside of the box. Sharp corners and edges shall be ground smooth, all parts cleaned of weld slag and hot-dip galvanized after fabrication.

2.09 NEMA 4 AND 4X BOXES

A. NEMA 4 BOXES:

1. Boxes larger than FD boxes shall be fabricated from welded 14/16-gauge steel. Finish shall be ANSI 61 light gray enamel over phosphate pretreatment. Fasteners, screws, hinge pin and hardware shall be 316 stainless steel. Box shall have hinged gasketed door and external mounting tabs. Boxes shall conform to NEMA ICS6 type 4. Furnish Hoffman Bulletin A4, or equal.

B. NEMA 4X BOXES:

1. FD boxes shall be PVC coated, cast boxes as manufactured by Robroy, FD series; or equal. Boxes larger than FD shall conform to NEMA ICS6, type 4X, 316 SS. Furnish Hoffman Bulletin A4S (type 316L), or equal.

2.10 NEMA 1 PRESSED STEEL BOXES

A. Boxes shall conform to UL 514A and NEMA ICS6 type 1, fabricated from deep drawn electro-galvanized pressed steel with electro-galvanized steel hardware. Single device boxes shall be 4 inches square by 1-1/2 inches deep. Two device boxes shall be 4-11/16 inches square by 1-1/2 inches deep. Boxes shall have conduit knockouts, integral mounting brackets and covers to suit the surface finish and depth. Masonry boxes shall be 3-3/4 inches high by 3-1/2 inches deep with concentric knockouts. Furnish Emerson Appleton 4SVB/8468 series, 4SJ/8486 series, 856/7 series, MX-350 series, or equal.

2.11 WIRING TROUGH

A. Wiring trough shall conform to UL 870 and NEMA ICS6, type 12. Trough shall be constructed of 14-gauge steel with gasketed hinged cover, mounting ears, and continuously welded end seams. Finish shall be ANSI 61 gray inside and outside. Furnish Hoffman, Bulletin F-20, or equal.

2.12 EXPANSION, WALL AND ROOF FITTINGS

A. SURFACE CONDUITS:

1. Expansion fittings in conduit racks shall be hot-dip galvanized malleable iron providing 4-inch conduit movement. Expansion fittings shall be provided with insulated bushings and bonding jumpers. Surface expansion fittings shall be Emerson O.Z. Gedney Type AX series, or equal.

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B. EMBEDDED CONDUITS:

1. Expansion fittings for conduits embedded in concrete on the centerline of the expansion joint shall provide 3/4-inch movement and 30 degree deflection in all directions. Fittings shall be rated NEMA ICS6 type 4. Materials shall include HDG ductile iron or bronze end couplings, neoprene sleeve, stainless steel bands and copper braid bonding jumper. Embedded expansion fittings shall be Emerson O.Z. Gedney Type DX series, Emerson Appleton Type DX series, or equal.

C. WALL FITTINGS:

1. Wall fittings for conduits shall be hot-dipped galvanized bodies and pressure clamps, 304 stainless steel pressure rings and tightening bolts with neoprene sealing grommets. For newly poured walls, furnish Emerson O.Z. Gedney WSK series and for existing core bored concrete furnish Emerson O.Z. Gedney CSMI/CSMC series, or equal.

D. ROOF JACKS:

1. Roof jacks shall be fabricated from 22-gauge galvanized steel. Counterflashing shall be 24-gauge collar umbrella with stainless steel draw band or rubber storm collar sized for the conduit outside dimension.

2.13 HANDHOLES

A. Handholes shall be precast concrete with checker plate, galvanized, traffic covers designed for AASHTO H-20 loading. Traffic covers shall be hinged with torsion spring-assisted opening to a full 180 degrees. Frame shall be hot-dipped galvanized steel angle with height adjustment bracket. Traffic covers shall be Oldcastle Precast, or equal. Dimensions and appurtenances shall be as shown on the drawings. Handholes shall be provided with precast solid concrete slab bottoms with sumps. Handholes shall be constructed of 3000 psi reinforced concrete. All handhole covers shall be marked "Electric" or "Signal" as applicable and have its equipment number marked on the cover per the handhole schedule. Lettering shall be block type at least 5/8 inch in height engraved, welded, or cast. Duct entries shall be schedule 40 PVC end bells cast into the handhole walls. Duct entries shall be no less than 6 inches above floor.

2.14 MANHOLES

A. Unless otherwise shown on the drawings, manholes shall be precast concrete, 3000-psi strength at 28 days, with reinforcing conforming to Division 3 requirements. Dimensions shall be as shown on the drawings. Manhole cover and frame shall be in accordance with the SANITARY UTILITY SEWERAGE MANHOLES, FRAMES, AND COVERS Section (33 39 13) and shall have a minimum diameter of 36 inches. Necking and extension shaft shall have 36-inch minimum clear opening. Manhole top slab shall be grooved to accept manhole cover extension rings. Manholes shall be

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designed for depth and sizes shown on the drawings. Manholes shall be watertight except for nominal leakage through cover and conduits. Manhole precast joints and extension rings shall be sealed with primer and preformed joint sealant, KT Snyder Co. Ram-Nek, or equal. Manhole cover, frame, extension, and manhole structure shall be designed to withstand AASHTO H-20 loading. Minimum wall thickness shall be 6 inches. Reinforcing shall be appropriate for the wall thickness to meet the H-20 loading, buried depth and ASTM C857.

B. Exterior surfaces of manholes shall be waterproofed with primer and 6 mils of waterproof membrane, Sonneborn Sonoshield Hydrocide #600 and Sonneborn Sonoshield HLM 5000 series, or equal.

C. All manholes shall meet OSHA requirements for maintaining personnel safety. All manholes shall be provided with an OSHA compliant 304 stainless steel access ladder.

D. Duct entries shall be schedule 40 PVC end bells cast into the manhole walls. Duct entries shall be no less than 18 inches above floor and 12 inches below ceiling. Corrosive duty, 12-gauge, #316 SS channels shall be embedded in the concrete at 2-foot intervals for attachment of cable supports. Manholes shall be provided with hot-dipped galvanized pulling eyes on each interior wall. Pulling eyes shall be secured to the steel reinforcement and rated for 10,000 pounds. Ground pigtails of 4/0 copper shall be stubbed out of each duct entrance window and exothermically connected to ground plates on the interior walls as shown on the drawings. Floor shall slope in all directions to the sump. Sump shall be sized 18 inches square by 12 inches deep. Sump pumps shall be provided as specified in the SUMP PUMPS Section (22 14 29).

E. All manhole covers shall be marked "Electric" or "Signal", "DANGER--CONFINED SPACE--DO NOT ENTER", and have the manhole equipment number marked on the cover and welded to the rim per manhole schedule. Additionally, manhole covers on systems over 600 volts shall be permanently marked "DANGER HIGH VOLTAGE--KEEP OUT". Lettering shall be block type at least 5/8 inch in height, engraved, welded, or cast.

2.15 RACEWAY SUPPORTS

A. INDIVIDUAL CONDUIT SUPPORTS:

1. STANDARD DUTY: Individual conduit supports shall include strap and clamp backs, beam clamps, tray clamps and jay hangers. Supports shall be fabricated from malleable iron finished with hot-dipped galvanization or zinc electroplate and aluminum paint. Furnish Emerson Appleton BH series, CL/B series, CH/D series, TCC/D series, Uni-strut J12XX series, or equal.

2. CORROSIVE DUTY: Corrosive duty individual conduit supports shall be the same as standard duty; except shall have 40 mil PVC jacket and #316 stainless steel

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hardware. Furnish Robroy Industries Plasti-Bond Redh2ot, C149 series, RA series, PAR series, CLB-M series, or equal.

B. EMBEDDED SUPPORTS:

1. STANDARD DUTY: Concrete inserts shall include; spot inserts and framing channels. Embedded supports shall be fabricated from cold rolled 12-gauge steel conforming to ASTM A570 GR33 with hot-dipped galvanized finish conforming to ASTM A123. Dimension shall be nominal 1-5/8-inch width with 1-1/2-inch welded tabs on 4-inch centerlines. Channels shall be Styrofoam filled with welded tab end caps. Furnish Uni-strut P3245, P3704, P3270 series, or equal.

2. CORROSIVE DUTY: Corrosive duty concrete inserts shall be the same as standard duty; except shall be 1-5/8-inches wide by 7/8-inch deep and be fabricated from 12-gauge stainless steel conforming to ASTM A240 type 316. Furnish special order Uni-strut P335X-SS, P3703-SS, P3370-SS series, or equal.

C. SUSPENDED RACEWAY SUPPORTS:

1. STANDARD DUTY: Suspended raceway supports shall be trapeze type consisting of threaded rods, nuts, square washers, fittings, framing channels, cable tray clamps and conduit clamps. Fittings and framing channels shall be fabricated from cold rolled 12-gauge steel conforming to ASTM A570 GR33 with hot-dipped galvanized finish conforming to ASTM A123. Channels shall have nominal 1-5/8-inch square slot with inturned lips. Double strut shall be two channels welded back to back. Hardware shall be fabricated from case hardened mild steel in conformance with ASTM A576, GR 1015 with electrogalvanized finish conforming to ASTM B633, Type III SC1. Threads shall be American coarse screw threads UNC, Class 2A/B. Channel conduit clamps shall be two-piece steel with hex head screw and nut. Plastic end caps shall be made specifically for framing channel ends. Furnish Uni-strut P1000/P1001 series, P11XX/P15XX series, P286X series, P2860-XX series and HTHRXXX series, Legrand P W Industries Cablofil 1811 series, or equal.

2. CORROSIVE DUTY: Corrosive duty suspended raceway supports shall be the same as standard duty; except they shall have a 40-mil PVC jacket and all rods, nuts and hardware shall be #316 stainless steel. Furnish Robroy Industries Plasti-Bond RedH2OT, P1000 series, C105 series, or equal.

2.16 RACEWAY MARKERS

A. Raceway markers shall be 1/2-inch wide by 2-inch-long stainless steel tape embossed with 1/4-inch characters. Markers shall be attached to the raceway with No. 16 AWG, 316 stainless steel wire.

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2.17 RACEWAY PLAQUES

A. Raceway plaques shall be located in manholes and handholes to identify each conduit number and their arrangement for each group of conduits entering the manhole or handhole. The plaque shall be a minimum of 12 inches wide by 8 inches high, made from 2-ply microsurfaced impact acrylic, 1/16-inch thick. Plaque shall have white background with ½-inch high black engraved letters. Retagging of conduits inside existing manholes or handholes shall follow the same requirements with the new “retagged” label sized to fit over the existing conduit label. Furnish Rowmark LaserMax LM922-204 or equal.

2.18 FIRESTOPS

A. FIRESTOP MORTAR:

1. Firestop mortar shall be a lightweight, low density, nonshrink, cementious product that forms an endothermic barrier conforming to UL 1479 and ASTM E814. Firestop mortar shall be packaged in premixed bags and have variable water mixing ratio to produce a consistency for pouring, pumping, or troweling. Furnish 3M Company Fire Barrier Mortar, or equal.

B. FIRESTOP BAGS:

1. Firestop bags shall be a tight weave, sealed cloth bags filled with mineral fibers, incombustible components, and fire retardant additives which forms an intumescent barrier conforming to UL 1479 and ASTM E814. Bags shall be sealed to form a dust-free barrier. Firestop bags shall be packaged in nominal 7-inch by 13-inch sizes with varying thickness. Furnish KBS Sealbags SBxxx series, or equal.

C. FIRESTOP SEALANT:

1. Firestop sealant shall be water based, high solids, elastomeric sealant, which forms an intumescent barrier conforming to UL 1479 and ASTM E814. Firestop sealant shall be packaged in caulk tubes or pails. Furnish Emerson Nelson Firestop CLK, ES1399, LBS3, or equal.

D. FIRESTOP PUTTY:

1. Firestop putty shall be adhesive, non-hardening, dielectric compound that forms an intumescent barrier conforming to UL 1479 and ASTM E814. Furnish 3M Company stix MP; Emerson Nelson Firestop FSP, or equal.

2.19 CABLE RACKS

A. Cable racks shall consist of stanchion and arm, both fabricated from 50 percent glass reinforced nylon. Stanchions shall be nominal 4 inches wide by 36 inches long with arm mounting slots and recessed mounting holes. Arms shall be nominal 4 inches wide

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with two hooks for mounting into the stanchion slots. Rated working load shall be 450 pounds for an 8-inch arm, 350 pounds for a 14-inch arm, and 250 pounds for a 20-inch arm. Furnish Underground Devices, Inc. CR36, RAxx series, or equal.

2.20 DUCT CABLE SEALS AND PLUGS

A. Duct cable sealing system for data, signal, and 600v conductors shall consist of an inflatable metallic laminate bladder with sealing strips, cable clips, and high temperature mastic. Duct seals shall be manufactured for specific duct sizes and number of cables. Inflation kit shall consist of on-off switch, pressure regulator, and CO2 cylinders. Furnish Raychem Corp. RDSS-xxx series, RDSS-CLIP-xxx series, RDSS-IT-16, or equal.

B. Duct plug shall be a two-piece nonmetallic reusable stopper consisting of a rigid plug and sealing-ring. Plug shall be fabricated from reinforced polypropylene and the sealing ring shall be thermoplastic rubber or polyurethane elastomer. Duct plugs shall be manufactured specifically for PVC schedule 40 pipes. Furnish ETCO Specialty Products, Inc. “T”-cone expandable stopper ST-x02 series, or equal.

C. Medium voltage cable sealing tape shall be 125-mil conformable mastic rated for 80 degrees C. Sealing tape shall form an environmental seal around wrapped conductors. Furnish 3M Scotch-Seal 2229 compound, or equal.

PART 3 -- EXECUTION

3.01 GENERAL

A. CONDUIT RUNS BETWEEN BOXES: The Contractor shall limit the number of directional changes of the conduit to total not more than 270 degrees in any run between pull boxes. Conduit runs shall be limited to a maximum of 400 feet, less 100 feet for every 90 degrees of change in direction. Bends and offsets shall be avoided where possible but, where necessary, shall be made with a hickey or conduit bending machine, or shall be factory preformed bends. Turns shall be made with cast metal fittings or conduit bends. Welding, brazing or otherwise heating of conduit is not acceptable.

B. JUNCTION AND PULL BOXES: Where required for pulling cable and as necessary to meet the requirements specified herein, the Contractor shall provide condulets, cast junction or pull boxes. Pull boxes used for multiple conduit runs shall not combine circuits fed from different MCCs, switchboards, or switchgear. All junction and pull boxes shall be identified with the number shown on the drawings with spray painted stenciled numerals.

C. CONDUIT TERMINATIONS: Conduit entering NEMA 1 type sheet steel boxes or cabinets shall be secured by a locknut on the exterior of the box or cabinet and an insulated bonding and grounding bushing on the interior side. Steel conduit entering

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26 05 34 - 13

all other boxes shall be terminated into a threaded hub. Boxes without threaded hubs shall be provided with conduit hubs with a grounding locknut for each conduit entry. Joints shall be made with standard couplings or threaded unions. Running threads shall not be used in lieu of conduit nipples, nor shall excessive thread be used on any conduit. The ends of conduit shall be cut square, reamed, and threaded with straight threads. Rigid steel conduit shall be made up tight and without thread compound. Exposed male threads on rigid steel conduit shall be coated with electrically conductive zinc-rich paint. All underground conduits that terminate at junction boxes, panels, switchgear, MCCs or structures shall be sealed with approved duct seal to prevent the transfer of moisture.

D. MATCHING EXISTING FACILITIES: When new conduit is added to areas that are already painted the conduit and its supports shall be painted to match the existing facilities. Where new conduit is used to replace existing conduit, the existing conduit and supports shall be removed, resulting blemishes shall be patched and repainted to match original conditions. Similarly, if existing conduits are to be reused and rerouted, resulting blemishes shall be corrected in the same manner.

E. Each conduit, wire way and tray shall be identified by a specified number. The numbering system is specified in the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00). All raceways identified in the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21) shall be tagged, even if not identified as such on the drawings.

F. CONDUIT SEPARATION:

1. Signal conduits shall be separated from AC power or control conduits. The separation shall be a minimum of 12 inches for metallic conduits and 24 inches for nonmetallic conduits.

2. Underground medium voltage duct banks shall be separated from 480V duct banks by 3 feet minimum for parallel alignments, and 1 foot minimum for crossing alignments.

3. Underground 480V duct banks shall be separated from signal duct banks by 2 feet minimum for parallel alignments, and 1 foot minimum for crossing alignments.

3.02 INSTALLATION

A. Perform all work in accordance with the following:

1. NECA 101 – Standard for Installing Rigid Steel Conduiyd

2. NECA 111 – Standard for Installing Nonmetallic Raceways (RNC).

01/28/19


26 05 34 - 14

3.03 CONDUIT

A. CONDUIT LOCATIONS:

1. Unless otherwise specified in Table A below, conduit shall be galvanized rigid steel.

Table A. Conduit Locations

Conduit type Location

Galvanized rigid steel All exposed noncorrosive areas. Schedule 40 PVC Encased in concrete duct banks, concrete

capped lighting and receptacle underground raceways

PVC coated rigid steel Exposed in corrosive areas and conduits which are stubbed-up through the soil or concrete; All hazardous locations with conduit seals

Liquid tight flexible Final raceway connections to equipment subject to vibration or adjustment in nonhazardous areas

2. Examine equipment outline and dimension drawings to coordinate routing of conduit with manufacturer's installation instructions. Conduit routing shall not interfere with subsequent maintenance activities. Position of new conduit within conduit racks shall be adjusted as necessary to minimize interference with existing raceways, boxes, piping, structural openings, future equipment and other equipment. Conduit shall not block access to boxes, equipment, or unused rack space. In general, conduits shall be located at positions near the top of racks and near walls where possible. Any conduit that interferes with maintenance activities shall be removed and rerouted at the Contractor's expense. The Contractor shall make allowance in his bid to make minor changes in routings at no additional cost to the District.

B. CONDUIT SUPPORT:

1. Exposed rigid steel or plastic coated conduit shall be run on supports spaced not more than 10 feet apart, within 3 feet of 90 degree turns and junction boxes and shall be constructed with runs parallel or perpendicular to walls, structural members, or intersections of vertical planes and ceiling. No conduit shall approach closer than 6 inches to any object operating above the rated temperature of the cable insulation it contains. Where three or more conduits are located in a parallel run, they shall be spaced out from the wall using framing channel or suspended raceway supports. All framing channel conduit support systems shall be oversized to allow for 25 percent additional conduit space. All exposed ends of framing

01/28/19


26 05 34 - 15

channels shall be protected with plastic end caps. Exposed expansion fittings shall be installed where conduit crossed building expansion joints.

2. Steel conduit shall be supported away from the structures using standard duty individual or suspended raceway supports. PVC coated conduit shall be supported away from the structure using corrosive duty individual or suspended raceway supports.

3. Conduit racks shall be secured to concrete walls and ceilings by means of standard duty embedded supports. Plastic inserts or gunpowder-driven inserts are not acceptable as a base to secure conduit supports. Stainless steel expansion anchors shall be used to support individual conduit supports in exterior areas.

C. CONDUIT ENCASEMENT:

1. Buried conduit shall be encased in Class 5 concrete in accordance with the CAST-IN-PLACE CONCRETE Section (03 30 00). Direct burial of conduit shall not be permitted, except for concrete capped lighting and receptacle circuits. Minimum size of conduit in duct banks interconnecting manholes or handholes shall be 2 inches.

2. Conduit encased in concrete that is in contact with the earth shall be separated from the earth by at least 3 inches of concrete. Clearances equal to the nominal conduit diameter, but not less than 2 inches, shall be maintained between conduits encased in slabs. Clearances of less than 2 inches at conduit crossing and terminating locations are acceptable.

3. Embedded expansion fittings shall be provided whenever embedded conduit crosses building expansion joints or between two adjacent structures.

4. Duct banks shall be placed on an undisturbed soil base. A Type C backfill as specified in the EARTH MOVING Section (31 20 00) shall be used as a base when an undisturbed soil base is not available. Backfill over the duct bank shall comply with the EARTH MOVING Section (31 20 00). The fill shall be brought up to finish grade. If the duct bank installation has cut through concrete or asphalt, the surface section shall be restored to original conditions with identical materials.

5. Plastic conduit spacers shall be located 5 feet on centers. The spacers shall be secured to the conduits by wire ties. The duct bank shall be securely anchored to prevent conduit flotation while the concrete is being placed. Conduit runs shall be watertight.

6. The ends of conduits shall be protected from damage during construction by using plastic plugs. A 1/4-inch hole shall be drilled in the lower portion of the plug to provide drainage.

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26 05 34 - 16

7. Where conduits are specified "spare" or "future," a nylon cord shall be provided in the conduits and fastened at each end.

8. Conduits shall be thoroughly swabbed inside immediately upon completion of pouring concrete. After the concrete has set, but before backfilling, a mandrel having a diameter equal to the nominal conduit inside diameter minus 1/2 inch, and not less than 4 inches long, shall be pulled through each conduit. The mandrel shall be lead covered or painted white to indicate any protrusion on the inside of the conduit. The protrusion shall be removed or the conduit section replaced.

9. Duct banks shall maintain a steady slope between the high point of the duct bank to the manhole or handhole. Duct banks shall slope away from buildings.

10. Duct banks through walls shall be cast-in-place or concreted into blockouts with water stops on all sides of the block out. Water stops shall be as specified in the WATERSTOPS Section (03 15 13).

11. Conduits entering manholes and handholes shall be labeled. A plaque shall be provided showing all the conduit numbers and their arrangement for each group of conduits entering the manhole or handhole. The plaque shall be attached to the wall above where the conduits enter. Apply adhesive to the clean back surface of the plaque and secure to the wall with 1/4-inch stainless steel screws in each corner. Use plastic kit for concrete (1/2-inch into the concrete).

12. Conduits that require retagging shall have the plaques in the manholes and handholes relabeled with a rectangular piece of plaque material placed over the existing conduit label. Apply 3M VHB 5952 (or equal) 45 mil double-sided tape to the entire cleaned back surface of the label following the manufacturer’s recommended instructions. Clean the surface of the existing plaque and carefully drill two 1/4-inch holes on each side of the retagging location using plastic kit for concrete. Secure new label with 1/8-inch stainless steel screws on each side.

D. RACEWAY PENETRATIONS:

1. Raceway routed perpendicular through floors, walls or other concrete structures shall pass through cast- in-place openings. In cases where cast-in-place openings are not possible, appropriate size holes shall be bored through the concrete to accommodate the raceway and sealing fitting. The size and location of the holes shall not impair the structure's integrity. After completion, grout or caulk around raceway and finish to match surroundings. A 3½-inch-high concrete pad with a sloping top shall protect raceway that rises vertically through a floor or slab. All penetrations shall be fire stopped.

2. Conduits entering manholes and handholes shall be horizontal. Conduits shall not enter through the concrete bottom of handholes and manholes.

01/28/19


26 05 34 - 17

3. Wherever individual conduits penetrate concrete walls or ceilings to outdoors or below grade, the Contractor shall provide a watertight link seal installed as shown on the drawing details. Install roof jacks and storm collars around all conduits penetrating roof surfaces prior to completing the conduit system. Split roof jacks or split collars are not acceptable. Leave roof jacks loose for installation into the roofing membrane per Division 7 requirements.

E. PVC COATED CONDUIT:

1. PVC coated conduit shall be made up tight with strap wrenches. All conduit threads shall be covered by a plastic overlap sleeve that shall be coated and sealed per manufacturer's recommendations. Pipe wrenches and channel locks shall not be used for tightening PVC coated conduits. The conduit coating shall be protected from damage when conduit is threaded in the field. Damaged areas shall be patched, using manufacturer's recommended material. The area to be patched shall be built up to the full thickness of the coating. Painted fittings are not acceptable. Conduit hubs shall be used for entering boxes.

F. FLEXIBLE CONDUIT:

1. Length of flexible conduit shall not exceed 36 inches.

G. UNSCHEDULED RACEWAY:

1. The lighting system and receptacle circuits are unscheduled and shall be provided.

2. The raceway shall be sized by the Contractor in accordance with the NEC Table C8 (RH insulation). Minimum size shall be 3/4 inch for exposed and 1 inch for embedded raceway; minimum size in duct bank interconnecting manholes or handholes shall be 2 inches.

H. SCHEDULED RACEWAY:

1. Provide the raceways as shown and specified in the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21).

2. The Contractor shall bring all conflicts between the drawings and the schedule to the attention of the District Representative prior to installation of the raceways.

3.04 RACEWAY SUPPORT SYSTEM

A. DESIGN:

1. The Contractor shall submit design calculations for raceway support systems and seismic bracing prior to installation. The design weight shall be increased by 25 percent to account for future loads. Seismic forces shall be as described in the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00). A

01/28/19


26 05 34 - 18

minimum safety factor of 3 shall be applicable to design values for all hardware and fasteners. All calculations shall be stamped and signed by a registered civil or structural engineer licensed to practice in the State of California.

B. MATERIALS:

1. Standard duty raceway supports shall be installed in all areas; except for areas identified as corrosive in the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00). In corrosive areas, corrosive duty raceway supports are required. Corrosive duty embedded supports are required in manholes.

3.05 RACEWAY NUMBERING

A. CONDUIT IDENTIFICATION:

1. A tag with number shall be fixed to each end of each conduit segment and at each manhole, pull box and handhole. Tags shall also be placed within 3 feet of every wall, ceiling, or floor penetration or fire stop.

B. WIREWAY AND TRAY IDENTIFICATION:

1. Wireway and trays shall be identified by stencils at intervals not exceeding 50 feet, at intersections, and at the end of each run. Lineal footage shall be shown every 10 feet starting at the beginning of the tray end nearest the served area control center (ACC).

C. RACEWAY DEMOLITION:

1. Raceway and fittings removed in accordance with the SELECTIVE ELECTRICAL RACEWAY DEMOLITION SCHEDULE Section (02 41 19.21) shall be returned to the District Representative. Abandoned raceway shall be tagged in accordance with the SELECTIVE ELECTRICAL RACEWAY DEMOLITION SCHEDULE Section (02 41 19.21).

3.06 DEMOLITION RACEWAY SCHEDULE

A. The SELECTIVE ELECTRICAL RACEWAY DEMOLITION SCHEDULE Section (02 41 19.21) describes and lists existing raceway to be removed. Removed raceway and fittings shall be palleted or boxed and returned to the District Representative.

3.07 RACEWAY SCHEDULE

A. New and/or reused raceway is included in the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21).

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26 05 34 - 19

3.08 CABLE TRAY AND WIREWAY

A. Install cable trays and wireways on suspended raceway supports. Install NEMA 12 rated wireways in switchgear, MCC and computer rooms only. In all other areas wireways shall be rated NEMA 4X. Install hubs on all conduits entering wireways. Cable trays are not allowed in switchgear and MCC rooms.

B. Cable trays shall be supported at intervals not exceeding 5 feet. Corners shall be supported by two supports installed as close as possible to the corner, with one support on each side of the corner.

C. Arrange supports to permit accessible lay-in of cable over entire length of tray assembly using cantilever support. Use trapeze hangers where cantilever supports are impractical.

D. Expansion joint splice plates shall be used to allow 1-1/2-inch free movement between adjacent trays when crossing a building expansion joint.

E. Trays shall be installed with 1-inch spacing from walls and a minimum of 12 inches from ceilings. A minimum spacing of 12 inches shall be maintained between trays or conduits, measured from the top of the upper tray to the bottom of the lower tray or conduit.

F. Cable trays and wireways that penetrate walls or floors shall be fire stopped to match the fire rating of the penetrated surface. Interior areas of trays and wireways shall be packed with fire stop bags after all conductors are installed the full width of the wall. Exterior spaces around tray sleeves and wireways shall have firestop sealant installed the full width of the wall or floor.

3.09 DEVICE, PULL AND JUNCTION BOXES

A. LOCATION:

1. Unless otherwise specified in Table B, boxes shall be NEMA 3R cast ferrous alloy type.

Table B. Box Locations

Box type Location

NEMA 1 Concealed in sheet rock and masonry walls onlyNEMA 3R cast Exposed indoor or outdoor locations in noncorrosive

and nonhazardous areasNEMA 3R cast PVC jacket

Embedded in outdoor or indoor nonhazardous areas

NEMA 4 Exposed in process areas below 7 feet in nonhazardous, non-corrosive areas

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26 05 34 - 20

Table B. Box Locations

Box type Location

NEMA 4X Corrosive nonhazardous areasNEMA 12 Exposed in conduit racks in nonhazardous,

noncorrosive areas above 7 feet. Exposed in switchgear rooms.

3.10 MANHOLES AND HANDHOLES

A. Manhole and handhole bedding material types shall conform to the EARTH MOVING Section (31 20 00). Manholes shall be set plumb on a 12 inch bed of Type F material (aggregate base). Handholes shall be set plumb on a 6 inch bed of Type F material or Type G material (unwashed river sand) or substitute Type E material (drain rock) if water is present in the excavation.

B. Manhole and handhole covers shall be installed 1 to 2 inches above finish grade with surrounding pavement sloping away from the manhole cover.

C. All hardware including ladders, cable support racks, pulling irons, local motor starters, disconnect switches, receptacles, and metallic raceways shall be grounded by connection to the handhole/ manhole ground plate. Connections shall be made using bolted connections and bonding jumpers. Grounding shall be in accordance with the NEC and the GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS Section (26 05 26).

D. Cable racks shall be installed on 2-foot centerlines in all trenches, manholes, and handholes. Racks shall be installed with a minimum of 9-inch vertical spacing between horizontal rows.

3.11 FIRESTOPS

A. Firestop mortar shall be installed around raceway where it penetrates floors and walls. The firestop shall be installed in accordance with the manufacturer's instructions. The firestop mortar shall be applied to the thickness shown on the drawings to maintain the fire rating of the penetrated surface. Clean openings and penetrating items from dirt, rust, debris, grease and loose items. Tape mask areas where firestop materials are not required. Firestop mortar shall be mechanically mixed with a grout paddle for a minimum of 5 minutes with the appropriate ratio of potable water. Wet down the opening with water using spray bottle or brush. Smooth mortar with trowel after initial set.

B. Firestop bags shall be installed inside and around cable trays after all conductors are installed. Pack bags tightly into gaps and openings by shifting or folding bags as necessary. Utilize insertion plates on the top row and under the cable tray.

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26 05 34 - 21

C. Firestop sealant shall be installed to fill gaps around raceway and sleeves. Install polyurethane backer rod for widths larger than 3/8 inch.

D. Firestop putty shall be packed inside the open end of conduits routed from cable trays through walls or floors. Do not install firestop putty in conduits routed from cable trays to panels or devices in the same room.

3.12 DUCT CABLE SEALS AND PLUGS

A. Duct banks entering buildings and all other structures from manholes and handholes shall be sealed on the high side of each duct to prevent the entrance of water from the duct bank system. Empty ducts shall be sealed with duct plugs. Duct plugs shall be installed hand-tight and then wrench tightened an additional one-half turn to seal watertight. Ducts with data, signal, or 600v rated conductors shall be sealed with the duct cable sealing system after all conductors are installed following the manufacturer installation instructions.

B. Duct bank cable seals and plugs shall be tested for leakage into buildings and structures by flooding the adjacent manhole or handhole with water. Replace all cable seals or plugs that leak. Pump out all water after one hour.

C. Ducts containing medium voltage cables terminating under switchgear or panels shall be sealed after the conductors are installed with metallic covers and sealing tape.

**END OF SECTION**

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26 05 34 - 22


PROJECT NUMBER: 149803

REV CONDUIT DESIGNATION FROM TOSIZEIN. CONTAINS DWG REF. NOTES

C80201AA CPNL80200 JB80201AD 2 1/2" 66C80205AA66C80206AA66C80207AA66C80208AA66C80201AD66C80202AB66C80205AB66C80206AB66C80207AB66C80208AB66C80201AC66C80202AA

66E008

C80201AB JB80201AD JB80201AE 1 1/4" 66C80201AC66C80202AA66C80201AD66C80202AB

66E008

C80201AC JB80201AE V80201A 3/4" 66C80201AC66C80202AA66C80201AD66C80202AB

66E008

C80201AD JB80201AE CV80201A 3/4" 66C80201AD 66E008C80202AA JB80201AE V80202A 3/4" 66C80202AA 66E008C80202AB JB80201AE CV80202A 3/4" 66C80202AB 66E008C80205AA JB80201AD V80205A 3/4" 66C80205AA 66E008C80205AB JB80201AD CV80205A 3/4" 66C80205AB 66E008C80206AA JB80201AD V80206A 3/4" 66C80206AA 66E008C80206AB JB80201AD CV80206A 3/4" 66C80206AB 66E008C80207AA JB80201AD V80207A 3/4" 66C80207AA 66E008C80207AB JB80201AD CV80207A 3/4" 66C80207AB 66E008C80208AA JB80201AD V80208A 3/4" 66C80208AA 66E008C80208AB JB80201AD CV80208A 3/4" 66C80208AB 66E008FO80200A CT8A SB15 1-1/2" 59FO80200A

66E006'66E008

USE EXISTING EMPTY CONDUIT

FO80200B SB15 CPNL80200 1-1/2" 59FO80200A 66E008

ZONE 80 CONDUIT SCHEDULE

01/15/19Gas Management SystemRehabilitation and Improvements 26 06 20.21 ‐ 1



P80200 CPNL80200 EXISTING HANDHOLE

3/4" 66P08200 66E008

P80201AA PNL80201AIGNITER 1

JB80201AA 3/4" 66P80201A66P808112A

66E008

P80201AB JB80201AA JB80201AB 3/4" 66P80201A66P80202A66P80202A66P80205A66P80206A66P80207A66P80208A

66E008

P80201AC JB80201AB JB80201AC 3/4" 66P80201A66P80202A

66E008

P80201AD JB80201AC MME80201A 3/4" 66P80201A 66E008P80202AA PNL80202A

IGNITER 2JB80201AA 3/4" 66P80202A 66E008

P80202AB JB80201AC MME80202A 66P80202A 66E008P80205AA PNL80205A

IGNITER 5JB80201AA 3/4" 66P80205A 66E008

P80205AB JB80201AB MME80205A 3/4" 66P80205A 66E008P80206AA PNL80206A

IGNITER 6JB80201AA 3/4" 66P80206A 66E008


IGNITER 7JB80201AA 3/4" 66P80207A 66E008


IGNITER 8JB80201AA 3/4" 66P80208A 66E008

P80208AB JB80201AB MME80208A 3/4" 66P80208A 66E008P808112 JB80201AA FIT8112 3/4" 66P808112A 66E008




S80201A CPNL80200 JB80201AF 1 1/4" 66S8020166S8020266S8020566S8020666S8080766S80208

66E008

S80201B JB80201AF JB80201AG 3/4" 66S8020166S80202

66E008

S80201C JB80201AG TIT80201 3/4" 66S80201 66E008S80202 JB80201AG TIT80202 3/4" 66S80202 66E008S80205 JB80201AF TIT80205 3/4" 66S80205 66E008S80206 JB80201AF TIT80206 3/4" 66S80206 66E008S80207 JB80201AF TIT80207 3/4" 66S80207 66E008S80208 JB80201AF TIT80208 3/4" 66S80208 66E008S808112 JB87009A FIT8112 3/4" 66S808112 66E008




REVCONDUIT DESIGNATION FROM TO

SIZEIN. CONTAINS DWG REF. NOTES

C870007 CPNL80200 CV870007A 3/4" 66C870007 66E008C870012A JB87524A CV870012A 3/4" 66C870012A 66E010C870013A JB87524A CV870013A 3/4" 66C870013A 66E010C87068 PNL87708 JB875068A 3/4" 66C87068

66C8706966E010

C87068A JB875068A CV87068 3/4" 66C87068 66E010C87069 JB875068A CV87069 3/4" 66C87069 66E010C87314A PNL873011 CV87314A 1" 66C87314A 66E011 USE AND RELABEL

EXISTING CONDUIT C87315A PNL873021 CV87315A 1" 66C87315A 66E011 USE AND RELABEL

EXISTING CONDUIT C87316A PNL873031 CV87316A 1" 66C87316A 66E011 USE AND RELABEL

EXISTING CONDUIT C87521AA PNL87708 HH33 2" 66C87521A

66C87522A66C87523A

66E010 USE EXISTING CONDUIT/CONDUCTORS FROM MSG COMPRESSOR BUILDING TO LSG GAS

C87521AB HH33 CV87521A 1" 66C87521A 66E00666E01066E012

REUSE AND RENAME EXISTING CONDUIT 3C87521A IN HH33.

C87522A HH33 CV87522A 1" 66C87522A 66E00666E01066E012


C87523A HH33 CV87523A 1" 66C87523A 66E00666E01066E012


C87524AA PNL87708 JB870014A 1" 66C87524A66C870012A66C870013A

66E010

C87524AB JB87524A CV87524A 3/4" 66C87524A 66E010

01/15/19Gas Management SystemRehabilitation and Improvement 26 06 20.21




D873011A (E) HANDHOLE JB873011 3/4" 66D873011 66E011

D873011B JB873011 PNL873011 3/4" 66D873011 66E011 UTILIZE EXISTING CONDUIT

D873021A (E) HANDHOLE (E) HANDHOLE 1" 66D87301166D873021

66E012

D873021B (E) HANDHOLE JB873021 1" 66D873021 66E011D873021C JB873021 PNL873021 1" 66D873021 66E011 UTILIZE EXISTING CONDUIT

D873031A CPNL80200 (E) HANDHOLE 1" 66D87303166D87302166D873011

66E011

D873031B (E) HANDHOLE JB873031 3/4" 66D873031 66E011D873031C JB873031 PNL873031 3/4" 66D873031 66E011 UTILIZE EXISTING CONDUIT

P870010A PNL8GAA JB870010A 34" 66P87001166P870010

66E010

P870010B JB870010A FIT870010 3/4" 66P870010 66E010P870011 JB8700014A FIT870011 3/4" 66P870011 66E010





S80110 JB875002 CV80110 1" 66S80110 66E010S870007A JB87009A CV870007A 3/4 66S870007A 66E008S870009A CPNL80200 JB870009 3/4" 66S870009B

66S80811266E008

S870009B JB870009A PIT870009 3/4" 66S870009B 66E008S870010 JB870014A FIT870010 3/4" 66S870010 66E010

S870011 JB870014A FIT870011 3/4" 66S870011 66E010S870014A PNL87708 JB87524A 2" 66S870014A

66S875966S870015A66S87001666S870017A66S870018A66S870019A66S87001466S87007A66S8011066S87001166S870010

66E010





S870014B JB870014A PIT870014 3/4" 66S870014 66E010S870015A JB870014A CV870015A 1" 66S870015A 66E010S870016 JB870014A PIT870016 3/4" 66S870016 66E010S870017A JB870014A CV870017A 1" 66S870017A 66E010S870018A JB870014A CV870018A 1" 66S870018A 66E010S870019A JB870014A CV870019A 1" 66S870019A 66E010

S870020A JB870020A PIT870020A 3/4" 66S870020A 66E012

S870020AA PNL87708 HH34 2" 66S87002266S870021

66E01066E012

USE EXISTING CONDUIT/CONDUCTORS FROM MSG COMPRESSOR BUILDING TO LSG GAS SCRUBBER AREA

S870020AB HH34 JB870021A 2" 66S87002266S870021

66E01066E012

USE EXISTING RACEWAY 3X8751B FOUND IN HH34 TO LSG GAS SCRUBBERS.

S870020AC HH34 JB870020A 2" 66S870020B66S870020A

66E012 USE EXISTING RACEWAY 3X5752B LOCATED IN HH34 TO LSG GAS SCRUBBERS.

S870020B JB870020A PIT870020B 3/4 66S870020B 66E012

S870021 JB870021A PIT870021 3/4" 66S870021 66E012S870022 JB870021A PIT870022 3/4" 66S870022 66E012





S87007 JB870014A CV87007 1" 66S87007 66E010

S87009A CPNL80200 JB87009A 1" 66S870007A 66E012S87318A PNL873011 CV87318A 1" 66S87318A 66E011 USE AND RELABEL

EXISTING CONDUIT 3X87301Q

S87319A PNL873021 CV87319A 1" 66S87319A 66E011 USE AND RELABEL EXISTING CONDUIT 3X87302Q

S87320A PNL873031 CV87320A 1" 66S87320A 66E011 USE AND RELABEL EXISTING CONDUIT 3X87303Q

S8759 JB870014A PIT8759 3/4 66S8759 66E010

END OF SECTION




REV CABLE ID FROM TO ROUTING TYPE QUANTITY SIZE GRD SIZE VOLTS NOTES

66C80201AC CCPNL80200 V80201A C80201AAC80201ABC80201AC

P&C SC 9 8 #14 1#14 600

66C80202AA CCPNL80200 V80202A C80201AAC80201ABC80202AA

P&C SC 9 8 #14 1# 14 600

66C80205AA CCPNL80200 V80205A C80201AAC80205AA

P&C SC 9 8 #14 1#14 600


P&C SC 9 8 #14 1#14 600


P&C SC 9 8 #14 1#14 600

66C80208A CCPNL80200 V80208A C80201AAC80208AA

P&C SC 9 8 #14 1#14 600

66C80201AB CCPNL80200 CV80201A C80201AAC80201ABC80201AD

P&C SC 9 8 #14 1#14 600

66C80202AB CCPNL80200 CV80202A C80201AAC80201ABC80202AB

P&C SC 9 8 #14 1#14 600

66C80205AB CCPNL80200 CV80205A C80201AAC80205AB

P&C SC 9 8 #14 1#14 600


P&C SC 9 8 #14 1#14 600


P&C SC 9 8 #14 1#14 600


P&C SC 9 8 #14 1#14 600

59FO80200A 08FOP10302 CPNL80200 CT14A4CT14A3CT14A2CT13CCT13ACT8AFO80200AFO80200B

FO 24 STRAND N/A

ZONE 80 CABLE SCHEDULE

01/15/19Gas Management SystemRehabilitation and Improvement 26 06 20.25 - 1




66P80200 CCPNL80200 EXISTING PANEL 8N

P80200 P&C SC 3 2#10 1#10 600

66P80201A PNL80201A MME80201A P80201AAP80201ABP80201ACP80201AD

SC SPR 2 2 #18 IGNITION

WIRE

1000

66P80202A PNL80202A MME80202A P80202AAP80201ABP80201ACP80202AB


WIRE

1000

66P80205A PNL80205A MME80205A P80205AAP80201ABP80205AB


WIRE

1000



WIRE

1000



WIRE

1000



WIRE

1000

66P808112A CCPNL80200 FIT8112 P80201AAP808112

P&C SC 3 2 #14 1 #14 600

66S80201 CPNL80200 TIT80201 S80201AS80201BS80201C

SC SPR 1 1PR#16 600

66S80202 CPNL80200 TIT80202 S80201AS80201BS80202

SC SPR 1 1PR#16 600

66S80205 CPNL80200 TIT80205 S80201AS80205

P&C SC 1 1PR#16 600

66S80206 CPNL80200 TIT80206 S80201AS80206

P&C SC 1 1PR#16 600

66S80207 CPNL80200 TIT80207 S80201AS80207

P&C SC 1 1PR#16 600

66S80208 CPNL80200 TIT80208 S80201AS80208

P&C SC 1 1PR#16 600





66S808112 CPNL80200 FIT8112 S87009AS87009B

SC SPR 1 1PR#16 N/A 600




REV CABLE ID FROM TO ROUTING TYPE QUANTITY QUANTITY/SIZE GRD SIZE VOLTS NOTES

66C870007 CPNL80200 CV870007A C870007A P&C SC 3 2 #14 1 #14 600 CONTROL VALVE DUMP

66C870012A PNL87708 CV870012A C87524AAC870012A

P&C SC 7 6 #14 1 #14 600

66C870013A PNL87708 CV870013A C87524AAC870013A

P&C SC 7 6 #14 1 #14 600

66C87068 PNL87708 CV87068 C87068AC87068

P&C SC 7 6 #14 1 #14 600

66C87069 PNL87708 CV87069 C87068C87069

P&C SC 7 6 #14 1 #14 600

66C87314A PNL873011 CV87314A C87314A P&C SC 7 6 #14 1 #14 600

66C87315A PNL873021 CV87315A C87315A P&C SC 7 6 #14 1 #14 600

66C87316A PNL873031 CV87316A C87316A P&C SC 7 6 #14 1 #14 600

66C87521A PNL87708 CV87521A C87521AAC87521AB

P&C SC 7 6 #14 1 #14 600

66C87522A PNL87708 CV87522A C87521AAC87522A

P&C SC 7 6 #14 1 #14 600

66C87523A PNL87708 CV87523A C87521AAC87523A

P&C SC 7 6 #14 1 #14 600

66C87524A PNL87708 CV87524A C87524AAC87524AB

P&C SC 7 6 #14 1 #14 600

66D873011 CPNL80200 PNL873011 D873031AD873021AD873011AD873011B

CAT-6 1 BELDEN 9463

66D873021 CPNL80200 PNL873021 D873031AD873021AD873021BD873031C

CAT-6 1 BELDEN 9463

66D873031 PNL87708 PNL873031 D873031AD873031BD873031C

CAT-6 1 BELDEN 9463

01/28/19Gas Management System Rehabilitation and Improvement 26 06 20.25 - 4



66P870010 PNL8GAA FIT870010 P870010AP870010B

P&C SC 3 2 #14 1 #14 600 FIT870010 120V

66P870011 PNL8GAA FIT870011 P870010AP870011

P&C SC 3 2 #14 1 #14 600 FIT870011 120V

66S80110 PNL87708 CV80110 S870014AS80110

SC SPR 2 1PR#16 600 ACTUATOR LOCATED IN MSG COMPRESSOR BUILDING

66S870007 CPNL80200 CV870007A S870009AS870007A

SC SPR 2 1PR #16 600

66S870009 CPNL80200 PIT870009 S87009AS87009B

SC SPR 1 1PR #16 600

66S870010 PNL87708 FIT870010 S870014AS870010

SC SPR 1 1PR#16 600

66S870011 PNL87708 FIT870011 S870014AS870011

SC SPR 1 1PR#16 600

66S870014 PNL87708 PIT870014 S870014AS870014B

SC SPR 1 1PR#16 600

66S870015A PNL87708 CV870015A S870014AJB875002S870015A

SC SPR 2 1PR#16 600

66S870016 PNL87708 PIT870016 S870014AS870016

SC SPR 1 1PR#16 600

66S870017A PNL87708 CV870017A S870014AS870017A

SC SPR 2 1PR#16 600

66S870018A PNL87708 CV870018A S870014AS870018A

SC SPR 2 1PR#16 600

66S870019A PNL87708 CV870019A S870014AS870019AS870020AA

SC SPR 2 1PR#16 600

66S870020A PNL87708 PIT870020A S870020AS870020AAS870020AC

SC SPR 1 1PR#16 600




66S870020B PNL87708 PIT870020B S870020BS870020AC

SC SPR 1 1PR#16 600

66S870021 PNL87708 PIT870021 S870021S870020AAS870020AB

SC SPR 1 1PR#16 600

66S870022 PNL87708 PIT870022 S870022S870020AAS870020AB

SC SPR 1 1PR#16 600

66S87007 PNL87708 CV87007 S870014AS87007

SC SPR 2 1PR#16 600

66S87318A PNL873011 CV87318A S87318A SC SPR 2 1PR#16 600



66S8759 PNL87708 PIT8759 S870014AS8759

SC SPR 1 1PR#16 600

END OF SECTION




26 08 10 - 1

SECTION 26 08 10

ACCEPTANCE TESTING OF ELECTRICAL SYSTEMS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies the acceptance testing of electrical materials, equipment and systems as specified in this section and in each section of Division 26 except the following:

a. Insulation resistance of cable/motor tests and cable continuity tests in accordance with the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00).

b. Pre-operational checkouts in accordance with the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00).

c. Instrumentation specified in the INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 70 00).

2. Engage the services of an independent testing firm for the purpose of performing all tests and inspections specified herein. Testing firm shall also perform the inspecting, setting, testing and calibrating applicable devices as specified herein.

3. Provide all labor, tools, material, power and technical supervision to perform the specified tests and inspections.

1.02 REFERENCES


Reference TitleNETA ATS International Electrical Testing Association, Inc.;

Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems

ANSI/NETA ETT Standard for Certification of Electrical Testing Personnel


26 08 10 - 2

1.03 SUBMITTALS



2. Test procedures and forms in accordance with the COMMISSIONING Section (01 91 00). The test forms shall be in accordance with NETA standards.

3. Submit proof that the independent testing firm and testing personnel qualifies as specified herein.

4. Provide one original copy of the latest issue of NETA ATS Acceptance Testing Specifications Manual.

5. Completed test report no later than 30 days after completion of the tests.

PART 2 -- PRODUCTS

2.01 DOCUMENTATION

A. GENERAL:

1. The collection and documentation of test data shall be provided in accordance with the COMMISSIONING Section (01 91 00).

B. DEFECTS:

1. Notify the District Representative of any material or workmanship found defective within 24 hours of discovery in accordance with the COMMISSIONING Section (01 91 00).

C. TEST REPORT:

1. Provide the test report with all items required in NETA ATS, paragraph 5.4.

2. All blanks on the test forms shall be filled in. If the item is not applicable, enter "N/A". All disparities and irregularities in the test results shall be noted on the test form and addressed and evaluated in accordance with industry standards in the report Recommendations. Where defective material is noted on the test form, the item shall be initialed and dated when the issue has been resolved and the item re-tested.


26 08 10 - 3

2.02 TEST EQUIPMENT AND MATERIALS

A. Test instruments shall be calibrated to references traceable to the National Bureau of Standards and shall have a current sticker showing date of calibration, deviation from standard, name of calibration laboratory and technician, and date recalibration is required. Test instruments shall be provided in accordance with the COMMISSIONING Section (01 91 00).

2.03 INDEPENDENT TESTING FIRMS

A. QUALIFICATIONS OF TESTING ORGANIZATION:

1. The testing organization shall be independent, third party, testing organization which can function as an unbiased testing authority, professionally independent of the manufacturers, suppliers, and installers of equipment or systems evaluated by the testing organization.

2. The testing organization shall be regularly engaged in the testing of electrical equipment devices, installations, and systems.

3. The testing organization shall utilize technicians who are regularly employed for testing services.

4. An organization having a “Full Membership” classification issued by the International Electrical Testing Association meets these criteria.

B. QUALIFICATIONS OF TESTING PERSONNEL:

1. Test technicians performing electrical tests, inspections, and calibrations shall be trained and experienced with the apparatus and systems being evaluated. Technicians shall conduct tests in a safe manner with complete knowledge of the hazards involved.

2. Technicians shall be certified in accordance with ANSI/NETA ETT. Each site crew shall have a technician with certification Level III, or higher.

C. ACCEPTABLE TESTING FIRMS:

1. The following firms qualify as independent testing agencies. Other firms that qualify shall be considered as equal.

a. Apparatus Testing & Engineering, Rancho Cordova, CA

b. Electrical Reliability Services, Pleasanton, CA


26 08 10 - 4

PART 3 -- EXECUTION

3.01 GENERAL

A. All testing shall be performed by an independent electrical testing laboratory in strict conformance with the electrical acceptance tests specified NETA ATS except as specified herein. Acceptance testing shall be performed, test report submitted and approved prior to energizing of the tested equipment.

B. Requirements for testing in accordance with this section are specified in other sections of Division 26. All discrepancies shall be noted on the test sheets, shall be resolved to the satisfaction of the District and then re-tested. All failed tests resulting in adjustment, repair, or replacement shall be re-tested, re-submitted, and approved prior to acceptance of material, equipment or systems.


3.03 TESTING

A. The following tests, calibrations and inspections conforming to the requirements of NETA ATS (Chapter 7- Inspection and Test Procedures) shall be performed:

1. Low voltage insulated/molded case circuit breakers (3-pole only): Visual and mechanical inspections, electrical tests (including optional calibration of all trip unit functions using secondary injection) evaluated to required test values.

2. Instrument transformers: Visual and mechanical inspections, electrical tests evaluated to required test values.

3. Grounding Systems; Visual and mechanical inspections, electrical tests evaluated to required test values.

4. Low voltage motor starters: Visual and mechanical inspections, electrical tests evaluated to required test values.

**END OF SECTION**

01/28/19


26 09 16 - 1

SECTION 26 09 16

ELECTRICAL CONTROLS AND RELAYS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies miscellaneous electrical control and power devices, control power transformers, relays, magnetic contactors, disconnect switches, manual starters, combination motor starters installed in enclosures, overcurrent protection, terminal blocks, nameplates and conductor markers.

1.02 REFERENCES


Reference Title

NEMA 250 Enclosures for Electrical Equipment (1000 volts maximum)

NEMA ICS series Industrial Control Systems

NEMA ICS-1 General Standards For Industrial Controls and Systems

NEMA ICS-2 Industrial Control Devices, Controllers, and Assemblies

NEMA ICS-6 Industrial Control Devices, Controllers, and Assemblies

NEMA KS 1 Enclosed Switches (600 volts maximum)

NEMA ST-1 Specialty Transformers

UL 224 Extruded Insulated Tubing

UL 508 Standards for Industrial Control Equipment

1.03 SUBMITTALS



2. Elementary diagrams.

01/28/19


26 09 16 - 2

3. Connection diagrams.

4. Panel arrangement drawings.

5. Installation instructions.

6. Manufacturer's catalog data for all material provided under this section shall be assembled in a folder with each page clearly marked with the item and reference number to the specification.

7. Electrical Overload relay selection data.

8. Nameplate engraving list.

1.04 OPERATION AND MAINTENANCE INSTRUCTIONS

A. Submit operation and maintenance (O&M) instructions in accordance with the OPERATION AND MAINTENANCE DATA Section (01 78 23) by submitting a copy of the OPERATION AND MAINTENANCE DATA Section (01 78 23) with each paragraph check marked to show compliance. O&M instructions shall be submitted after all submittals specified above have been returned mark “No Exceptions Taken” or “Make Corrections Noted.” O&M instructions shall reflect the approved materials and equipment.

PART 2 -- PRODUCTS

2.01 NAMEPLATES

A. Nameplates shall be provided for all electrical equipment, including device enclosures, and shall be made from laminated phenolic plastic. The nominal size of the nameplates shall be 3/4 inch high by 2 inches long. Nameplates shall have black backgrounds with 3/16-inch white letters. If abbreviations are required because of space limitations, abbreviations shall be submitted to the District Representative prior to manufacture. The nameplate shall be engraved with the equipment number and description as shown on the drawings and specification schedules.

2.02 CONTROL DEVICES

A. PUSHBUTTONS:

1. Pushbuttons shall be nominal 1-1/2-inch diameter, flush head, heavy-duty, with NEMA rating to match enclosure type. Unless otherwise shown on the drawings, the escutcheon legends shall be included. Unless otherwise shown on the drawings, pushbuttons shall be momentary contact type. Contact blocks shall be rated NEMA ICS-2 A600. Furnish Eaton, 10250T, Allen-Bradley, 800T (NEMA 4, 13) or equal. Furnish Eaton, E34, Allen Bradley 800H (NEMA 4X, 7) series, or equal. Contacts monitored by programmable controllers or other

01/28/19


26 09 16 - 3

solid-state circuits shall be hermetically sealed logic-reed type with contacts rated NEMA ICS-2 B600. Furnish Eaton, 10250T/E34, Allen-Bradley, 800R (NEMA 4) series, or equal.

B. SELECTOR SWITCHES:

1. Selector switches shall be nominal 1-1/2-inch diameter, heavy-duty, with NEMA rating to match enclosure type. Selector switches shall have spring return or maintained position contacts as shown on the control diagram drawings. Switches shall be provided with contact blocks and number of positions as required to perform the operations as shown on the control diagram drawings. Contact blocks shall be rated as specified in this specification section. Unless otherwise shown on the drawings, the escutcheon legends shall be included. Furnish Eaton, 10250T, Allen-Bradley, 800T (NEMA 4,13) or equal. Furnish Eaton, E34, Allen Bradley 800H (NEMA 4x, 7) series, or equal.

C. INDICATING LIGHTS:

1. AC indicating lights shall be nominal 1-1/2-inch diameter, push-to-test transformer type, with 6.3-volt lamps. DC indicating lights shall be nominal 1-1/2-inch diameter, push to test, full voltage type. Lamps shall be heavy-duty, with NEMA rating to match enclosure type. Lamps shall be LED, neon or incandescent type as specified in this specification section. Furnish Eaton, 10250T Allen-Bradley, 800T (NEMA 4,13) or equal. Furnish Eaton E34, Allen Bradley 800H (NEMA 4X, 7) series, or equal.

D. CONTROL CIRCUIT FUSES:

1. CONTROL TRANSFORMER SECONDARY:

a. Secondary fuses for 120V AC control transformers rated 1000 VA or less shall be rated 10,000 amperes interrupting current (symmetrical) at 125V AC (UL). The fuses shall be 1/4 x 1-1/14-inch glass body type. Fuse holders shall be panel mounted, indicating type, with neon blown fuse indicating lamp. The fuse holder shall be visible and mounted on the front of the panel where the fuse can be replaced from the outside of the enclosure. The fuse holder shall be Cooper Bussman type HKL, Littlefuse 344 series, or equal.

b. Secondary fuses for 120V AC control transformers rated 1000 VA or greater shall be protected with fuses as specified in this specification section.

2. CONTROL POWER FROM BRANCH CIRCUITS: Control circuits deriving power from a 120V AC branch circuit, with no control power transformer less than 1000 VA ahead of the fuse, shall be protected with a current limiting fuse at the panel. The fuse shall be the rejection type, rated for 200,000 ampere interrupting current (symmetrical) at 250V AC. The fuse block shall match the class rating of the fuse Copper Bussman type R, or equal.

01/28/19


26 09 16 - 4

2.03 CONTROL RELAYS

A. MACHINE TOOL TYPE CONTROL RELAYS:

1. Relays shall be heavy duty industrial machine tool type. AC relays shall have NEMA A600 contact ratings and electrical clearances for up to 600 volts DC relays shall have NEMA P300 contact ratings and electrical clearances of up to 250 volts. Relays shall have modular construction with replaceable and convertible contacts. Contacts shall, as a minimum, be 4-pole and be field interchangeable to either normally open or normally closed. Relay shall be capable of accepting a 4-pole adder. Furnish Allen-Bradley Bulletin-700-P series, Schneider Electric Square D Class 8501, Type X series, or equal.

B. ENCLOSED PLUG-IN TYPE CONTROL RELAYS:

1. Relays shall be enclosed plug-in type with heavy-duty, barrier-protected screw terminal sockets and clear poly-carbonate dust cover with clip fastener. Relays shall have a minimum of three silver-cadmium oxide SPDT contacts rated 10 amps resistive at 120V AC or 28V DC. Relays shall be mounted on DIN rail socket bases. AC models shall have a push-to-test button and a neon lamp indicator wired in parallel with coil, IDEC RH Series, or equal.

C. SOLID STATE TIMING RELAYS:

1. Timing relays shall be enclosed plug-in type with solder terminals and solid lexan dust cover. Time delays of 0.1 second to 600 hours shall be available with each timer model having an adjustable range. Interval, delay on operate, delay on release, single shot and repeat modes shall be available. Timers shall reset within 0.1 seconds and shall have a set point accuracy of plus or minus 10.0 percent with a repeatability of plus or minus 0.2 percent. Relays shall have silver-cadmium oxide contacts rated 10 amps resistive at 120V AC or 28V DC. Relays shall be mounted on DIN rail socket bases. All relays shall have a lamp indicator wired in parallel with the coil. Timing relays shall be Idec RTE, or equal.

2.04 MANUAL STARTERS AND MAGNETIC CONTACTORS

A. MANUAL STARTING SWITCHES:

1. Manual starting switches shall consist of a snap switch combined with a thermal overload device operating on the solder-ratchet principle to manually start single phase motors. Manual starting switches shall conform to NEMA ICS 2 and UL 508. The switch shall be designed to prevent being held closed during motor overload. Reset from overload shall be accomplished by moving the toggle switch to “OFF”. Furnish Eaton B230 series, Allen-Bradley Bulletin 600 series, or equal.

01/28/19


26 09 16 - 5

B. MOTOR CONTACTORS:

1. Motor contactors shall be designed for continuous operation of induction motors at 600 volts or less at 60 Hz and shall comply with NEMA ICS-2-210. Minimum contactor size shall be NEMA size 1. Contactors shall have a 3 pole class 20 eutectic alloy overload relay. The contactor shall be supplied with a normally open auxiliary contact for use as a hold-in contact as a minimum. Additional contacts shall be provided as shown on the drawings. The coil voltage, frequency and number of poles shall be as shown on the drawings. Furnish Eaton Freedom series, or equal.

2.05 DISCONNECT SWITCHES

A. NONFUSED DISCONNECT SWITCHES:

1. Disconnect switches shall be heavy-duty, non-fusible, safety type rated 600 volts AC. The operating handle shall be capable of being padlocked in the "off" position. The operator shall be a positive, quick-make, quick-break mechanism.

2. Switches shall be horsepower rated for motors and shall comply with NEMA KS-1. Switches shall be provided with defeatable door interlocks that prevent the door from opening when the operating handle is in the "on" position. Switches shall have line terminal shields. Switches shall be Eaton Type Heavy DutyH-600; General Electric Heavy Duty Type TH; or equal.

3. Where shown on the drawings, disconnect switches shall be provides with auxiliary control circuit interlock contacts. Interlock contacts shall be 1NO/1NC rated for 15A continuous at 120Vac. Interlock contacts shall operate before the main power contacts.

B. FUSED DISCONNECT SWITCH:

1. Fused disconnect switch shall be the same as non-fused safety disconnect switch specified in this specification section except switch shall accept Class R fuses only.

C. CIRCUIT BREAKER SWITCH:

1. Circuit breaker shall be in accordance with this specification section. The external operating handle shall indicate if the circuit breaker is in "ON," "OFF," or "TRIPPED."

2.06 CIRCUIT BREAKERS

A. Circuit breakers shall be thermal magnetic, molded case type with the ampere rating as specified. Unless otherwise specified, circuit breaker interrupting rating shall be 18,000 amperes symmetrical for service at 240 volts and below; Eaton Cutler-Hammer Type FDE, or equal. For service above 240 volts, the interrupting rating shall be

01/28/19


26 09 16 - 6

42,000 symmetrical, Eaton Cutler-Hammer HFDE, or equal. Breaker settings shall include Ground Fault Protection.

2.07 TERMINAL BLOCKS

A. Electrical equipment terminal blocks for control conductors shall be pan head screw strap type, rated 600 volts, 20 amperes minimum. An integral marking strip shall be permanently marked with the connecting wire numbers as shown on the connection diagrams. All metal parts shall be made of 85percent copper alloy nickel plated. Insulated housing shall be made of 6.6 polyamide suitable for DIN rail mounting. Terminal blocks for power conductors (power 208-600 volts) shall be rated not less than the conductor current rating and shall not be rated less than 600 volts AC. Furnish Phoenix Contact USK series, or equal.

2.08 CABLE AND WIRE MARKERS

A. Lettering shall be resistant to smudging, fading, chemical and harsh environment deterioration. Sleeves shall be sized to fit the conductor insulation and shrunk to fit the conductor with hot air after installation. Cable and wire markers shall be heat shrinkable irradiated polyolefin, conforming to UL 224. The letters and numbers that identify each cable or wire shall be machine printed with 1/8-inch high characters on 2-inch sleeves with permanent black ink. The wire marking system shall be Brady Perma-sleeve PS-XXX-2W series and Brady PS Printer, or equal.

2.09 CONTROL POWER TRANSFORMERS

A. Control power transformers shall provide stepped-down voltages for the control devices in a control circuit. The control transformers shall meet the requirements of NEMA ST-1. The control transformer shall be protected by two 600V AC fuses on the primary side and one 250V AC fuse on the secondary side.

2.10 COMBINATION MOTOR STARTERS

A. GENERAL:

1. Individual motor starters shall be a factory assembled combination of a disconnect switch, motor circuit protector, motor starter with overload relays, fused control circuit transformer, surge protectors, control devices, and accessories specified herein and shown on the control diagrams. Furnish General Electric CR3XX series or equal.

B. ENCLOSURE:

1. The door to the motor starter enclosure shall be interlocked with an externally operated disconnect handle. Disconnect handle shall be arranged to indicate disconnect position. The operator handle shall have provisions to accept up to three 3/8-inch shackle padlocks to lock the disconnect in the open position. Enclosures

01/28/19


26 09 16 - 7

shall have an internal ground lug for connection to the grounding system. Enclosures shall be NEMA 12 for indoors dry areas and NEMA 4X, 304SS stainless steel for outdoor areas and indoor wet and corrosive areas subject to hose down and NEMA7 cast metal for hazardous areas.

C. MOTOR BRANCH CIRCUIT PROTECTION:

1. MOLDED CASE MOTOR CIRCUIT PROTECTORS:

a. The molded case circuit breaker shall operate on the magnetic principle with a current sensing coil in each of the three poles to provide an instantaneous trip for short circuit protection. The trip setting shall be adjustable over a range of 700 to 1300 percent of the full load current of the motor served and shall be adjustable from the front of the breaker. Circuit breaker, when used in conjunction with the starter, shall be rated to interrupt 65,000 ampere (symmetrical); Eaton HMCP, General Electric Mag-Break, or equal.

D. MOTOR STARTERS:

1. GENERAL:

a. The basic full voltage, non-reversing starter shall consist of a 600 volt AC contactor, transient surge suppressor, and overload relays, NEMA size1 minimum. Reversing and multispeed starters shall have additional contactors, overload relays and auxiliary relays as required for the specified functions.

b. The contactors shall be in compliance with NEMA ICS2 and shall be NEMA rated for the horsepower as specified.

2. AC CONTACTOR:

a. Single-phase motor starters shall have two poles, and 3-phase starters shall have three poles.

3. OVERLOAD RELAYS:

a. Overload relays shall be electronic type with monitory and control. Monitor parameters include motor status, individual RMS phase currents, average of three-phase RMS current, percent thermal capacity and phase unbalance, ground fault current, with communication protocols supports 4 in / 2 out IO. Eaton Cutler-Hammer C441 type, or equal.

4. TERMINAL BLOCKS:

a. Terminal blocks shall be provided for external control connections. Four (4) spare terminals shall be provided. Terminals shall be permanently identified

01/28/19


26 09 16 - 8

with numbers. Terminal blocks shall conform to the requirements of this specification section.

E. CONTROL DEVICES:

1. Combination starters shall be provided with control devices as shown on the control diagrams. Control devices shall be as specified in this specification section.

F. TRANSIENT SURGE SUPPRESSORS:

1. Transient surge suppressors shall be provided in each starter. Suppressors shall be encapsulated, three component, solid state circuit, in a module suitable for mounting directly to the starter coil. Additional space for suppressors shall not be required. Suppressors shall be rated 120 volts AC/DC; Rockwell Automation Allen Bradley #199-FSMA1, or equal.

G. CONTROL CIRCUIT TRANSFORMERS:

1. Each combination motor control unit shall be provided with a control circuit transformer rated for 480 by 240-120V, single phase, 60Hz. Transformers shall have a minimum volt-ampere rating as follows:

Starter Minimum volt-ampere rating

Size 1 100Size 2 150Size 3 200Size 4 300

2. The transformer size shall be increased if the devices applied will cause a control transformer overload or secondary terminal voltage to drop to or below 95 percent of rated secondary control voltage when rated primary voltage is applied.

H. CONTROL CIRCUIT FUSING:

1. Two primary fuses, rated to interrupt 200,000 amperes at 600 volts, shall be provided on all control circuit transformers.

2. Each control circuit transformer shall be provided with one control circuit secondary fuse. Secondary fuses shall be 1/4 by 1-1/4 inches. The secondary fuse shall have an interrupting rating of 10,000 amperes at 250 volts.

3. The secondary fuse shall be sized at 125 percent of full load current. Fuses shall have time delay characteristics as required to prevent false tripping due to coil inrush currents.

4. Fuse holders shall be indicating type, for blown fuse indication, and shall contain neon lamp, clear transparent knob, and solder terminals.

01/28/19


26 09 16 - 9

I. CONDUCTORS AND WIRE MARKERS:

1. Conductors shall be 90 degree C switchboard type "SIS". Conductors shall be identified with tag numbers as specified in this specification section.

PART 3 -- EXECUTION

3.01 GENERAL (NOT USED)

3.02 INSTALLATION

A. CALIBRATION:

1. Size the electronic overload relay to the actual nameplate full load amperes of the motor connected to the starter.

2. The motor circuit protector shall be adjusted to the lowest setting not causing false tripping.

B. CONTROL DEVICES:

1. NEMA RATING:

a. Control devices shall have an environmental rating to match the NEMA ICS-6 enclosure type as follows:

NEMA Enclosure NEMA Control Device Rating

NEMA 1 NEMA 4/13

NEMA 4 NEMA 4/13

NEMA 4X NEMA 4X

NEMA 12 NEMA 4/13

2. PUSHBUTTONS AND SELECTOR SWITCHES:

a. Pushbutton operators shall be red for stop or open, green for start or close, and black for all other functions.

3. INDICATING LIGHTS:

a. Indicating lights located indoors shall have LED or neon lamps, and lights located outdoors shall have incandescent lamps. For panels with multiple lights; the push to test feature can be deleted, if a common push button is included to test all lamps as a group. Indicating lamp colors shall be in accordance with the following schedule:

01/28/19


26 09 16 - 10

Color Function Example

Red Run, valve status Equipment operating, motor running, valve open

Green Normal condition, ready, valve status

Equipment ready, status OK, valve closed

Amber Abnormal condition Failure of equipment or status abnormal, fault condition

White Control power Control power on

b. If a white lamp is unavailable then control power can be designated with a green lamp.

C. CONTROL RELAYS:

1. Control relays and timers used for switching loads (solenoids, actuators, contactors, motor starter coils, etc.) shall be heavy-duty machine tool types. Relays that have contacts used for remote interlocking or for which the switching load is not shown on the drawings shall also be heavy-duty machine tool type. Control relays used for switching control logic, signal and solid-state circuits shall be the enclosed plugin type, and timers shall be the solid-state types.

D. STARTERS, CONTACTORS, DISCONNECTS AND CONTROL STATIONS:

1. Unless otherwise shown on the drawings, starters, contactors, disconnects and control station enclosures shall be rated for the environment in which they are located in accordance with NEMA ICS-6 enclosure type rating as follows:

NEMA Enclosure type Location

NEMA 1 Office or architectural areas

NEMA 12 Electrical, mechanical (HVAC) or computer equipment rooms

NEMA 4 Indoor or outdoor noncorrosive, nonhazardous areas

NEMA 4X Corrosive, nonhazardous areas

NEMA 7 Hazardous areas

E. TERMINAL BLOCKS:

1. Terminal blocks for signal conductors and custom fabricated panels shall be as specified in the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00). Terminal blocks shall be numbered with permanent type written characters with minimum 1/8-inch text height. Provide 15 percent spare terminals with a minimum of two spares.

01/28/19


26 09 16 - 11

F. CABLE AND WIRE MARKERS:

1. All conductors and cables shall be identified with markers. Conductors shall be identified at each connection point with printed wire markers in accordance with the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00). Each wire shall be numbered in accordance with approved connection or interconnection drawings. Signal cable markers shall not be heat shrunk until the outer jacket and foil shield is cut back so that the marker shall also serve to insulate the end of the foil shield from ground. Installed markers shall be positioned to be read without twisting the conductor. Installed conductor markers that can be smudged or erases after installation shall be sprayed with a clear acrylic fixative.

G. MOUNTING HEIGHT:

1. Mount individual motor starters between 48 and 60 inches above the floor.

H. NAMEPLATES:

1. Nameplates shall be fastened using self-tapping stainless steel screws. The use of adhesives will not be permitted.

2. If abbreviations are required because of space limitations, abbreviations shall be submitted and approved prior to manufacture.

3.03 TESTING

A. Miscellaneous electrical devices shall be tested with the equipment in which they are installed in accordance with the ACCEPTANCE TESTING OF ELECTRICAL SYSTEMS Section (26 08 10) and the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00).


**END OF SECTION**

01/28/19


26 09 16 - 12


DIVISION 31 - EARTHWORK 31 10 00 SITE CLEARING31 20 00 EARTH MOVING31 41 00 SHORING



31 10 00 - 1

SECTION 31 10 00

SITE CLEARING

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies site preparation which consists of clearing, grubbing, stripping, demolition, weed control, protection, restoration, disposal, and dust control. The Contractor shall determine the field condition of the site as it affects this portion of work and incorporate all costs thereof in his bid.

1.02 REFERENCES

A. The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed references, the requirements of this section shall prevail.

Reference Title

CASQA California Stormwater Quality Association California Stormwater BMP Handbook – Construction

SACSPEC County of Sacramento Standard Construction Specifications

Guidelines for the Use of Reclaimed Water

State of California, Department of Health Services, Environmental Management Branch -- Guidelines for the Use of Reclaimed Water for Construction Purposes

1.03 SUBMITTALS



2. Information on herbicides used for weed control including product labeling, product material safety data sheet, and application rate.


31 10 00 - 2


PART 2 -- PRODUCTS (NOT USED)

PART 3 -- EXECUTION

3.01 GENERAL

A. The Contractor shall notify the District Representative when site preparation is complete. Further work shall not be started until all site preparation is completed to the satisfaction of the District Representative.


3.03 TESTING (NOT USED)


3.05 RESTORATION

A. Unless otherwise shown on the drawings, site preparation shall not damage structures, pavement, walkways, piping, and all other existing improvements, landscaping or vegetation adjacent to the site. The Contractor shall repair, or replace, any damaged property to its pre-existing condition.

3.06 CLEARING AND GRUBBING

A. Unless otherwise shown on the drawings, the Contractor shall completely remove objectionable materials and obstructions such as brush, trees, logs, stumps, roots, heavy sod, vegetation, rock, stones larger than 6 inches in any dimension, broken or old concrete and pavement, debris, and structures where the completion of the work require their removal.

B. Grubbing shall consist of the complete removal of stumps and roots to a depth of 3 feet below natural ground.

C. Material removed from clearing and grubbing operations shall not be incorporated in fills and backfill.

D. The Contractor shall save and protect all trees located on District property not specifically identified in the contract for removal. No trees shall be removed without approval of the District Representative.


31 10 00 - 3

3.07 STRIPPING

A. Unless otherwise shown on the drawings, stripping shall consist of removing at a minimum the top 12 inches of soil. The District will pay for material that the Contractor is directed to remove as stripping below 12 inches in depth.

B. Stripped material is not suitable for fill material, and shall be stockpiled in a separate location prior to being hauled offsite.

3.08 DEMOLITION AND REMOVAL

A. STRUCTURES AND PIPES:

1. Demolition and removal of structures and pipes consist of removal of abandoned superstructures, foundation walls, footings, compacted granular backfill, slabs, buried pipes and any other structures except as otherwise shown on the drawings. Excavations caused by removal and disposal of existing structures and pipes shall be cleared of waste, debris and loose soil, and backfilled as specified in the EARTH MOVING Section (31 20 00).

2. Pipes to be abandoned in-place shall be plugged with concrete or capped in accordance with the drawings.

B. PAVEMENT:

1. When portions of asphalt pavements and concrete pads are to be removed and the remaining portions are to be connected to new construction, edges shall be saw cut, on a neat line at right angles to the curb, concrete or pavement face.

C. EQUIPMENT, MATERIAL, PIPING, CONDUIT AND WIRE:

1. Existing equipment, material, piping, conduit, wire, etc. shall be abandoned, demolished, or removed in accordance with the contract documents.

2. The District Representative may direct the Contractor to demolish and remove existing work not identified in the contract documents and will be paid for as extra work.

D. SALVAGE:

1. The District has the right to salvage items scheduled for removal. The Contractor shall notify the District Representative five days prior to any salvage or demolition work. The District will mark items to be salvaged. Contractor shall be responsible for such items to be disconnected at flange connections, bolted connections or wire terminals, where practical, removed from their foundations, flushed, and placed at a location on the plant site as directed by the District Representative.


31 10 00 - 4

E. PROTECTION OF EXISTING WORK:

1. Before beginning any cutting or demolition work, the Contractor shall carefully survey the existing work and examine the drawings and specifications to determine the extent of the work. The Contractor shall take all necessary precautions to ensure against damage to existing work to remain in place. Any damage to such work shall be repaired or replaced as approved by the District Representative at no additional cost. The Contractor shall carefully coordinate the work of this section with all other work and construct and maintain shoring, bracing and supports, as required.

3.09 WEED CONTROL

A. Project site weed control shall be the responsibility of the Contractor. Weed control may consist of mechanical control measures or the application of herbicides. Herbicide application and mechanical control measures such as mowing, disking, or blading shall conform to all other contract specifications and environmental mitigation measures.

B. Contractor shall provide written notice to the District Representative no less than 48 hours prior to the intended weed control operations. If herbicide application is involved, written notice shall include approved herbicide submittal and description of the area to receive application. If mechanical control measures are involved, written notice shall include description of proposed methods and area to receive treatment. If Contractor is unable to perform weed control operations on or within seven days following the intended date, the Contractor shall resubmit advance written notice.

C. The Contractor shall ensure that all herbicide applications are conducted in accordance with the product labeling and conform to all Federal and State laws and regulations set by the California Department of Pesticide Regulation (DPR) as well as by the Sacramento County Agricultural Commission. District approval of an herbicide application does not supersede nor circumvent Federal and State laws and local regulations governing the use of herbicides. All herbicide use reporting to the Sacramento County Agricultural Commission shall be the responsibility of the Contractor.

D. Contractor shall be responsible for the safety of their employees and the protection of their equipment and belongings prior to, during, and after application of herbicides.

3.10 PROTECTION

A. The Contractor shall provide temporary protection devices, including barricades, fencing, guardrails, warning signs, lights and other devices necessary to ensure the security of, and safety within, the project site during all of the work. Contractor shall comply with the standards specified by SACSPEC.


31 10 00 - 5

3.11 DISPOSAL

A. All material that results from clearing, grubbing, stripping, and demolition shall become the property of the Contractor and shall be removed from the plant site and lawfully disposed of by the Contractor at his expense.

3.12 DUST CONTROL

A. Contractor shall provide dust control for the duration of construction operations. The Contractor shall water areas prior to starting work. The amount of dust control shall be as directed by the District Representative.

B. Non-potable water sources suitable for dust control are listed in the TEMPORARY UTILITIES Section (01 51 00).

C. Controls on hauling and use of reclaimed water for construction purposes shall comply with guidelines established by the State of California, Department of Health Services

**END OF SECTION**


31 10 00 - 6



31 20 00 - 1

SECTION 31 20 00

EARTH MOVING

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies earthwork which consists of all labor, materials, equipment and incidentals necessary to perform excavation, backfill, structure backfill, grading, compaction, dewatering, dust control and disposal of unsuitable and excess material.

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part

of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed references, the requirements of this section shall prevail.

1. American Society of Testing Materials

(ASTM) Reference Title C136 Method for Sieve Analysis of Fine and Coarse Aggregates D1557 Test Method for Laboratory Compaction Characteristics of

Soil Using Modified Effort D2216 Test Method for Laboratory Determination of Water

(Moisture) Content of Soil and Rock D2419 Standard Test Method for Sand Equivalent Value of Soils

and Fine Aggregate D2487 Standard Practice for Classification of Soils for

Engineering Purposes (Unified Soil Classification System)

D4318 Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils

D6938-10 Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)


31 20 00 - 2

2. State of California - Department of Transportation (Caltrans) Reference Title Caltrans Standard Specifications CTM 231 Method of Test for Relative Compaction of Untreated

and Treated Soils and Aggregate

3. County of Sacramento - Public Works Reference Title SACSPEC Standard Construction Specifications

4. American Association of Highway and Transportation Officials

(AASHTO) Reference Title T88 Method of Test for Particle Size Analysis of Soils

5. California Building Code

(CBC) Reference Title Chapter 18 Soils and Foundations

B. DEFINITIONS

1. BEDDING: The material that extends below the pipe barrel to the bottom of trench.

2. COMPACTION: The degree of compaction is specified as percent compaction or

relative compaction and refers to the in-place dry density of soil expressed as a percentage of the maximum dry density of the same soil determined in accordance with the specified test method. Optimum moisture content is the water content (percentage by weight) corresponding to the maximum dry density. Relative compaction shall be determined in accordance with the test methods specified herein.

3. EMBANKMENT SLOPE: An inclined surface formed by placement of material

above existing grade.

4. EXCAVATION SLOPE: A sloped surface formed by removing material from below existing grade.

5. INITIAL BACKFILL: The material placed from the top of the bedding to a point

6 inches above the top of the pipe and pipe bell.

6. STRUCTURE BACKFILL: Backfill material placed against the outside of structure within a distance of one-half the maximum depth of fill.

7. SUBSEQUENT BACKFILL: The material placed from top of initial backfill to

roadway or structure subgrade. Where subgrade is not present, place material to finish grade.


31 20 00 - 3

1.03 SUBMITTALS


1. A copy of this specification section, with addenda updates, with each paragraph

check marked to show specification compliance or marked to show deviations.

2. One sample of each imported fill material to be used shall be submitted 60 days in advance of use. Each sample shall consist of 0.5 cubic feet of each type of material.

3. A dewatering plan to control water in excavations.

4. A detailed Trench Excavation Plan in accordance with governing state and federal

requirements, describing the design of shoring, bracing, sloping, or other provisions to be made for worker protection from the hazard of caving ground during the excavation of any trench five feet or more in depth. Shoring plans shall be prepared and signed by a civil engineer registered in the State of California.

5. Daily field and laboratory compaction test results.

6. A compaction report, upon completion of backfill and grading operations.

7. A Construction Traffic Control Plan as referenced in the TRAFFIC CONTROL

Section (01 55 26).

1.04 OPERATION AND MAINTENANCE INSTRUCTIONS (NOT USED) PART 2 -- MATERIALS

2.01 FILL MATERIALS

A. GENERAL:

1. Fill materials include native and import types. Import materials, if required, shall

meet the specified requirements stated herein for each type of material or requirement for use. Native materials (Type B, Type C and Type K) shall be removed from excavations and stockpiled in the laydown area as specified in Sub Section 3.07, or in the Excess Fill Disposal Area and as directed by the District Representative. The Contractor’s geotechnical engineer shall classify native material prior to use as fill material.


31 20 00 - 4

B. TYPE B:

1. Type B material is native material which is highly expansive clay. Type B material is unsuitable for structure backfill. Type B material is suitable for liner subgrade and for secondary soil in the LDLD when blended with other suitable secondary soil materials and placed according to paragraphs 3.07.C and 3.07.D of this section.

2. Material properties shall be based on ASTM D4318. Material shall be classified by

the Unified Soil Classification System and ASTM D2487.

a. Plasticity index: greater than 15.

b. Classification: CL-CH

C. TYPE C:

1. Type C material is native material which shall be free from organic peat, wood, roots, bark, debris, garbage, rubbish or other extraneous material which may be compressible or which cannot be properly compacted. The maximum size of stone shall not exceed 2 inches.

2. If the material excavated from the site meets these requirements, it may be

classified as Type C. Use of Type C material for fill must first be accepted in writing by the District Representative.

D. TYPE D:

1. Type D material shall be granular material commonly known as pea gravel (which

is smooth and free of fractured faces) and shall conform to the following gradation: U.S. standard Sieve size Percent by weight passing 1/2 inch 1003/8 inch 90-100 or 95-100 No. 4 0-4No. 8 0-2


31 20 00 - 5

E. TYPE E:

1. Type E material shall be free draining, clean crushed rock commonly known as drain rock and shall conform to the following gradation:

U.S. standard Sieve size Percent by weight passing 1 inch 1003/4 inch 80 - 901/2 inch 15-303/8 inch 0-10No. 4 0-5

2. Type E material shall be composed of hard, durable, sound pieces having a specific gravity of not less than 2.65. At least 50% of material retained on the 3/8 inch sieve shall have three or more fractured faces.

F. TYPE F:

1. Type F material shall be Class 2 aggregate base per Caltrans Standard Specifications

and shall conform to the 3/4-inch gradation (operating range).

G. TYPE G:

1. Type G material shall be unwashed river sand, clean and free of trash, peat, organics or other objectionable material and shall conform to the following gradation: U.S. standard Sieve size Percent by weight passing No. 4 100No. 8 80 - 100No. 100 0-35No. 200 0-8


31 20 00 - 6

H. TYPE H:

1. Type H material shall be 6-inch riprap. Riprap shall be graded rock having a range of individual rock weights as follows:

Weight of stone Percent smaller by weight

10 pounds 100

5 pounds 80 - 1002 pounds 45-801 pound 15-451/2 pound 5-15Below ½ pound 0-5

2. Specific gravity shall be between 2.5 and 2.82 and all rocks shall have three or

more fractured faces.

I. TYPE I:

1. Type I material shall be 12-inch riprap. Riprap shall be graded rock having a range of individual rock weights as follows:

Weight of stone Percent smaller by weight

160 pounds 100100 pounds 80 - 10050 pounds 45-8020 pounds 15-455 pounds 5-151 pound 0-5

1. Specific gravity shall be between 2.5 and 2.82 and all rocks shall have three or more fractured faces.

B. TYPE J:

1. Type J material shall be controlled low strength material in accordance with the

requirements of the CONTROLLED LOW-STRENGTH CONCRETE Section (03 34 13).

C. TYPE K:

1. Type K material shall be very low to medium expansive soil per Chapter 18 of the

UBC.


31 20 00 - 7

2. Material properties shall be based on ASTM D4318 and AASHTO T88. Material shall be classified by the UBC Unified Soil Classification System and ASTM D2487.

a. Classification: SM or SC.

b. Maximum size: 3 inches c. Percent passing No. 4 sieve: >50

d. Plasticity index: 15 or less

e. Expansion index: 30 or less

3. Type K material may be select native, lime-treated native, or import material.

If the native material excavated from the site meets the specified requirements, it may be classified as Type K. Type C native material treated with 3% lime (CaO) may be expected to meet Type K criteria. Treated or untreated native material to be used as fill must first be accepted in writing by the District Representative.

PART 3 -- EXECUTION

3.01 GENERAL

A. CONTROL OF WATER:

1. The Contractor shall prepare and submit and obtain approval for a surface water control and groundwater dewatering plan prior to commencing any excavation or stockpiling work. The Contractor shall keep excavations and stockpiles free from water and ponding during construction. Water shall be controlled to prevent ponding, softening of the bottom of excavations, or formation of "quick" conditions due to either surface water or groundwater. Dewatering and surface water control systems shall not remove natural soils or stockpiles. Groundwater shall be controlled to prevent disturbance of the natural foundation soils or compacted fill and to prevent flotation or movement of structures or pipelines.

2. The Contractor shall not allow water to pond on unlined portions of LDLD 5 or stockpiles of excavated material. The Contractor shall construct and maintain all excavations and stockpiles within the LDLD 5 boundaries and provide temporary water control systems, grades and swales that prevent accumulation of ponded water at any time.

3. The Contractor shall be or shall employ a specialty Contractor with experience

in the field of surface water control and dewatering system design, installation, operation and maintenance. The Contractor shall document successful completion of at least three (3) projects in soils and groundwater conditions similar to the project.

4. The surface water control and dewatering system shall be designed by a


31 20 00 - 8

California registered Civil Engineer experienced in the design, installation, and operation of dewatering systems.

5. Groundwater discharge shall be based on the approved surface water control

and groundwater dewatering plan. Unless indicated to be provided by the District, Contractor shall obtain all necessary permits and associated costs.

6. The Contractor shall provide, install, operate, and maintain surface water control

dewatering systems of sufficient size and capacity to permit excavation, stockpiling and subsequent construction in dry conditions and prevent hydraulic heave or ponding. Control groundwater table at least 3 feet below the bottom of any excavation at all times.

7. Surface water control and dewatering equipment may include the combination of

sump pumps, eductors, well point system, temporary pipelines for water disposal, rock or gravel placement, holding basins, sediment traps, settling tanks and/or other means. Standby pumping equipment including self-contained emergency power generators shall be maintained on the Project site at all times.

a. Sump pumps in the pipe trench shall not be the primary means of dewatering.

Sump pumps will be allowed in situations only to remove small quantities of accumulated seepage and stormwater run-off. Discharge of any sump pump shall be subject to all the provisions of dewatering permits and plans.

8. System redundancy shall be provided as required to keep excavations and

stockpiles free of water in event of failure of well point, pump, eductor, or other component. Contractor shall promptly repair failed equipment and groundwater pipelines. Under no circumstances shall the groundwater be allowed to rise above the bottom of the excavation.

9. Install groundwater monitoring wells as necessary. After work has been completed,

wells shall be properly abandoned in accordance with State or local Health Department regulations.

10. In the event that failure of dewatering system caused pipe to rise from the intended grade contractor shall remove and reinstall the pipe, regrade the trench subgrade.

11. If groundwater contaminated with hazardous materials is encountered, the

Contractor shall stop dewatering operations and report to the District Representative immediately. Dewatering operations shall not resume until approved by the District Representative.

12. Install and maintain storm water pollution prevention measures in accordance with

the approved Storm Water Pollution Prevention Plan (SWPPP) or Water Pollution Control Plan (WPCP), as appropriate.

13. Keep the surface water control and dewatering system in operation until liner

installation is complete and pipe is properly backfilled.


31 20 00 - 9

14. Shut off dewatering system at such a rate to prevent a quick upsurge of water

that might weaken the subgrade.

15. Cost of surface water control and groundwater dewatering shall be included in the bid price of the pipe installation and earth moving activities described in this section.

16. The Contractor shall be fully and solely responsible and liable for all damages

which may result from failure to adequately keep excavations dewatered. The Contractor is required to pay all costs associated with damage or delay in schedule that water imposes on the project.

17. The Contractor shall repair without additional cost to the District any damage

due to cracking or settlement that may result from his negligence, inadequate or improper installation, maintenance, or operation of the dewatering system, including but not limited to mechanical or electrical failures.

18. Contractor shall be responsible for monitoring settlement of adjacent property

resulting from lowering groundwater table. Contractor shall be responsible for property damages due to dewatering operation.

19. PERMITTING:

a. Contractor shall remain in compliance with approved disposal methods and

disposal locations as specified herein and in the National Pollution Discharge Elimination System (NPDES) requirements, Blanket Low Threat Discharge Permit, and Storm Water Pollution Prevention Plan (SWPPP) or Water Pollution Control Plan (WPCP), as appropriate.

b. Prior to start of work in waters, including wetlands or other jurisdictional lands,

or dewatering, Contractor must ensure that all environmental related permits have been secured and are in place.

c. Removal of sediment through ponds and filters, and testing for contaminants shall be in compliance with the appropriate permits and/or other requirements for disposal.

d. Contractor shall dispose of water in accordance with permit conditions and

without causing damage to adjacent property.

20. DISPOSAL OF WATER:

a. No surface water or dewatering flows from the Project may be discharged to any local drainage ditches, storm drains, or sanitary sewers except as specified in this section.

b. All surface water control and dewatering water shall be desilted through


31 20 00 - 10

adequately sized desilting tanks prior to discharge. Desilted water shall be discharged through temporary pumps and pipes installed by the Contractor into the existing outlet structure in the runoff zone of LDLD 5. From there, water is conveyed through existing pipes to the SRWTP treatment process.

c. The Contractor shall dispose of water from the Work in a suitable manner

without damage to adjacent property. No water shall be drained into work built or under construction or to locations not specified in this section without prior written authorization of the District Representative. Water shall be desilted using a method to remove sand and fine-sized soil particles before disposal into any drainage system.

d. The release of groundwater to its static level shall be performed in such

a manner as to maintain the undisturbed state of the natural foundation soils, prevent disturbance of compacted backfill and prevent flotation or movement of structures, pipelines, and sewers.

e. The Contractor shall obtain approval from the District Representative prior

to disposing of water into the plant's stormwater or process system. Disposal of water shall not damage property or create a public nuisance.

21. Dewatering system shall be designed to prevent excessive draw down of

groundwater table which may cause settlement at neighboring properties.

22. To reduce the migration of water along the pipeline through relatively porous pipe bedding, seepage barriers shall be placed at no more than 1,000-ft intervals along the constructed pipeline. Seepage barriers shall be constructed a minimum of 3-ft from any pipe joints and as shown on the Plans.

23. Contingency Plan: Section 01 14 20 lists a contract milestone for completion of

HDPE liner installation. The surface water and groundwater dewatering plan prepared by the Contractor shall include a contingency plan in the event the milestone date is not met. At a minimum, the plan shall include enhanced surface water control facilities and procedures to prevent ponding in open excavations and stockpiles due to storm events. The Contractor is responsible for providing additional surface water control measures as required to prevent ponding at no extra cost to the District.

24. The surface water control and groundwater dewatering plan is subject to approval

by the District and the Central Valley Regional Water Quality Control Board (Board). The District will transmit the Contractor’s plan to the Board for review and approval and will notify the Contractor of any comments and required modifications. The Contractor shall anticipate that review by the Central Valley Regional Water Quality Control Board may take up to six weeks to complete.


31 20 00 - 11

B. OVEREXCAVATION:

1. Where the undisturbed condition of natural soils is inadequate for support of the planned construction, the District Representative will direct the Contractor to overexcavate to adequate supporting soils.

2. The overexcavated space shall be filled to the specified elevation with backfill. 3. The type, quantity and placement of such material will be paid for as extra work.

C. SURPLUS MATERIAL:

1. Surplus materials, resulting from excavations or trenching operations shall be used

for backfill or embankment construction as set forth on the plans and specifications.

2. Material shall not be stockpiled to a depth greater than 5 feet above finished grade within 25 feet of any excavation or structure. Within 25 feet of any excavation or structure, the depth of stockpiled material shall be as specified. The Contractor shall maintain stability of the soil adjacent to any excavation.

D. SURVEY MONUMENTS:

1. Survey monuments have been or will be set by the District as references for vertical

and horizontal control at the locations indicated on the drawings. Survey monuments set by the District shall be carefully preserved by the Contractor. In case such survey monuments are destroyed or damaged, they will be replaced by the District at the Contractor's expense.

2. The Contractor shall be responsible for setting all additional stakes or marks

required for the completion of the work indicated on the drawings and in these specifications.

E. HAULING:

1. When hauling is done over existing SRWTP roads, highways or city streets,

the loads shall be trimmed and the vehicle shelf areas shall be cleaned after each loading. The loads shall be watered after trimming to eliminate dust. Any spilled material shall be immediately cleaned-up.

F. FINISH GRADING:

1. Finished surfaces shall be smooth, compacted and free from irregularities.

2. Finished grade shall be as specified by the contours plus or minus 0.05 foot except

where a local change in elevation is required to match sidewalks, curbs, manholes and catch basins, or to ensure proper drainage.


31 20 00 - 12

3. When the work is at an intermediate stage of completion, the lines and grades shall be sufficient to provide adequate drainage.

G. CONTROL OF EROSION: 1. The Contractor shall maintain earthwork surfaces true and smooth and protected

from erosion in conformance with the approved SWPPP or WPCP, as appropriate.

H. MISCELLANEOUS:

1. For miscellaneous earthwork items not covered in this specification refer to SACSPEC.


3.03 CLASSIFICATION OF FILL

A. Unless otherwise shown on the drawings, fill classes shall be used where specified in Table A under General Application.


31 20 00 - 13

Table A, Fill Classifications

Fill Class

Material type

Maximum uncompressed layer depth, inches

Minimum relative, compaction, percent

General Application

B1 B 8 90 1. Subsequent trench backfill not under improvements

C1 C 8 95 1. Site fill not under structures, equipment pads, pavement or any improvement

2. Embankments 3. Subsequent trench backfill not under

improvements 4. Backfill over pipes and electrical

ductbanks encased in concrete and not under improvements

5. Backfill outside a horizontal distance equal to one half the total depth of fill from structures

D1 D 8 N/A --E1 E 6 N/A 1. Fill under slabs for structures with

pressure relief valves 2. Bedding and initial pipeline backfill for

SD and STD piping systems < 48 inches in diameter. Completely encase bedding and initial backfill with geotextile fabric with a minimum overlap of 18 inches.

F1 F 8 95 1. Top 6 inches of fill under slab-on-grade and foundations for structures

2. Asphalt paving aggregate base 3. Structure backfill. 4. Bedding for precast concrete,

underground structures. 5. No recycled/reclaimed asphalt will be

allowed where exposure to groundwater may occur.

G1 G 8 95 Bedding and initial pipeline backfill for all pipelines except SD and STD piping systems

H1 H N/A N/A RIPRAP SHALL BE PLACED WHERE SHOWN OR SPECIFIED

I1 I N/A N/A RIPRAP SHALL BE PLACED WHERE SHOWN OR SPECIFIED


31 20 00 - 14

Fill Class

Material type

Maximum uncompressed layer depth, inches

Minimum relative, compaction, percent

General Application

J1 J N/A N/A 1. Bedding and initial backfill under exposed existing utilities

2. Bedding and initial backfill at utility crossings or where utilities are stacked

3. Bedding and backfill up to springline for reinforced concrete pipe > 48 inches diameter

K1 K 8 95 1. Fill below top 6 inches of Class F1 fill under structures

2. Structure backfill 3. Subsequent trench backfill 4. Fill in overexcavated structure foundation

areas outside DSOD jurisdiction


31 20 00 - 15

3.04 EARTHWORK FOR STRUCTURES

A. GENERAL:

1. Refer to requirements of Division of Safety of Dams in paragraph 1.05 of this section and on the drawings.

B. STRUCTURE EXCAVATION:

1. The bottom shall not be more than 0.15 foot below the lines and grades specified.

If the elevation of structure excavation is not specified, the excavation shall be not more than 0.15 foot above or below the elevation specified for fill material below the structure.

2. Should the excavation be carried below the lines and grades specified on the

drawings or should the bottom of the excavation be disturbed because of the Contractor's operations and require overexcavation and backfill, the Contractor shall backfill such excavated space to the proper elevation in accordance with the procedure specified for structure backfill. The cost of such work shall be borne by the Contractor.

3. Excavations shall extend a sufficient distance from walls and footings to allow

for placing and removal of forms, installation of services, and for inspection, except where concrete is specified to be placed directly against excavated surfaces.

4. Whenever any structure excavation is substantially completed to grade, the

Contractor shall notify the District Representative who will make an inspection of the subgrade.

C. FOUNDATION TREATMENT:

1. The subgrade under structures shall be scarified to a depth of 8 inches, uniformly

moisture conditioned to the range of minus one percent (-1%) to plus two percent (+2%) of optimum, and recompacted to the minimum relative compaction shown in Table A for the type of fill to be placed on the subgrade. No fill material, concrete or masonry shall be placed until the subgrade has been inspected and approved by the District's Representative. Within DSOD jurisdiction, no fill material, concrete or masonry shall be placed until the subgrade has been inspected by the District's Representative and DSOD.

2. All footings, foundations, slabs-on-grade, and asphalt paving shall be underlaid

with a minimum of 6 inches of Type F fill. This minimum 6 inches of Type F fill shall be provided whether indicated on the plans or not.

When footings are to be supported on piles or piers, excavations shall be completed

to the bottom of the footings before any piles or piers are installed. When swell


31 20 00 - 16

or subsidence results from driving piles, the Contractor shall excavate, or backfill, the footing area to the grade of the bottom of the footing.

3. If material under footings is such that it would not support the weight of the fluid

concrete, the Contractor shall replace the material, or otherwise provide a suitable platform on which to cast the footing as directed by the District Representative. This will be paid for as extra work.

D. STRUCTURE BACKFILL:

1. After completion of construction below the elevation of the final grade, and prior

to backfilling, forms shall be removed and the excavation shall be cleaned of debris.

2. Structure backfill shall not be placed until the at-grade decks and subgrade portions

of the structure have been inspected and approved by the District Representative.

3. No backfill material shall be deposited against concrete structures until the concrete has developed a compressive strength of at least 3000 pounds per square inch and the concrete has been in place for at least 7 days.

4. Backfill material shall be brought up uniformly on all sides of the structure.

5. Compaction shall be accomplished by mechanical equipment such as tamping

rollers, sheepsfoot rollers, pneumatic tire rollers, vibrating rollers, or other mechanical tampers suitable for the work.

6. Light hand-operated tampers shall be used within 1 foot of structures to minimize

the possibility of overstressing structure walls. Maximum uncompressed layer depth shall be 4 inch lifts.

7. Compaction by ponding and jetting shall not be permitted.

3.05 EARTHWORK FOR PIPELINES

A. GENERAL:

1. Pipelines shall be installed in trenches.

2. Backfill around and above pipelines within the excavation of any structure shall

be the same as that specified for structures.

3. Perform dewatering prior to excavation.

4. Excavation support: Install and maintain trench excavation support system as specified.

5. Do not over-excavate without written authorization of the District Representative.


31 20 00 - 17

B. TRENCH EXCAVATION

1. Trench excavation shall include the removal of all materials or obstructions of

any nature.

2. Before excavation of the pipe trench in fill areas or roadway embankments, the fill area or embankment shall be completed to a height above the pipe invert grade line of not less than 12 inches above the top of the pipe or as recommended by the pipe manufacturer, whichever is greater.

3. When the trench is in an existing paved area, the pavement shall be saw cut on

neat lines parallel and equidistant from the trench centerline. Pavement between the lines shall be broken and removed immediately ahead of the trenching operations. The width of pavement removed shall be sufficient that the trenching operation does not damage the edges of the pavement left in place.

a. When the existing pavement is concrete, it shall be removed to a neat line

a minimum of 6 inches wider on each side than the actual trench width.

b. When the existing pavement is asphalt concrete, it shall be removed to a neat line a minimum of 12 inches wider on each side than the actual trench width.

4. The fill area or embankment shall be compacted to a minimum relative compaction

of 95 percent for a distance on each side of the pipe equal to at least two pipe diameters. Prior to excavation contact Underground Services Alert (USA) to mark underground utilities.

5. Where the existing utility piping is expected, hand dig (pothole) the area to expose

the existing utilities and survey the utility piping size and elevation prior to trench excavation.

6. Install traffic control devices in accordance with approved traffic control plan

as required.

7. Excavate trenches per approved Trench Excavation Plan:

a. Excavate trench to lines and grades shown or as established by the District Representative with proper allowance for pipe wall thickness and bedding.

b. Support existing piping where proposed utility line crosses at a lower

elevation. Exposed existing piping shall be supported and braced against seismic forces.


31 20 00 - 18

c. Stabilize excavation to prevent undermining of existing structures, utilities and piping.

d. Install trench shield or sheeting/shoring system in accordance with the

approved Trench Excavation Plan.

8. Open trench outside buildings, units, and structures:

a. Cover open trench with H-20 traffic rated steel plates at the end of each working day.

9. Trenching within buildings, units, or structures:

a. No more than 100 lineal feet at any one time.

10. Any trench or portion of trench, which is opened and remains idle for 7 calendar

days, or longer, as determined by the District Representative, may be directed to be immediately refilled, without completion of work, at no additional cost to District.

a. Said trench may not be reopened until the District Representative is satisfied

that work associated with trench will be prosecuted with dispatch.

11. Trench width for pipelines:

a. Unless otherwise shown on the drawings, minimum trench width for piping shall be the outside diameter of the piping plus 12 inches.

b. Maximum trench widths at the top of the pipe shall be as shown on the plans

for the designated type bedding.

c. For drainage pipe, if no maximum is shown, the Contractor shall limit top trench widths to pipe outside diameter plus 16 inches for pipe 33 inches or smaller, and pipe outside diameter plus 24 inches for pipe 36 inches and larger, except upon a specific approval of the District Representative.

12. Observe following trenching criteria:

a. Excavate width to accommodate free working space for joint installation

and soil compaction.

b. With the exception of pipe joints where trench width and depth should be increased to allow joint installations, maximum trench width at top of pipe or conduit may not exceed outside diameter of pipe by more than 36 inches:


31 20 00 - 19

c. If a movable trench shield is used during excavation operations, the trench width shall be wider than the shield so that the shield is free to be lifted and then moved horizontally without binding against the trench sidewalls.

d. If the trench walls cave in or slough, the trench shall be excavated as an open

excavation with sloped sidewalls or with trench shoring.

e. Cut trench walls vertically from bottom of trench to 1 foot above top of pipe, conduit, or utility service.

f. Keep trenches free of surface water runoff. Include cost in Bid. No separate

payment for surface water runoff pumping will be made.

13. Whenever the bottom of the trench is soft or rocky, or, in the opinion of the District Representative, otherwise unsuitable as a foundation for the pipe the unsuitable material shall be removed and replaced with suitable material to provide a stable and satisfactory base. This will be paid for as extra work.

C. PIPE BEDDING AND INITIAL BACKFILL:

1. All loose material shall be removed from the trench bottom before placing

the bedding material.

2. The pipe shall be placed on a bed of imported materials. The pipe shall be bedded uniformly throughout its length. Bedding shall extend at least 4 inches below the pipe barrel and 1-1/2 inches below the pipe joint bell.

3. No wedging or blocking of the pipe will be permitted to remain permanently

in place. The bearing shall be achieved by shaping the bedding or by lightly "bouncing" the pipe to set it into the bedding.

4. The Contractor shall then place backfill material to the spring line of the pipe,

thoroughly compacting it by shovel slicing and tamping to provide proper support under the pipe haunches. Care shall be used not to disturb or displace the pipe.

5. Initial backfill shall be carefully placed evenly on both sides of the pipe so as not

to disturb or damage the pipe, and compacted to the specified compaction. Jetting will not be allowed.

6. Compaction of layers shall be accomplished with a minimum two passes of light

hand-operated equipment with complete coverage across the width of the field. 7. Type D material shall be vibrated under and around pipe with a high cycle concrete

vibrator.

D. TRENCH BACKFILL:

1. Subsequent trench backfill above the initial backfill shall be placed and compacted to obtain 6-inch layers. Machine-placed backfill material shall not be allowed to


31 20 00 - 20

"free-fall" more than 2 feet, until the total backfill above the top of the pipe exceeds 3 feet.

2. If the excavation is through an area used for horticulture, lawns or other cultivated

areas, the final 12 inches of backfill shall be the original topsoil which shall have been removed and stockpiled separately. The backfill shall be thoroughly compacted by wheel rolling, then refilled with topsoil as necessary to bring the trench up to the level higher than the surrounding ground.


rollers, sheepsfoot rollers, pneumatic tire rollers, vibrating rollers, or other mechanical equipment suitable for the work.


the possibility of overstressing structure walls.

5. Compacting by flooding or jetting will not be allowed.

3.06 EARTHWORK FOR ELECTRICAL CONDUIT DUCT BANKS

A. GENERAL:

1. Duct banks shall be installed in trenches.

2. Backfill around and above duct banks within the excavation of any structure shall be the same as that specified for structures.

B. TRENCH EXCAVATION:

1. Trench excavation shall include the removal of all materials or obstructions of any nature.

2. When the trench is in an existing paved area, the pavement shall be saw cut on

neat lines parallel and equidistant from the trench centerline. Pavement between the lines shall be broken and removed immediately ahead of the trenching operations. The width of pavement removed shall be sufficient that the trenching operation does not damage the edges of the pavement left in place. a. When the existing pavement is concrete, it shall be removed to a neat line

a minimum of 6 inches wider on each side than the actual trench width.

b. When the existing pavement is asphalt concrete, it shall be removed to a neat line a minimum of 12 inches wider on each side than the actual trench width.

3. Trench width of duct banks:

a. For reinforced concrete duct banks, the trench width shall provide a


31 20 00 - 21

minimum of 3 inch clear from edge of trench to reinforcing steel.

b. For unreinforced concrete duct banks, the minimum trench width shall be 6 inches wider than the outside dimension of the conduit ducts.

4. Whenever the bottom of the trench is soft or rocky, or, in the opinion of the District

Representative, otherwise unsuitable as a foundation for the duct bank the unsuitable material shall be removed and replaced with suitable material to provide a stable and satisfactory base. This will be paid for as extra work.

5. The District's Representative shall inspect and approve the trench foundation

before the placement of any material in the trench.

C. TRENCH BACKFILL:

1. Trench backfill shall not be placed until the duct bank concrete has been in place for 48 hours.

2. Trench backfill shall be placed and compacted to obtain 6-inch layers.

3. If the excavation is through an area used for horticulture, lawns or other cultivated

areas, the final 12 inches of backfill shall be the original topsoil which shall have been removed and stockpiled separately. The backfill shall be thoroughly compacted by wheel rolling, then refilled with topsoil as necessary to bring the trench up to the level higher than the surrounding ground.


rollers, sheepsfoot rollers, pneumatic tire rollers, vibrating rollers, or other mechanical equipment suitable for the work.


the possibility of overstressing structure walls.

6. Compacting by flooding or jetting will not be allowed.

3.08 EARTHWORK FOR EMBANKMENTS

A. FOUNDATION PREPARATION: 1. The foundation soils shall not exceed the optimum moisture content for a minimum

of 3 foot depth below the bottom of excavation. The surface of the foundation shall be free of loose material, foreign objects and rocks greater than 6 inches in maximum dimension.

2. Immediately prior to placement of embankment fill material, the foundation surface

shall be moistened, scarified to a depth of 8 inches, moisture conditioned to optimum moisture content, and recompacted to the relative compaction as shown.


31 20 00 - 22

3. After the preparation has been completed, the Contractor shall immediately place

and compact the first lift of embankment on the foundation to prevent damage to the surface. If the foundation surface is damaged, the Contractor shall repair the surface to the specified condition.

B. EMBANKMENT FILL:

1. The temporary differential elevation between any two adjoining zones of the

embankment due to construction operations shall not exceed 24 inches.

2. Fill slopes shall be overfilled and trimmed back to the lines and grades shown on the drawings to expose a firm surface free of loose material.

3. If the compacted surface of any layer of material is too smooth to bond properly

with the succeeding layer, the surface shall be scarified. The surface shall be moisture conditioned before the succeeding lift is placed. Any surface crust formed on a layer of fill material that has been dumped and spread shall be broken up and the full depth of the affected layer shall be moisture conditioned to the optimum moisture content immediately prior to rolling.

4. The surface of the embankment shall be maintained to permit travel of construction

equipment. In any areas where materials become soft or yielding, such materials shall be removed, disposed of, and replaced with specified material. Ruts in the surface of any layer shall be filled and leveled before compacting.

5. Embankment material moisture shall be within optimum minus one percent (-

1.0%) to optimum plus two percent (+2.0%) as determined by ASTM D1557.

6. When the moisture content and conditions of the embankment material are satisfactory, fill material shall be placed and compacted by a minimum of eight passes of a sheepsfoot tamper roller or approved equivalent. Roller drums shall be no less than 60 inches in diameter and not less than 60 inches in length. The weight of the roller shall not be less than 4000 pounds per linear foot of drum length. If, with the required water content, it is found necessary to roll each 8-inch layer more than eight times to obtain the required compaction, the number of passes shall be changed accordingly as directed by the District Representative. However, the embankment fill shall be compacted to an average density of at least 97 percent with no test less than 95 percent, as determined by ASTM D1557.

C. EMBANKMENT TOLERANCES:

1. GENERAL:

a. Embankment slopes shall vary less than 0.5 foot from the designated slope.

Measurements for variance shall be made perpendicular to the slope. Slopes which are 6:1 or flatter shall vary less than 0.2 foot from the designated slope.


31 20 00 - 23

2. ROADWAY EMBANKMENT TOLERANCES:

a. The excavated surface shall be less than 0.08 foot above or below the grades

specified after deducting for the roadway pavement thickness.

b. Vertical alignment tolerances permitted on the roadway surface shall not exceed plus or minus 0.30 feet from the vertical alignment specified, with the provision that within the tolerance range local surface irregularities shall not exceed 0.15 foot as measured by the gap between the roadway surface and a 10 foot straightedge placed on any flat graded surface. On vertical curves, the same standards will apply except that an additional gap allowance will be made for the road surface curvature over the 10 foot length of the straightedge.

c. Horizontal alignment tolerances permitted shall not exceed plus or minus 1

foot providing the departure is relatively uniform over any specific length of the roadway.

d. Roadway median strips shall be graded to drain and shall not vary more than

0.1 foot from the specified grade.

3.09 EARTHWORK FOR PAVEMENT

A. The prepared subgrade shall be scarified a minimum of 12 inches below finish subgrade and recompacted to at least 95 percent of the maximum density.

B. Pavement aggregate base material shall be installed in accordance with Caltrans

Standard Specifications Section 26 Material shall be compacted per California Test 231.

3.10 SITE FILL

A. If the existing slope in an area to be filled is greater than 5:1, the Contractor shall bench the area prior to filling.

3.11 DUST CONTROL

A. Contractor shall provide dust control as specified in paragraph 3.12 of the SITE CLEARING Section (31 10 00).

3.12 SHORING AND SHEETING

A. The Contractor shall construct and maintain all shoring, sheeting, and slope layback necessary to protect the excavation, as needed for the safety of the employees and as required by applicable state and federal laws and as specified in the SHORING Section (31 40 00).


31 20 00 - 24

3.13 TESTING

A. QUALITY CONTROL:

1. The Contractor shall be completely responsible for conducting all compaction testing and quality control of compacted fill to determine that the compaction requirements are being met.

2. The Contractor shall have the equipment and capability to perform in-place and

maximum density tests, as specified, in the field at the construction site. All testing shall be conducted under the authority and responsible charge of a professional civil or geotechnical engineer or a certified engineering geologist.

3. Field density tests during fill compaction shall be performed at least once for every

1,000 cubic yards of fill and at least once for every 1 foot of vertical fill height. Tests will be made in accordance with the following criteria:

Standard Procedure Test Reference

Moisture Content ASTM D2216 and D6938-10 Gradation ASTM C136 Moisture-Density Relationship ASTM D1557 Sand Equivalent ASTM D2419 Maximum Density ASTM D1557 Pavement Base Compaction CTM 231

B. QUALITY ASSURANCE:

1. The District will take samples and perform tests during placement of fill and backfill materials to check compliance with these specifications. This quality assurance will serve to validate the quality control testing provided by the Contractor.

2. The Contractor shall remove surface material at locations designated by the District

Representative and provide such assistance as necessary for sampling and testing. The District Representative may direct the Contractor to construct inspection trenches in compacted or consolidated backfill to determine that the Contractor has complied with these specifications. Payment for inspection trenches shall be as specified in the GENERAL CONDITIONS Section (00 72 00).

3.14 TRAINING – NOT USED

**END OF SECTION**

01/28/19


31 41 00 - 1

SECTION 31 41 00

SHORING

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies requirements for sheeting, shoring, and bracing of trenches and structural excavations greater than 5 feet in depth. The Contractor shall design sheeting, shoring, and bracing in accordance with Title 8, Division 1, Chapter 4, Sub-Chapter 4, Article 6 of Cal/OSHA.

1.02 REFERENCES


Reference Title

Title 8Article 6 Section 6705

California Code of Regulations, Title 8, Division 1, Chapter 4, Subchapter 4, Article 6 – Excavations California Labor Code

1.03 SUBMITTALS

A. The following information shall be submitted for review for trenches and excavations deeper than five feet or those requiring support in accordance with the SUBMITTAL PROCEDURES Section (01 33 00):


2. Contractor designed shoring system signed and stamped by a registered California Engineer. Calculations and design drawings shall be submitted for shoring systems for:

a. Trench excavation

01/28/19


31 41 00 - 2

b. Structure excavation

3. MANUFACTURER'S DATA:

a. Wood sheeting, plywood, dimensional lumber.

b. Hydraulic shoring, screwjacks.

4. Qualified personnel resumes.


PART 2 -- PRODUCTS

2.01 CONTRACTOR'S DESIGN

A. Contractor’s design shall include access, barricades, shoring, bracing, sloping, benching, bulkheads, cofferdams, dewatering, and other items required to conform to CAL/OSHA Article 6. The design shall be prepared and signed by a registered civil engineer registered in the state of California for depths to 20 feet or a California registered structural engineer for depths greater than 20 feet.

B. The Contractor's attention is directed to the provisions for "Shoring and Bracing Drawings" in Section 6705 of the California Labor Code. The Contractor, prior to beginning any trench or structure excavation 5 feet deep or over shall submit to the District Representative and shall be in receipt of the District Representative’s written acceptance of the Contractor's detailed plan showing design of all shoring, bracing, sloping of the sides of excavation, monument monitoring, or other provisions for worker protection against the hazard of caving ground during the excavation of such trenches or structure excavation. If such plan varies from the shoring system standards established in the Construction Safety Orders of the State of California, such alternative systems plans shall be prepared and sealed by a civil or structural engineer licensed in the State of California.

C. The Contractor's attention is also directed to the California Code of Regulations, Title 8, Section 1541.1. The code requires when excavation is adjacent to an existing structure, a registered professional engineer must approve the determination that such excavation work will not pose a hazard to employees. It is the Contractor’s responsibility to hire a California Registered Civil Engineer to prepare analysis on trench safety, and to install all safety measures recommended by the Registered Engineer.

D. Excavation support systems shall be designed by the Contractor to support earth pressure, unrelieved hydrostatic pressure, utility loads, equipment, applicable traffic loads, and other surcharge loads in such manner as will allow safe construction and will prevent damage to adjacent structures (including existing pipelines and utilities) and injury to workers and the public. In addition, a shoring deflection analysis shall be

01/28/19


31 41 00 - 3

performed. The installation of excavation support system shall not cause a disruption to SRWTP operations or maintenance access. Design shall be prepared and sealed by a California registered Civil or Structural Engineer.

E. If utilized, all soldier piles shall be placed in pre-drilled holes and grouted in-place to a depth in accordance with the Contractor’s Plan.

F. The District’s approval of the Contractor’s plans and methods of construction does not relieve the Contractor of the responsibility for adequacy of the design, installation or resulting trench support.

2.02 MATERIALS

A. Materials shall conform to the requirements of CAL/OSHA Article 6.

PART 3 -- EXECUTION

3.01 GENERAL

A. The construction of sheeting, shoring, and bracing shall not disturb the state of soil adjacent to or below the excavation bottom. This work shall be coordinated with the EARTH MOVING Section (31 20 00).

B. Horizontal strutting below the barrel of a pipe being installed is not acceptable. The pipe being installed shall not be used for support of the excavation.




3.05 SEQUENCE

A. Excavation of 5 feet or more shall not be started until the design of the sheeting, shoring and bracing system has been submitted in accordance with the SUBMITTAL PROCEDURES Section (01 33 00).

B. Excavations of less than 5 feet can be started only after the qualified supervisor (competent person as defined by OSHA) has inspected the ground and determined there is no potential cave-in hazard.

3.06 SUPERVISION

A. Work in an excavation of 5 feet or more shall at all times be under the immediate supervision of a qualified person who is authorized to modify the shoring or sloping in accordance with CAL/OSHA Article 6.

01/28/19


31 41 00 - 4

B. A qualified supervisor shall inspect the excavation, air quality, adjacent areas and protective equipment. Inspections shall be made daily, at shift start, and as needed throughout the shift. Inspections shall also be made after every rainstorm or other hazard intensity occurrence.

3.07 ACCESS

A. A convenient and safe means of access shall be provided to enter and leave an excavated area. This shall consist of a stairway, ladder or ramp securely fastened in-place. For trenches 4 feet or more in depth, a safe means of access shall be provided and located so as to require no more than 25 feet of lateral travel.

3.08 CROSSINGS

A. When walkways or bridges are provided across excavated areas, they shall be provided with standard guardrail and toeboards when the depth of excavation exceeds 6 feet in depth and is more than 30 inches wide.

3.09 AIR QUALITY TESTING

A. The qualified supervisor shall test the atmosphere for oxygen deficiency and flammable gas concentrations before any person enters excavations greater than 4 feet in depth.

**END OF SECTION**

DIVISION 32 – EXTERIOR IMPROVEMENTS 32 12 16 ASPHALT PAVING



32 12 16 - 1

SECTION 32 12 16

ASPHALT PAVING

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies paving consisting of scarifying, grading, compacting, sealing, asphaltic concrete, and associated materials.

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern, except where a specific date or edition is given below. In case of conflict between the requirements of this section and those of the listed references, the requirements of this section shall govern.

Reference Title

County of Sacramento Standard Construction Specification (SACSPEC)

SS-23 Asphalt Concrete

Section 48 Traffic Stripes and Pavement Markings

State of California Department of Transportation (Caltrans)

Standard Plans and Specifications

CTM 205 Method of Test for Percentage of Crushed Particles

CTM 216 Method of Test for Relative Compaction of Untreated and Treated Soils and Aggregate

CTM 231 Method of Testing for Relative Compaction of Untreated and Treated Soils and Aggregates by the Area Concept Utilizing Nuclear Gauges



32 12 16 - 2

1.03 SUBMITTALS



2. Manufacturer's data and mix design.

3. A certificate of compliance signed by the manufacturer shall be furnished prior to the use of all bituminous materials. The certificate shall state that the material complies with the requirements of these specifications. A certificate shall be furnished with each lot of material delivered to the site and the lot so certified shall be clearly identified in the certificate.


PART 2 -- PRODUCTS

PART 3 -- LIQUID ASPHALT

A. Liquid asphalt base shall be Grade MC 250 conforming to Caltrans Section 93.

3.02 SEAL COAT

A. The bituminous binder shall meet all requirements of Caltrans Section 94-1.02 including Table 1 for Type SS-1 slow setting anionic asphaltic emulsion.

3.03 TACK COAT

A. Material for tack coat shall be SS-1 grade emulsified asphalt conforming to Caltrans Section 94.

3.04 PAVEMENT REINFORCING FABRIC

A. Pavement reinforcing fabric, where required on the drawings, shall conform to the provisions of Section 39-4.03 and Section 88-1.02 of the State Standard Specifications, “Pavement Reinforcing Fabric”. Paving fabric shall have minimum asphalt retention of 0.2 gallon per square yard per Task Force 25 Method #8, certified by the manufacturer, shall be of stable fiber construction in order to resist delamination and shall be heat bonded on one side in order to facilitate handling and trafficking.

3.05 ASPHALT CONCRETE

A. Aggregate shall be Type A, 3/4-inch maximum medium grading, conforming to Caltrans Section 39. Asphalt binder shall be paving asphalt, Grade PG-64-10, and


32 12 16 - 3

shall comply with Caltrans Section 92. Asphalt concrete mixing and proportioning shall comply with Caltrans Section 39.

3.06 TRAFFIC LINE PAINT

A. Traffic line paint and pavement markings shall conform to Section 48 of the Sacramento County Standard Specifications and Section 84 of the Standard State Specifications.

3.07 CHIP SEAL

A. This work shall consist of preparing and applying two coats of asphalt emulsion and screenings to the compacted aggregate base roadway. This double chip seal shall consist of an application of asphalt emulsion followed with an application of screenings, and another application of asphalt emulsion followed with another application of screenings.

B. Asphalt emulsions shall be composed of a bituminous material uniformly emulsified with water and an emulsifying or stabilizing agent and conform to the requirements prescribed in Caltrans Section 94-1.02 “Requirements”. Emulsified asphalt shall be Type CRS-2, or equal.

C. Screenings shall consist of broken stone, crushed gravel, or both. At least 90 percent by weight of the screenings shall consist of crushed particles as determined by Caltrans CTM 205. Screenings shall be clean and free from dirt and other deleterious substances. Screenings shall be sized at 3/8-inch by No. 6 or 5/16-inch by No. 8, as specified as a “medium or medium fine” seal coat type in Caltrans standard specifications Section 37-1.02 “Materials”.

3.08 GEOTEXTILE FABRIC

A. Geotextile fabric, where required on the drawings, shall be Mirafi 140.

PART 4 -- EXECUTION

4.01 GENERAL

A. Construction shall conform to the details, dimensions and grades specified and shown on the drawings. Maximum variations in finished grade of paving shall be plus or minus 0.05 feet. Survey monuments have been or will be set by the District in the locations indicated on the drawings as reference for vertical and horizontal control. The Contractor shall be responsible for setting all additional stakes or marks required for the completion of the work. New paving shall be installed after all trenching and backfilling is completed beneath it in accordance with the EARTH MOVING Section (31 20 00) and all associated piping has been tested and accepted. Installation shall comply with "Standard Construction Specifications" of the County of Sacramento


32 12 16 - 4

referred to herein as CSCS and with "Standard Plans and Specifications" of the State of California, Department of Transportation referred to herein as Caltrans.

4.02 INSTALLATION

A. PLACEMENT OF AGGREGATE BASE AND SUBGRADE FOR ROADWAYS:

1. Refer to the EARTH MOVING Section (31 20 00) for aggregate base and subgrade materials.

2. SUBGRADE PREPARATION:

a. The subgrade shall be compacted as specified in accordance with the EARTH MOVING Section (31 20 00).

3. AGGREGATE BASE TOLERANCE:

a. The aggregate base shall not be placed before the subgrade is approved by the District Representative. The finished aggregate base shall not vary more than 0.05 foot above, nor 0.10 foot below, the planned grade.

4. AGGREGATE BASE PLACING:

a. The aggregate base material shall be spread on the prepared subgrade by means of approved spreading devices subject to approval by the District Representative; the aggregate base material may be dumped in piles upon the subgrade and spread by bulldozing ahead from the dumped material. Each layer shall not exceed 0.50 feet. Segregation of large or fine particles of aggregate shall be avoided, and the material as spread shall be free from pockets of large and fine material.

b. The relative compaction of each layer of compacted aggregate base and subgrade material shall in accordance with the EARTH MOVING Section (31 20 00). Compaction shall not be less than 95 percent of Caltrans CTM 216 as determined by Caltrans CTM 231). Compaction shall be in accordance with Caltrans Section 26-1.05. Aggregate base, after compaction, shall be watered as provided in Caltrans Section 17.

B. TACK COAT APPLICATION:

1. TACK COAT:

a. In advance of spreading bituminous material upon an existing bituminous or Portland cement concrete surface, a tack coat shall be applied to all areas to be surfaced and to all vertical surfaces of existing pavement, curb, gutters and construction joints in the surfacing against which additional material is to be placed. When two or more lifts of asphaltic concrete are required, a tack coat


32 12 16 - 5

shall be applied between each lift unless successive lifts are placed within eight hours.

2. PREPARATION:

a. Immediately before applying a tack coat, the area to be surfaced shall be cleaned of all loose material by power broom or equivalent method acceptable to the District Representative.

3. APPLICATION:

a. The tack coat shall be applied by means of pressure distributors by pressure hand-spray equipment. The rate of application shall be 1/20 of a gallon per square yard. Emulsified asphalt shall not be applied when the atmospheric temperature is below 50 degrees F. If emulsified asphalt Type SS-1 is used, it may be diluted with an equal part of water. The rate of application of the dilution shall be such that the rate of application of undiluted emulsion shall be within the tolerances specified.

C. placement of pavement reinforcing fabric:

1. REINFORCING FABRIC:

a. Mechanical laydown equipment used must be capable of handling full rolls of fabric, and be capable of laying the fabric smoothly, without excessive wrinkles and/or folds. The laydown equipment shall maintain a 50- to 100-foot separation from the asphalt binder distributor truck to allow the proper inspection of the binder application. The minimum asphalt binder temperature shall be 290 degree F with a distributor tank temperature not to exceed 325 degrees F. While the separate tractor is desired, a single laydown unit may be used, subject to the approval of the District Representative, if inspection of the oil distribution system can be verified as operating properly and accurately. Such a procedure must be presented in writing prior to the start of the job and approved in advance by the District Representative.

b. Asphalt binder shall be spread at a minimum rate of 0.2 gallon per square yard regardless of ambient or pavement temperature, and up to 0.25 gallon per square yard at the discretion of the District Representative. Actual spread rate will be determined by the District Representative, and gallonage corrected for temperature will be verified from weigh-backs for each load of asphalt binder spread.

c. The Contractor shall calibrate, prior to starting asphalt binder application, the bituminous distributor.


32 12 16 - 6

D. PLACEMENT OF ASPHALT CONCRETE:

1. DELIVERY AND SPREADING:

a. Bituminous mixtures shall be delivered to the roadbed at temperatures specified in Caltrans Section 39. Spreading of the mixture shall be in accordance with Caltrans Section 39. All loads shall be covered with tarpaulin or other material during transportation. The top layer of asphalt concrete shall not exceed 0.20 foot in compacted thickness. The next lower layer shall not exceed 0.25 foot in compacted thickness, and any lower layers shall not exceed 0.50 foot in compacted thickness.

2. COMPACTION:

a. Initial or breakdown rolling and the final rolling of the uppermost layer of the asphalt concrete shall be compacted in accordance with Caltrans Section 39. Compaction by vehicular traffic shall not be permitted. The District reserves the right to require an adjustment of the temperature of the asphalt concrete at the time of placement at the direction of the District Representative.

3. PAVEMENT THICKNESS:

4. Pavement shall match the existing adjoining pavement in thickness, as indicated on the Drawings, Joining Pavement:

a. The joints between old and new pavements or between successive days' work shall be carefully made in such a manner as to ensure a continuous bond between old and new sections of the course. Edges of existing pavement shall be exposed and cleaned and edges cut to straight, vertical surfaces. All joints shall be painted with a uniform tack coat before the fresh mixture is applied.

5. PROTECTION OF PAVEMENT:

a. After final rolling, no vehicular traffic of any kind shall be permitted on the pavement until it has cooled and hardened and in no case less than 6 hours.

E. APPLICATION OF FOG SEAL:

1. A fog seal shall be applied to the upper surfaces of all installed asphalt concrete as indicated on the drawings. It shall be applied in accordance with the applicable requirements of Caltrans Section 37.

2. A final fog seal shall be applied to asphalt concrete after all other construction is complete.


32 12 16 - 7

F. CHIP SEAL:

1. Asphalt emulsions shall be applied to the width of the section to be primed by means of a pressure distributor is a uniform, continuous spread at a rate of between 0.25 to 0.35 gallons per square yard. Asphalt emulsions shall be applied as specified in Caltrans Section 94-2.06 “Applying.” Asphalt emulsion shall not be applied on a wet surface, or when weather conditions would prevent the proper application and curing of the coat. When traffic is maintained, not more than one-half of the width of the section shall be treated in one application. Traffic shall not be permitted on the roadway until the asphalt emulsion and screenings have been placed and completely cured. Care shall be taken that the application of asphalt emulsion at junctions is not in excess of the specified amount. Excess material shall be squeegeed from the surface.

2. Screenings shall be applied at a rate of 20 to 30 pounds per square yard and conform to Caltrans Section 37-1.06 “Spreading Screenings” and Section 37-1.07 “Finishing.”

G. PAINTING:

1. Line paint shall be applied in accordance with the paint manufacturer’s instructions and Caltrans Section 84.

4.03 TESTING

A. QUALITY CONTROL:

1. The Contractor shall be completely responsible for conducting all testing and quality control of asphalt pavement to ensure that all requirements of Caltrans Section 26 and 39 are met.

2. The Contractor shall be completely responsible for conducting all compaction testing and quality control of compacted fill to determine that the compaction requirements are being met in accordance with the EARTH MOVING Section (31 20 00).

3. The Contractor shall have the equipment and capability to perform all tests, as specified, in the field at the construction site. All testing shall be conducted under the authority and responsible charge of a professional civil or geotechnical engineer or a certified engineering geologist.

4. All daily field and laboratory testing reports shall be provided within 24 hours of completion to the District Representative during mass grading and during backfill of utilities and structures.

5. All areas not meeting the specified compaction requirements shall be reworked and retested within 24 hours.


32 12 16 - 8

B. QUALITY ASSURANCE:

1. The District will take samples and perform tests during placement of materials to check compliance with these specifications. This quality assurance will serve to validate the quality control testing provided by the Contractor.

2. The Contractor shall remove surface material at locations designated by the District Representative and provide such assistance as necessary for sampling and testing.

4.04 TRAINING – NOT USED

4.05 REGULATORY REQUIREMENTS

A. The Contractor shall comply with the requirements of the Sacramento Metropolitan Air Quality Management District with regard to all asphalt paving materials and application.

**END OF SECTION**

DIVISION 40 – PROCESS INTERCONNECTIONS 40 05 03 COMMON WORK RESULTS FOR PIPING SYSTEMS 40 05 07 HANGERS AND SUPPORTS FOR PROCESS PIPING 40 05 23 STAINLESS STEEL PROCESS PIPE AND TUBING 40 05 24 STEEL PROCESS PIPE40 05 32 POLYETHYLENE PROCESS PIPE40 05 57 ACTUATORS FOR PROCESS VALVES AND GATES 40 05 63 BALL VALVES40 05 64 BUTTERFLY VALVES 40 05 66 FIRE-RATED FIRE ISOLATION VALVES 40 06 60.13 POWER ACTUATED VALVE AND GATE SCHEDULES 40 06 70 SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS 40 61 13 PROCESS CONTROL SYSTEM GENERAL PROVISIONS 40 61 21 PROCESS CONTROL SYSTEM TESTING 40 61 26 PROCESS CONTROL SYSTEM TRAINING 40 61 93.20 PROGRAMMABLE LOGIC CONTROLLER INPUT/OUTPUT 40 61 96.10 PLANT COMPUTER CONTROL SYSTEM CONTROL

STRATEGIES40 61 96.20 PROGRAMMABLE LOGIC CONTROLLER CONTROL

NARRATIVES40 63 43 PROGRAMMABLE LOGIC CONTROLLERS 40 66 35 FIBER OPTIC CABLE, CONNECTORS, AND PANELS 40 67 00 CONTROL SYSTEM EQUIPMENT PANELS AND RACKS 40 70 00 INSTRUMENTATION FOR PROCESS SYSTEMS 40 79 00 MISCELLANEOUS INSTRUMENTS, CALIBRATION

EQUIPMENT, INSTRUMENTATION VALVES, AND FITTINGS



40 05 03 - 1

SECTION 40 05 03

COMMON WORK RESULTS FOR PIPING SYSTEMS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies systems of process piping and general requirements for piping systems in all project applications.

2. Detailed information for piping systems are contained in the Piping System Specification Sheets (PIPESPEC) located at the end of this specification section.

3. Additional detailed specifications for the components listed on the Piping System Specification sheets are found in other project specification sections. This section shall be used in conjunction with those sections.

1.02 REFERENCES


Reference Title

ANSI A13.1 Scheme for the Identification of Piping Systems

ASTM A36 Carbon Structural Steel

ASTM A53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A240 Heat-Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels

ASTM A312 Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A778 Standard Specification for Welded, Unannealed Austenitic Stainless Steel Tubular Products


40 05 03 - 2

Reference Title

ASTM D2000 Standard Classification System for Rubber Products in Automotive Applications

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

ASTM F104 Standard Classification System for Nonmetallic Gasket Materials

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

CPC California Plumbing Code

NSF-61 National Sanitation Foundation, Drinking Water System Components – Health Effects

UPC Uniform Plumbing Code

B. DEFINITIONS:

1. PIPESPEC: Piping system detail information located at the end of this specification section.

2. Pressure terms used in these project specifications are defined as follows:

a. MAXIMUM: The greatest continuous pressure at which the piping system operates.

b. TEST: The hydrostatic pressure used to determine system acceptance.

3. Exposure location terms used in these specifications are defined as follows:

a. INTERIOR: Inside of a building or structure.

b. EXTERIOR: Outside of a building or structure and exposed to weather elements.

c. BURIED: Below grade and in contact with backfill material or concrete encasement. Piping may or may not be insulated.

d. SUBMERGED: Submerged or below the top elevation of structures or facilities containing liquids, such as: tanks, channels, digesters, manholes, sumps, basins, rivers, and other areas as indicated or shown on the drawings.

4. Exposure severity terms are defined as follows:

a. MILD ENVIRONMENT: Standard commercial facility conditions.


40 05 03 - 3

b. MODERATE ENVIRONMENT: Industrial facility conditions where surfaces may be occasionally exposed to light-moderately aggressive liquids, solids or gases.

c. HARSH ENVIRONMENT: Industrial facility conditions where surfaces may be subject to aggressive liquids, solids or gases, or surfaces may be normally exposed to light-moderately aggressive liquids, solids or gases.

1.03 SUBMITTALS



2. Information on piping materials as specified in individual specification sections for piping materials, flanges, fittings, gaskets, valves, supports and components. Include manufacturer's data, ASTM conformance, and catalog numbers.

3. Piping layout and support shop drawings for all piping systems including all pipes, drains, vents, valves, supports, seismic braces, and specific locations of all instrument taps. Drawings shall be original layouts by the Contractor photocopies of contract drawings are not acceptable.

4. Sample of the valve identification tag.



PART 2 -- PRODUCTS

2.01 PIPING MATERIALS

A. GENERAL:

1. Piping materials including pipe, gaskets, fittings, connections, and joint assemblies, lining and coatings, shall be provided from those listed on the Piping System Specification sheets associated with this section and as shown on the drawings.


40 05 03 - 4

2. Piping materials shall conform to detailed specifications for each type of pipe and piping appurtenances specified in other project specification sections.

3. Pipe connection types shall also be provided as listed in the project specifications and where shown on the drawings.

4. To assure uniformity and compatibility of piping components, fittings and couplings for grooved end piping systems shall be furnished by the same manufacturer.

B. FLANGE GASKETS:

1. GENERAL:

a. Flange gaskets shall be full-face type or ring type, as specified. Gasket thickness shall be as specified, unless otherwise shown on the drawings.

2. COMPRESSED NON-ASBESTOS-NITRILE:

a. ACCEPTABLE PRODUCTS: Garlock BLUE-GARD Style 3000, or equal.

b. MATERIAL: ASTM F104 Compressed non-asbestos sheet gasket with Aramid fibers and nitrile binder. Full face. ANSI Class 150. Continuous temperature limit = 400 F (not for saturated steam). Pressure limit = 1,000 psi. Thickness = 0.125 inches.

3. EPDM:

a. ACCEPTABLE PRODUCTS: Garlock Style 8314; Biltrite Style 475; or equal.

b. MATERIAL: Premium-grade ASTM D2000 EPDM rubber sheet gasket. Full face. Durometer Shore A hardness = 60. Temperature limit = 300 F. Pressure limit = 150 psi. Thickness = 0.125 inches.

4. NEOPRENE:

a. ACCEPTABLE PRODUCTS: Garlock Style 7986, or equal.

b. MATERIAL: Premium-grade ASTM D2000 neoprene rubber sheet gasket. Full face. Durometer Shore A hardness = 70. Temperature limit = 250 F.

5. NEOPRENE CI (CLOTH INSERT):

a. ACCEPTABLE PRODUCTS: Garlock Style 3205; Biltrite Cloth-Inserted Neoprene – Regular Polyester Ply; or equal.

b. MATERIAL: Reinforced rubber diaphragm gasket. Premium-grade ASTM D2000 neoprene rubber sheet gasket with polyester fabric insert. Full face.


40 05 03 - 5

Durometer Shore A hardness = 70. Temperature limit = 200 F. Thickness = 0.125 inches.

6. NITRILE:

a. ACCEPTABLE PRODUCTS: Garlock Style 9122; Biltrite Premium Nitrile; or equal.

b. MATERIAL: Premium-grade ASTM D2000 nitrile (Buna N) rubber sheet full face gasket. Durometer Shore A hardness = 70. Temperature limit = 250 F. Pressure limit = 150 psi. Thickness = 0.125 inches.

7. NITRILE CI (CLOTH INSERT):

a. ACCEPTABLE PRODUCTS: Garlock Style 9200; or equal.

b. MATERIAL: Reinforced rubber flange gasket. Premium-grade ASTM D2000 nitrile (Buna-N) rubber sheet gasket with non-weeping nylon fabric insert. Full face. Durometer Shore A hardness = 70. Temperature limit = 250 F. Thickness = 0.125 inches.

8. PTFE BONDED:

a. ACCEPTABLE PRODUCTS: ASAHI/America Style AV; CTG model ET; or equal.

b. MATERIAL: PTFE full face envelope gasket with concentric, convex molded rings bonded to an EPDM core. ANSI Class 150. EPDM Durometer Shore A hardness = 65. Temperature range = -4 to +250 F.

9. PTFE ENVELOPE:

a. ACCEPTABLE PRODUCTS: Flexitallic, or equal.

b. MATERIAL: PTFE split type full face envelope gasket with neoprene cloth-insert gasket core. ANSI Class 150. Temperature range = -350 to +480 F. Core thickness = 0.125 inches.

10. FIRE-RATED STAINLESS STEEL/GRAPHITE:

a. ACCEPTABLE PRODUCTS: Durlon CFG, or equal.

b. MATERIAL: Corrugated flexible graphite ring gasket with 24-gauge Type 316 stainless steel corrugated core. ANSI Class 150. API 607 modified fire test certified.

11. SPIRAL WOUND:


40 05 03 - 6

a. ACCEPTABLE PRODUCTS: Flexitallic model CG or LSI, or equal

b. MATERIAL: Type 316 stainless steel outer ring, inner ring, spiral. Flexicarb graphite filler. Ring type. ANSI Class 150.

C. COUPLING GASKETS:

1. GENERAL:

a. Gaskets for sleeve-type, plain end, and grooved end couplings shall be provided by the coupling manufacturer.

2. EPDM:

a. EPDM rubber.

b. Temperature range = -30 to +230 F.

c. NSF-61 certified for potable water service.

3. NEOPRENE:

a. Neoprene rubber.

b. Temperature range = +30 to +180 F.

4. NITRILE:

a. Nitrile (Buna N) rubber.

b. Temperature range = -20 to +180 F.

5. Fluoroelastomer:

a. Fluoroelastomer (Viton).

b. Temperature range = +20 to 300 F.

D. SLEEVE-TYPE COUPLINGS:

1. ACCEPTABLE PRODUCTS

a. ACCEPTABLE PRODUCTS: PowerSeal, Romac Industries, Smith-Blair, or equal, modified as required to meet the specifications in accordance with the tables below. Sleeve-type couplings shall only be used on pipe types that are compatible per manufacturer’s requirements with the acceptable products in the tables below.


40 05 03 - 7

Acceptable Products for Stainless Steel Sleeve-Type Couplings Description PowerSeal

Allowable SizesRomac Industries Allowable Sizes

Smith-Blair Allowable Sizes

Standard 3506AS 2 to 12 inches

3538 12 inches and up

400 12 to 96+ inches

custom

Extended Range 3506AS 2 to 12 inches

N/A N/A

Reducing 3562 12 inches and up

RC400 26 to 96+ inches

N/A

Flanged adapter custom custom customInsulating N/A N/A N/A

2. MATERIAL:

a. Materials for Stainless Steel sleeve-type couplings shall be in accordance with the following tables:

Materials for Stainless Steel Sleeve-Type Couplings

Acceptable Exposure Severity: Mild & Moderate & Harsh Exposure Locations Interior Exterior Buried Submerged

Center Body ASTM A240 Type 316 stainless steel

ASTM A240 Type 316 stainless steel



End Glands ASTM A240 Type 316 stainless steel




Gasket Per PIPESPEC sheets

Per PIPESPEC sheets

Per PIPESPEC sheets

Per PIPESPEC sheets

Bolts and Nuts Type 316 stainless steel

Type 316 stainless steel



Finish N/A N/A N/A N/A

2.02 PIPING IDENTIFICATION

A. PIPE LABELING:

1. ACCEPTABLE PRODUCTS:

a. ADHESIVE LABELS: Brady B-681 polyester with overlaminate; Craftmark model Duramark HT polyester with overlaminate; or equal, modified as required to meet the specifications.


40 05 03 - 8

b. SELF-COILING LABELS: Brady model B-915 Snap-On & Strap-On; Craftmark model Specmark HT; or equal, modified as required to meet the specifications.

2. Labels for identifying piping shall conform to ANSI A13.1.Piping labels shall include system, contents, and direction of flow. Labels shall be provided bearing the label lettering on the background colors specified in Table A. Color field shall be long enough to print the entire lettering

3. Size of legend letters and minimum length of color field:

Outside Diameter of Pipe or Covering

(inches)

Minimum Length of Color Field

(inches)Letter Height

(inches) ¾ to 1¼ 8 ½1½ to 2 8 ¾2½ to 6 12 1¼ 8 to 10 24 2½ Over 10 32 3½

4. LABEL construction:

a. Adhesive labels shall be weather, water, and grease-resistant, with 5 to 8 year average outdoor life. Labels shall be polyester with polyester overlaminate. Vinyl labels are not acceptable.

b. Self-coiling, around-pipe markers shall be weather, water, and grease-resistant, with 5 to 8 year average outdoor life. Pipe markers shall be polyester with polyester overlaminate. Vinyl pipe markers are not acceptable.

c. In the event of a short piping run and none of the above methods will be practical, a metal tag fastened with stainless steel wire may be used to identify the piping system.

B. PIPE COLOR:

1. Piping shall be painted in accordance with the attached PIPESPECS and the PAINTING AND COATING Section (09 90 00). Stainless steel pipes are typically not painted. The following are general SRWTP reserved piping paint colors:

a. ORANGE: Chlorine

b. YELLOW: Sulfur dioxide

c. BONE WHITE: All chemical piping other than chlorine and sulfur dioxide

d. RED: Fire suppression


40 05 03 - 9

e. LIGHT GRAY: All piping other than chemical and fire suppression

C. VALVE LABELS AND TAGS:

1. Labeling or tagging of valves and other fixtures shall use the method that is both durable and readily viewable.

2. Approved tagging media are as follows:

a. METAL TAGS:

1) 16-gauge aluminum or 0.025 inch Type 304 stainless steel construction

2) Minimum 1-inch by 4-inch rectangular in size with rounded corners

3) 1/8” diameter hole in one end for attachment

4) ½-inch high letters, deeply and legibly engraved or stamped

5) Attached with 16-gauge 304 stainless steel wire

D. UNDERGROUND WARNING TAPE:


a. T. Christy Enterprises, Inc., W.H. Brady Co., Seton Name Plate Corp., or equal.

2. MATERIAL:

a. Underground warning tape shall be 6 inches wide and 3.5 mil thick polyethylene.

b. Two messages shall be printed on the tape. The first message shall read "CAUTION CAUTION CAUTION". The second message shall state the type of buried utility line: Reclaimed Water, Gas, Water, Stormwater or Sewer.

E. UNDERGROUND TRACER WIRE:

1. Underground tracer wire shall be #10 AWG THWN solid copper wire, with yellow insulation.

2.03 PIPING APPURTENANCES (NOT USED)


40 05 03 - 10

PART 3 -- EXECUTION

3.01 GENERAL - NOT USED

3.02 INSTALLATION

A. LOCATION:

1. Piping shall be installed as shown on the drawings, except for adjustments to accommodate conflicts. A minimum vertical clearance of 8 feet shall be provided over walkways and throughways in all tunnels and galleries. Unless otherwise indicated on the drawings, minimum depth of cover for buried, non-plastic pipe shall be 42 inches over the top of the pipe. Unless otherwise indicated on the drawings, minimum depth of cover for buried, plastic pipe shall be 48 inches over the top of the pipe.

B. COATING:

1. All piping shall be coated and lined as specified in the individual piping sections and PIPESPEC sheets located at the end of this specification section.

2. Unless otherwise specified, finish coating shall conform to the SCHEDULES FOR PAINTING AND COATING Section (09 06 90) and the PAINTING AND COATING Section (09 90 00).

C. PIPE SUPPORT, ANCHORAGE AND SEISMIC BRACING:

1. Piping shall be supported, anchored, and seismically braced as shown on the drawings and as specified in the HANGERS AND SUPPORTS FOR PROCESS PIPING Section (40 05 07).

2. Where a specific type of support or anchorage is indicated on the layout drawings, then only that type shall be used there.

3. Supports shall be provided on each run at each change of direction.

4. Unless otherwise shown on the drawings, existing pipes and supports shall not be used to support new piping.

D. RESTRAINTS FOR PIPING:

1. All pipe-to-pipe joints, plugs, caps, tees, bends, and valves shall be restrained for all exposed and buried piping unless otherwise specified. Restrained pipe-to-pipe joints, shall be flanged or grooved end for exposed service and restrained push-on for buried service or as specified in the individual piping sections.

2. Concrete thrust blocks shall be as shown on the drawings.


40 05 03 - 11

E. BEDDING AND BACKFILL:

1. Bedding and backfill for buried piping shall be as specified in the EARTH MOVING Section (31 20 00) and as shown on the drawings.

F. NOT-BURIED TO BURIED PIPING MATERIAL TRANSITIONS:

1. Unless otherwise shown on the drawings, all piping shall transition on the not-buried side of the ground penetration.

G. PROCESS INSTRUMENTATION CONNECTIONS:

1. Process instrumentation taps shall be as shown on the detail drawings. Taps shall be located, sized and orientation coordinated with the requirements of the INSTRUMENTATION OF PROCESS SYSTEMS Section (40 70 00) and the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70).

2. Direct drill and tap of a pipe wall is not acceptable.

3.03 PIPING IDENTIFICATION

A. PIPE LABELS:

1. After application of the specified coating and insulation systems, non-buried piping shall be identified with labels. Labels shall be neat, readable and uniform in appearance. Labels shall be readily visible from normal working locations and must not impede normal operations.

2. Labels shall not be located where they will be damaged by normal use or tools.

3. Each exposed pipe will be identified:

a. At intervals of 40 feet on straight pipe runs greater than 120 feet, otherwise

b. At intervals of 30 feet

c. At least one time in each room

d. Within 2 feet of all turns, ells, valves, and on the upstream side of all distribution fittings, branches and headers

e. On both sides of wall or floor penetrations

f. Within 3 feet of penetrating the ground


40 05 03 - 12

B. VALVE TAGS:

1. Attach valve tags to the valve stem.

2. Buried valves shall be identified by a metal tag attached to the collar of the valve box or riser. Do not attach metal tags to lids because they are often swapped from box to box.

C. UNDERGROUND WARNING TAPE:

1. A single line of tape shall be provided 2.5 feet above the top of all buried piping systems.

2. For pipelines buried 8 feet or greater below finished grade, Contractor shall provide a second line of tape 12 inches below finished grade, above and parallel to each buried pipe. Tape shall be spread flat with message side up before backfilling.

D. UNDERGROUND TRACER WIRE:

1. Underground tracer wire shall be tie-wrapped to the top centerline of the pipe on buried nonferrous, plastic, reinforced thermosetting resin, and non-electrically continuous ferrous pipelines. For large diameter piping, taping may be used in sizes where tie-wrap is not available. Tie-wrapping shall be done at 5-foot intervals and at every tee, bend, cross or valve.

2. Tracer wire shall be electrically continuous. Splices shall be underground wire nut type with silicone sealant, designed specifically for underground connections. IDEAL® UnderGround™ Wire Nut®, or equal.

3. Wiring shall be brought up to valve boxes, cleanout boxes, aboveground penetrations, etc. with 5 feet of extra wire coiled neatly and accessibly.

3.04 CLEANING AND FLUSHING

A. GENERAL:

1. Clean piping systems following completion of testing and prior to connection to operating, control, regulating or instrumentation equipment.

B. TYPE 1 (not used):

C. TYPE 2:

1. Clean piping with a swab or cleaning ball. Flush with clean water.


40 05 03 - 13

D. TYPE 3:

1. Clean piping with a swab or cleaning ball. Flush with airstream. Purge sludge gas and natural gas systems with nitrogen and maintain a nitrogen pad of 10 psi until put in service.

E. TYPE 4 (not used):

F. TYPE 5 (not used):

3.05 TESTING

A. GENERAL:

1. Upon completion of piping, but prior to application of insulation on non-buried piping, the Contractor shall test the piping systems.

2. Buried piping systems shall be tested upon completion of piping, but prior to backfill.

3. Testing shall be in accordance with this section and the COMMISSIONING Section (01 91 00).

4. Pressures, media and test durations shall be as specified in the PIPESPEC sheets located at the end of this specification section.

5. Equipment which may be damaged by the specified test conditions shall be isolated.

6. Testing shall be performed using certified, calibrated test gauges.

a. Required pressure tests of 10 psig or less shall be performed with gauges of 1/10 psig increments or less.

b. Required pressure tests exceeding 10 psig but less than 100 psig shall be performed with gauges of 1 psig increments or less.

c. Required pressure tests exceeding 100 psig shall be performed with gauges incremented for 2% or less of the required test pressure.

d. Test gauges shall have a pressure range not greater than twice the test pressure.

7. Testing shall be performed using certified, calibrated volumetric measuring equipment to determine leakage rates.

8. Testing, as specified herein, shall include existing piping systems that connect with new pipe systems. Existing pipe shall be tested to the nearest existing valve. Any piping which fails the test shall be repaired. Repair of existing piping will be considered and paid for as extra work.


40 05 03 - 14

B. TYPE 1:

1. Leakage shall be zero at the specified test pressure throughout the specified duration unless specifically allowed in the individual PIPESPEC sheets located at the end of this specification section.

C. TYPE 2 (not used):

D. TYPE 3 (not used):


3.07 PIPING SYSTEM SPECIFICATION SHEETS

A. Piping and valves are specified on individual Piping System Specification (PIPESPEC) sheets located at the end of this specification section. Piping services specified in the PIPESPEC sheets and shown on the drawings are alphabetically arranged by designated service abbreviations as shown in Table A. Table A also indicates the pipe label legend, background color, and lettering color of each service. Existing pipe systems may vary from the PIPESPEC. The Contractor shall field verify the pipe type, location and arrangement required for each connection to existing pipe systems.

Table A, Piping Services

Symbol

Pipe Legend Pipe Paint

Color (except

stainless)

Pipe Label Background

Color

Pipe Label

Lettering Color

D DRAIN Light Gray Green White

FSG FLARE SUPPLY GAS Light Gray Yellow Black

LSG LOW PRESSURE SLUDGE GAS Light Gray Yellow Black

MSG MEDIUM PRESSURE SLUDGE GAS Light Gray Yellow Black

NG NATURAL GAS Light Gray Yellow Black

SA SERVICE AIR Light Gray Blue White

V VENT Light Gray Green White

WN NON-POTABLE WATER Light Gray Purple White

**END OF SECTION**


40 05 03 - 15

PIPING SYSTEM SPECIFICATION

SERVICE: GMS - Drain SYMBOL: D FLUID: Digester Gas Condensate

PRESSURE – PSIG TEMPERATURE - F MAX: N/A TEST: 30 TEST TYPE: 1 NORMAL: N/A MAX: N/A

TEST MEDIUM: Water TEST DURATION: 120 minutes CLEANING TYPE: 2

PIPE AND FITTING SPECIFICATION SIZE EXPOSURE PIPE FITTINGS

¼” to 2” Interior Exterior

Submerged Buried

Stainless Steel, ASTM A312, Type 316L, Schedule 40S seamless

Type 316L, ANSI Class 150 forged stainless steel flanged fittings meeting ASTM A182, Class 150 stainless steel threaded fittings meeting ANSI/MSS SP-114 & ASTM A351, or Schedule 40S stainless steel welded fittings meeting ASTM A403 or A774. Joints: Threaded, flanged, or TIG welded.


Submerged Buried

Threaded Joint Sealant: Products for Non-Oxygen Piping per STAINLESS STEEL PROCESS PIPE AND TUBING Section (40 05 23).

Flange Gaskets: PTFE bonded.

Flange Fasteners: Fasteners per Stainless STAINLESS STEEL PROCESS PIPE AND TUBING Section (40 05 23).

Stainless Steel Welding: Welded per STAINLESS STEEL PROCESS PIPE AND TUBING Section (40 05 23).

Diaphragm Seals: None required.

Pressure Gauges: None required.

GENERAL VALVE SPECIFICATIONS, UNLESS OTHERWISE SPECIFIED IN VALVE SCHEDULE

SIZE EXPOSURE DUTY SPECIFICATION OPERATOR


Non-Fire Isolation & Control Valves

Ball Valve, Type SS-3P, per BALL VALVES Section (40 05 63).

MLQ

REMARKS: 1. Specified piping complies with minimum pipe wall thickness for internal pressure calculations in accordance with ASME B31.3 paragraph 3.04.1.2.

2. Remove weld discoloration from the heat affected zone with a Scotch Brite disc or equal. 3. All new or replacement valves shall be provided with an attached, engraved factory tag identifying the

materials of construction for each of the specified components. No exceptions.


40 05 03 - 16


SERVICE: Flare Supply Gas SYMBOL: FSG FLUID: Digester Gas

PRESSURE TEMPERATURE - F MAX: 25” WC

(note7) TEST: 30 psig TEST TYPE: 1 NORMAL: MAX:

TEST MEDIUM: Nitrogen Gas TEST DURATION: 120 minutes CLEANING TYPE: 3



Submerged


316L, ANSI Class 150 forged stainless steel flanged fittings meeting ASTM A182, Class 150 stainless steel threaded fittings meeting ANSI/MSS SP-114 & ASTM A351, or Schedule 40S stainless steel welded fittings meeting ASTM A403 or A774. Joints: Threaded, flanged, or TIG welded.

Buried HDPE, ASTM D3035 or F714; AWWA C901; SDR 11.0, PE 4710, IPS size, rated 200 psig working pressure.

HDPE molded fittings to match pipe. Joints: Butt-fusion or socket-fusion welded connections.

2½” to 24” Interior Exterior

Submerged

Stainless Steel, ASTM A312 or A778, Type 316L, Schedule 10S minimum.

Type 316L, ANSI Class 150 forged stainless steel flanged fittings meeting ASTM A182, or Schedule 10S stainless steel welded fittings meeting ASTM A403 or A774. Joints: Flanged, TIG welded, or flanged coupling adapter.

Buried HDPE, ASTM D3035 or F714; AWWA C901 or C906; SDR 11.0, PE 4710, IPS size, rated 200 psig working pressure.

HDPE molded fittings to match pipe. Joints: Butt-fusion or socket-fusion welded connections, or flanged, as noted on drawings.


Submerged Buried


Flange Gaskets: Spiral Wound. Stainless/Graphite Ring. (see Remark 6 below): PTFE bonded.

Mechanical sleeve gaskets:

Viton

ASME Man Way Gaskets:

Premium grade Viton rubber.

Flange Fasteners: Fasteners per STAINLESS STEEL PROCESS PIPE AND TUBING Section (40 05 23).

Stainless Steel Welding:

Welded per STAINLESS STEEL PROCESS PIPE AND TUBING Section (40 05 23).


Pressure Gauges: Pressure Gages per INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 70 00).

GENERAL VALVE SPECIFICATIONS, UNLESS OTHERWISE SPECIFIED IN VALVE SCHEDULE SIZE EXPOSURE DUTY SPECIFICATION OPERATOR

¼” to 2” Interior Exterior Buried



MLQ



Butterfly Valve, Type GP-050-FKM, per BUTTERFLY VALVES Specification (40 05 64).

MLQ & MGQ

2 ½” to 4” Interior Exterior


Ball Valve, Type SS-F, per BALL VALVES Section (40 05 63).

MLQ & MGQ


40 05 03 - 17


Fire Isolation Valves Butterfly Valve, Type HPDO-FS, per BUTTERFLY VALVES Section (40 05 66).

REMARKS: 1. FSG piping shall be designed in accordance with the following: a. NFPA 54 Chapter 5 – Gas Piping System Design, Materials, and Components b. NFPA 54 Chapter 6 – Pipe Sizing

2. Specified piping complies with minimum pipe wall thickness for internal pressure calculations in accordance with ASME B31.3 paragraph 3.04.1.2.

3. Remove weld discoloration from the heat affected zone with a Scotch Brite disc or equal. 4. For the swivel joints flanges on Digester 9, use the SAE J429 Grade 5 bolts. 5. All new or replacement valves shall be provided with an attached, engraved factory tag identifying the

materials of construction for each of the specified components. No exceptions. 6. This fire-rated gasket is required for use on flanged fire-rated valves. 7. Pressure may fluctuate up to 5 psi between the pressure reducing valves that connect to the MSG system.


40 05 03 - 18

PIPING SYSTEM SPECIFICATION SERVICE: Low Pressure Sludge Gas SYMBOL: LSG FLUID: Digester Gas

PRESSURE TEMPERATURE - F MAX: 15” WC TEST: 30 psig TEST TYPE: 1 NORMAL: MAX:




Submerged


316L, ANSI Class 150 forged stainless steel flanged fittings meeting ASTM A182, Class 150 stainless steel threaded fittings meeting ANSI/MSS SP-114 & ASTM A351, or Schedule 40S stainless steel welded fittings meeting ASTM A403 or A774. Joints: Threaded, flanged, or TIG welded.

Buried HDPE, ASTM D3035 or F714; AWWA C901; SDR 11.0, PE 4710, IPS size, rated 200 psig working pressure.

HDPE molded fittings to match pipe. Joints: Butt-fusion or socket-fusion welded or flanged connections.


Submerged

Stainless Steel, ASTM A312 or A778, Type 316L, Schedule 10S minimum.

Type 316L, ANSI Class 150 forged stainless steel flanged fittings meeting ASTM A182, or Schedule 10S stainless steel welded fittings meeting ASTM A403 or A774. Joints: Flanged, or TIG welded.

Buried HDPE, ASTM D3035 or F714; AWWA C901 or C906; SDR 11.0, PE 4710, IPS size, rated 200 psig working pressure.

HDPE molded fittings to match pipe. Joints: Butt-fusion welded connections, or flanged.


Submerged Buried


Flange Gaskets: Spiral Wound. Stainless/Graphite Ring. (see Remark 6 below) PTFE bonded. PTFE envelope.


Stainless Steel Welding:

STAINLESS STEEL PROCESS PIPE AND TUBING Section (40 05 23).




¼” to 2” Interior Exterior Buried





Butterfly Valve, Type GP-050-FKM, per BUTTERFLY VALVES Section (40 05 64).

2 ½” to 4” Buried Non-Fire Isolation & Control Valves

Ball Valve, Type SS-F, per BALL VALVES Section (40 05 63).




40 05 03 - 19

REMARKS: 1. LSG piping shall be designed in accordance with the following: a. NFPA 54 Chapter 5 – Gas Piping System Design, Materials, and Components b. NFPA 54 Chapter 6 – Pipe Sizing


3. Remove weld discoloration from the heat affected zone with a Scotch Brite disc or equal. 4. For the swivel joints flanges on Digester 9, use the SAE J429 Grade 5 bolts. 5. All new or replacement valves shall be provided with an attached, engraved factory tag identifying the

materials of construction for each of the specified components. No exceptions. 6. This fire-rated gasket is required for use on flanged fire-rated valves.


40 05 03 - 20


SERVICE: GMS – Digester Medium Pressure Sludge Gas SYMBOL: MSG FLUID: Digester Gas

PRESSURE – PSIG TEMPERATURE - F WORK: 15 MAX: 30 TEST: 1 NORMAL: MAX:




Submerged

Stainless Steel, ASTM A312, Type 316L, Schedule 40S seamless.


Buried HDPE, ASTM D2513; SDR 11.0, PE 4710, IPS size.

HDPE molded fittings to match pipe. Joints: Butt-fusion or socket-fusion welded connections.


Submerged

Stainless Steel, ASTM A312 or A778, Type 316L, Schedule 10S

Type 316L, ANSI Class 150 forged stainless steel flanged fittings meeting ASTM A182, or Schedule 10S stainless steel welded fittings meeting ASTM A403 or A774. Joints: Flanged, or TIG welded.

Buried HDPE, ASTM D2513; SDR 11.0, PE 4710, IPS size.

HDPE molded fittings to match pipe. Joints: Butt-fusion welded connections.


Submerged


Flange Gaskets: Spiral Wound. Stainless/Graphite Ring. (See Remark 5 below):

ASME Man Way Gaskets: Premium grade Buna-N rubber.











Butterfly Valve, Type GP-050-FKM, per BUTTERFLY VALVES Section (40 05 64).




40 05 03 - 21

REMARKS: 1. MSG piping shall be designed in accordance with the following: a. NFPA 54 Chapter 5 – Gas Piping System Design, Materials, and Components b. NFPA 54 Chapter 6 – Pipe Sizing



materials of construction for each of the specified components. No exceptions. 5. This fire-rated gasket is required for use on flanged fire-rated valves.


40 05 03 - 22

PIPING SYSTEM SPECIFICATION SERVICE: Natural Gas SYMBOL: NG FLUID: Natural Gas

PRESSURE – PSIG TEMPERATURE - F MAX: 60 TEST: 90 TEST TYPE: 1 NORMAL: 60 MAX: 85

TEST MEDIUM: Air TEST DURATION: 120 minutes CLEANING TYPE: 3


≤ 2” Interior Exterior

Steel; ASTM A53, seamless, Schedule 40 Grade A, black, no lining, no coating. Ref. Spec section 15061.

Malleable iron, ASTM A197, ANSI B16.3, Class 150, black steel. Joints: Threaded or welded.

Buried Medium Density Polyethylene; SDR-11. Ref Spec Section 40 05 32. Provide underground tracer wire.

Medium Density Polyethylene; SDR to match pipe. Joints: Butt fusion welded connections.

All All Flange Gaskets: Compressed non-asbestos nitrile.

Push-on/Mech. Couplings: N/A


≤ 2” Other Isolation Ball Valve, Type SS-3P, per BALL VALVES Section (40 05 63).

MLQ

REMARKS: 1. NG piping shall be designed in accordance with the following: a. NFPA 54 Chapter 5 – Gas Piping System Design, Materials, and Components b. NFPA 54 Chapter 6 – Pipe Sizing





40 05 03 - 23

PIPING SYSTEM SPECIFICATION SERVICE: Service Air SYMBOL: SA FLUID: Compressed Air


TEST MEDIUM: Air TEST DURATION: 120 minutes CLEANING TYPE: 3


< ½” O.D. Interior or Exterior

Copper tube, ASTM B88, Type K hard or Type K soft copper.

Wrought copper fittings, ANSI B16.22, with silver bearing solder. Or, brass compression fittings, ANSI B16.26.

Interior or Exterior

Light-stabilized, black Nylon 11 flexible tubing. 2000 psi minimum burst pressure @ 75°F. Eaton Synflex N2, model 4212, or equal.

Nickel-plated brass push-to-connect tube fittings, designed for Nylon 11 tubing. Nitra Pneumatics or equal.

½” – 2” Interior or Exterior

Copper tube, ASTM B88, Type K hard copper. Wrought copper fittings, ANSI B16.22, with silver bearing solder.

Buried HDPE 8CCR462. HDPE molded fittings to match pipe. Joints: Butt-fusion or socket-fusion welded connections. Electrofusion joints are not acceptable.

All All Flange Gaskets: EPDM

Push-on/Mech. Couplings:


≤ 2” Interior or Exterior

Isolation Ball valve, Type SS-3P, BALL VALVES Section (40 05 63).

MLQ

REMARKS: 1. Per California Code of Regulations, Title 8, Section 462, all piping between an air receiver and the first isolation valve shall be Schedule 80 steel.





40 05 03 - 24

PIPING SYSTEM SPECIFICATION SERVICE: GMS - Vent SYMBOL: V FLUID: Air

PRESSURE – PSIG TEMPERATURE - F MAX: N/A TEST: 30 TEST TYPE: 1 NORMAL: N/A MAX: N/A




Submerged Buried




Submerged Buried


Flange Gaskets: PTFE bonded.

Flange Fasteners: Fasteners per Stainless STAINLESS STEEL PROCESS PIPE AND TUBING Section (40 05 23).



Pressure Gauges: None required.

GENERAL VALVE SPECIFICATIONS, UNLESS OTHERWISE SPECIFIED IN VALVE SCHEDULE

SIZE EXPOSURE DUTY SPECIFICATION OPERATOR




MLQ





40 05 03 - 25


SERVICE: Non-Potable Water SYMBOL: WN FLUID: Water




≤ 2”. Interior or Exterior

Stainless steel, ASTM A312, Type 316L, Schedule 40S seamless.


Buried HDPE, ASTM D3035 or F714, SDR 11.0, PE 4710, IPS size, rated 200 psig working pressure.

HDPE molded fittings to match pipe. Joints: Butt-fusion or socket-fusion welded connections. Electrofusion joints are not acceptable.

All All Flange Gaskets: EPDM

Push-on/Mech. Couplings: EPDM


≤ 2” Interior Exterior

Isolation Ball Valve, Type SS-3P, per BALL VALVES Section (40 05 63).

MLQ


2. All new or replacement valves shall be provided with an attached, engraved factory tag identifying the materials of construction for each of the specified components. No exceptions.

**END OF SECTION**


40 05 03 - 26


01/28/19


40 05 07 - 1

SECTION 40 05 07

HANGERS AND SUPPORTS FOR PROCESS PIPING

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies requirements for design, selection, installation and inspection of hangers, supports, and seismic restraints for all piping systems specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03), except for fire sprinkler systems. The Drawings specify hangers, supports, and seismic restraints for piping larger than 12-inch nominal diameter that is outside the Contractor’s design professional responsibility. All process piping supports and seismic restraints designed by the Contractor’s design professional and all supports and seismic restraints specified in the Drawings shall be provided by the Contractor.

B. SEISMIC CRITERIA:

1. The design criteria for the seismic restraints for all piping systems shall be in accordance with the California Building Code and the seismic parameters shown on the Drawings. The component importance factor IP shall be 1.50. The seismic restraint system shall be designed by a professional Engineer registered in the State of California.

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent that they are referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed references, the requirements of this section shall prevail.

Reference Title

AISC Manual Manual of Steel Construction - 13th Edition ASTM A193 / A193M Standard Specification for Alloy-Steel and Stainless

Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

ASTM A240 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A575 Standard Specification for Steel Bars, Carbon, Merchant


40 05 07 - 2

Reference Title

Quality, M-GradesASTM A576 Standard Specification for Steel Bars, Carbon, Hot-

Wrought, Special QualityASTM A1011 Standard Specification for Steel, Sheet and Strip, Hot-

Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength

ASTM D635 Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position

ASTM E84 Standard Test Method for Surface Burning Characteristics of Building Materials

CBC California Building CodeFEDSPEC WW-H-171e Hangers and Supports, PipeMSS SP-58 Pipe Hangers and Supports - Materials, Design and

ManufactureMSS SP-69 Pipe Hangers and Supports - Selection and Application OSHPD California Office of Statewide Health Planning and

DevelopmentSAE J429 Mechanical and Material Requirements for Externally

Threaded Fasteners

B. DEFINITIONS:

1. Longitudinal direction: direction parallel to the pipe axis.

2. Lateral/Transverse direction: direction perpendicular to the pipe axis.

3. Essential Facilities: buildings and other structures that are intended to remain operational in the event of extreme environmental loading from flood, wind, snow or earthquakes.

4. Exposure location terms used in these specifications are defined as follows:

a. Interior: Inside of a building or structure.

b. Exterior: Outside of a building or structure and exposed to weather elements.

c. Buried: Below grade and in contact with backfill material or concrete encasement. Piping may or may not be insulated.

d. Submerged: Submerged or below the top elevation of structures or facilities containing liquids, such as: tanks, channels, digesters, manholes, sumps, basins, rivers, and other areas as indicated or shown on the drawings.


40 05 07 - 3

5. Exposure severity terms are defined as follows:

a. Mild Environment: Standard commercial facility conditions.

b. Moderate Environment: Industrial facility conditions where surfaces may be occasionally exposed to light-moderately aggressive liquids, solids or gases.

c. Harsh Environment: Industrial facility conditions where surfaces may be subject to aggressive liquids, solids or gases, or surfaces may be normally exposed to light-moderately aggressive liquids, solids or gases.

1.03 SUBMITTALS



2. Manufacturer's information and catalog data showing compliance with this specification and a full description of the product.

3. Hanger and support locations and hanger components, including elbow thrust restraints as required by the piping system, shall be indicated on the piping layout drawings required by the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03). Pipe hanger spacing shall not exceed the maximum spans shown on the Drawings. Contractor shall provide a legend that includes support identification number, support type, pipe size and service, and support weight. Failure to include this information with pipe layout drawing submittal shall be cause for rejection of the layout drawings.

4. Pipe hanger, thrust restraints and seismic restraint calculations prepared and stamped by a professional structural or civil engineer registered in the State of California. Calculations shall include the effects of thermal expansion and contraction of the piping system using the temperature ranges included in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

5. Seismic restraint locations and components shall be indicated on the piping layout drawings required by the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).


40 05 07 - 4

PART 2 -- PRODUCTS

2.01 MATERIALS

A. GENERAL:

1. All hangers, supports, hardware and components shall be of the material and finish per the following table, unless specifically shown otherwise on the drawings:

Locations

Interior Exterior Buried Submerged Mild Environment HDGAF HDGAF N/A N/A

Moderate Environment HDGAF HDGAF 304 SS N/AHarsh Environment (not Hypochlorite)

316 SS 316 SS 316 SS 316 SS

Harsh Environment (Hypochlorite)

FRP FRP FRP FRP

HDGAF = Steel, Hot Dip Galvanized After Fabrication SS = Stainless Steel FRP = Fiberglass Reinforced Plastic

2.02 CHANNEL STRUT

A. ACCEPTABLE PRODUCTS:

1. Single channel: B-Line B22; Unistrut P1000; B-Line BFV22SH; or equal.

2. Double channel: B-Line B22A; Unistrut P1001; B-Line BFV22A; or equal.

3. Double deep channel: B-Line B12A; Unistrut P5501; or equal.

B. MATERIALS:

1. ASTM A1011 Grade 33 steel channel shall be 1-5/8 inches square, roll formed, 12-gage material. Channel shall have a continuous slot along one side with in-turned clamping ridges.

2. ASTM A240 stainless steel channel shall be 1-5/8 inches square, roll formed, 12-gage material. Channel shall have a continuous slot along one side with in-turned clamping ridges.

3. Fiberglass channel shall be 1-5/8 inches square, pultruded, ¼-inch thick material with vinyl ester resin. Channel shall meet ASTM E84 Class 1 Flame Rating, and self-extinguishing requirements of ASTM D635. Channel shall have a continuous slot along one side with in-turned clamping ridges. Channel profile shall match steel channel profile.


40 05 07 - 5

2.03 PIPE HANGERS AND SUPPORTS

A. TYPE 1 - CLEVIS PIPE HANGER:

1. ACCEPTABLE PRODUCTS: B-Line B3100; Anvil Fig. 260; B-Line BFV3104; or equal.

2. MATERIALS:

a. Steel and stainless steel clevis hangers shall comply with MSS and FEDSPEC Type 1.

b. FRP hangers shall be glass reinforced polyurethane or glass reinforced vinyl ester.

B. TYPE 4 - ADJUSTABLE ROLLER HANGER:

1. ACCEPTABLE PRODUCTS: B-Line B3110; Anvil Fig. 181; or equal.

2. MATERIALS: Rollers shall be cast iron, and shall comply with MSS Type 43 and FEDSPEC Type 44.

C. TYPE 5 - SINGLE PIPE ROLLER:


2. MATERIALS: Rollers and sockets shall be cast iron, and shall comply with MSS Type 41 and FEDSPEC Type 42.

D. TYPE 6 - FRAMING CHANNEL ONE-BOLT PIPE CLAMP:

1. ACCEPTABLE PRODUCTS: B-Line B2000 series; Unistrut P 1109 series; B-Line BFV2000; or equal.

2. MATERIALS:

a. Gage of steel and stainless steel one-bolt clamps shall be as follows:

1) Pipe sizes 3/8 inch and 1/2 inch shall be 16 gage.

2) Pipe sizes 3/4 inch through 1 1/4 inches shall be 14 gage.

3) Pipe sizes 1 1/2 inches through 3 inches shall be 12 gage.

4) Pipe sizes 3 1/2 inches through 5 inches shall be 11 gage.

5) Pipe sizes 6 and 8 inches shall be 10 gage.

b. FRP clamps shall be glass reinforced polyester or vinyl ester.


40 05 07 - 6

E. TYPE 7 - U-BOLT:

1. ACCEPTABLE PRODUCTS: B-Line B3188; Anvil Fig. 137; B-Line BFV501 series; or equal.

2. MATERIALS:

a. Steel and stainless steel U-bolts shall comply with MSS and FEDSPEC Type 24.

b. FRP U-bolts shall be glass reinforced polyurethane or glass reinforced polyester or vinyl ester.

F. TYPE 8 - ADJUSTABLE PIPE ROLLER SUPPORT:


2. MATERIALS: Rollers and sockets shall be cast iron.

G. TYPE 9 - WELDED PIPE STANCHION:

1. MATERIALS: Minimum material thickness shall be standard schedule pipe, cut to match contour of the pipe elbow. Use of this support shall be limited to ambient systems only.

H. TYPE 10 - PIPE STANCHION SADDLE:

1. ACCEPTABLE PRODUCTS: B-Line B3090; Carpenter & Patterson Fig. 125; or equal.

2. MATERIALS: Saddles and yokes shall be steel or stainless steel, and shall comply with MSS type 37 and FEDSPEC Type 38. Include matching base stand.

I. TYPE 11 - OFFSET PIPE CLAMP:


2. MATERIALS:

a. Pipe clamp shall be carbon or stainless steel.

b. Vertical pipe support applications shall be as specified above except that insulation shields shall not be used for insulated pipe. Clamp support directly to pipe and insulate supports same as the pipe.


40 05 07 - 7

J. TYPE 12 - RISER CLAMP:

1. ACCEPTABLE PRODUCTS: B-Line B3373; Anvil Fig. 261; B-Line B3373 CT; Anvil Figure 261C; or equal.

2. MATERIALS: Riser clamps shall comply with MSS and FEDSPEC Type 8.

K. TYPE 13 - CHANNEL STRUT SINGLE PIECE PIPE STRAP:

1. ACCEPTABLE PRODUCTS: B-Line 2400 series; Unistrut P2558 series; B-Line BFP2400 series; or equal.

2. MATERIALS:

a. Steel and Stainless Steel: Pipe straps shall comply with MSS Type 26.

b. FRP: Glass reinforced polyurethane or glass reinforced polyester or vinyl ester.

2.04 RACK AND TRAPEZE SUPPORTS:

A. GENERAL:

1. Trapeze and pipe rack components shall have a maximum deflection 1/240 of the span.

B. TYPE 20 - TRAPEZE PIPE SUPPORT:

1. MATERIALS: Trapeze pipe support cross members shall be channel strut with flat plate fittings square washer.

C. TYPE 21 - PIPE SUPPORT RACK:

1. MATERIALS:

a. Post and cross members shall be channel strut. Channel fittings shall be manufactured by the channel strut manufacturer.

b. 90-degree fittings shall have gussets. B-Line B844W; Unistrut P2484W; or equal.

c. Channel strut post base fittings shall be as specified.

D. CANTILEVER PIPE SUPPORT RACK:

1. ACCEPTABLE PRODUCTS: Interlake Mecalux model Structural Cantilever; Bluff Manufacturing model Cantilever Rack; or equal, modified as required to meet the specifications.

2. MATERIALS:


40 05 07 - 8

a. Cantilever rack components shall be fabricated from structural steel shapes. Roll formed cantilever rack components shall not be acceptable. Columns shall be fabricated from wide flange beams. Bases shall be fabricated from wide flange beams, and shall be welded to the columns. Arms shall be fabricated from structural steel shapes, and shall be bolted to the columns. Rack components shall be powder coated. See Standard Detail Drawing M82 for additional information.

2.05 STRUCTURAL ATTACHMENTS

A. TYPE A - MALLEABLE IRON CONCRETE INSERT:

1. ACCEPTABLE PRODUCTS: B-Line B3014; Anvil Figure 282; or equal.

2. MATERIALS: Concrete inserts shall be malleable iron and shall comply with MSS and FEDSPEC Type 18.

B. TYPE B – CONTINUOUS CHANNEL STRUT CONCRETE INSERT:

1. ACCEPTABLE PRODUCTS: B-Line B22-I series; Unistrut P3270 series; or equal.

2. MATERIALS: Concrete inserts shall include strut, Styrofoam filler, closure strips and end caps. Design capacity shall be 2000 lbs/ft with a safety factor = 3.

C. TYPE C - MALLEABLE IRON BEAM CLAMP WITH EXTENSION PIECE:

1. ACCEPTABLE PRODUCTS: B-Line B3054; Anvil Figure 218 with Figure 157 extension piece; or equal.

2. MATERIALS: Clamp and extension piece shall be malleable iron, and shall comply with MSS and FEDSPEC Type 30.

D. TYPE D – HEAVY DUTY STEEL BEAM CLAMP WITH EYE NUT:

1. ACCEPTABLE PRODUCTS: B-Line B3291 series; Anvil Figure 292; or equal.

2. MATERIALS: Beam clamp and eye nut shall be forged steel, and shall comply with MSS and FEDSPEC Type 28.

E. TYPE F - WELDED BEAM ATTACHMENT:


2. MATERIALS: Beam attachment shall comply with MSS and FEDSPEC Type 22.


40 05 07 - 9

F. TYPE G - ADJUSTABLE ROD BEAM ATTACHMENT:

1. ACCEPTABLE PRODUCTS: B-Line B3082; or equal.

2. MATERIALS: Steel or stainless steel.

G. TYPE H - DOUBLE CHANNEL BRACKET:

1. ACCEPTABLE PRODUCTS: B-Line B297 series; Unistrut P2542 series; or equal.

2. MATERIALS: Wall channel shall be single channel strut. Cantilever bracket shall be double-channel assembly.

H. TYPE J - SINGLE CHANNEL BRACKET:

1. ACCEPTABLE PRODUCTS: B-Line B409 series; Unistrut P2513 series; or equal.

2. MATERIALS: Wall channel shall be single channel strut. Cantilever bracket shall be single-channel assembly.

I. TYPE L - PIPE STANCHION BASE STAND:

1. ACCEPTABLE PRODUCTS: B-Line B3088S; or equal.

2. MATERIALS:

a. Steel or Stainless Steel: Baseplate shall be rated for seismic applications. Anchor bolt holes shall be 1/16 inch larger than the anchor bolt diameter. The space between the baseplate and the floor shall be filled with nonshrink grout.

J. TYPE M - WELDED STEEL BRACKET:

1. ACCEPTABLE PRODUCTS: B-Line B3066 or B3067; Anvil Figure 195 or 199; or equal.

2. MATERIALS: Brackets shall comply with MSS Type 32 and FEDSPEC Type 33 for medium welded bracket. Heavy welded bracket shall comply with MSS type 33 and FEDSPEC Type 34. Bracket type as required for load.

K. TYPE P - CHANNEL STRUT POST BASE:


a. Single channel: B-Line B280; Unistrut P2072A SQ; B-Line BFV280SQ; or equal.


40 05 07 - 10

b. Double channel: B-Line B281; Unistrut P2073A SQ; B-Line BFV281SQ; or equal.

2. MATERIALS:

a. Steel or Stainless Steel: Post base shall be manufactured by the channel strut manufacturer.

b. FRP: Glass reinforced polyurethane or polyester or vinyl ester.

L. TYPE Q - SIDE BEAM BRACKET:


2. MATERIALS: Steel or stainless steel.

2.06 ACCESSORIES

A. HANGER RODS:

1. MATERIALS:

a. Rods shall be threaded on both ends or continuously threaded and sized as specified.

b. Steel: ASTM A575 & A576; SAE J429 Grade 2; or equal.

c. Stainless Steel: ASTM A193 B8 Class 1 or 2, Type 304 stainless steel, and ASTM A193 B8M Class 1 or 2, Type 316 stainless steel.

d. FRP: Glass reinforced vinyl ester.

B. WELDLESS EYE NUT:


2. MATERIALS: Eye nut shall be forged steel and shall comply with MSS and FEDSPEC Type 17.

C. WELDED EYE ROD:


2. MATERIALS: Eye rod shall be welded closed. Inside diameter of eye shall accommodate a bolt diameter 1/8 inch larger than the rod diameter.

D. TURNBUCKLE:

1. ACCEPTABLE PRODUCTS: B-Line B3202; Grinnell Figure 230; or equal.


40 05 07 - 11

2. MATERIALS: Turnbuckle shall be forged steel and shall comply with MSS SP-58.

2.07 THERMAL PIPE HANGER SHIELD

A. HOT PIPE SHIELDS:

1. ACCEPTABLE PRODUCTS: B-Line B3380-B3387; or equal.

2. MATERIALS: Asbestos-free, hydrous calcium silicate insert, treated for water resistance, and encased in a 360 galvanized steel jacket. The jacket thickness shall be as recommended by the manufacturer. Shield shall have butt connection to pipe insulation. Jacket and insulation shall be flush with end. Provide stainless steel band clamps to prevent slippage between the pipe wall and the thermal shield. Temperature range: 20 to 500 F.

B. COLD PIPE SHIELDS:

1. ACCEPTABLE PRODUCTS: B-Line B3380-3387; or equal.

2. MATERIALS: Asbestos-free, hydrous calcium silicate insert, treated for water resistance, and encased in a 360 galvanized steel jacket. The jacket thickness shall be as recommended by the manufacturer. Shield shall have butt connection to pipe insulation. Insulation shall extend 1 inch each side of steel jacket for vapor tight connection to pipe insulation vapor barrier. Provide stainless steel band clamps to prevent slippage between the pipe wall and the thermal shield. Temperature range: 20 to 500 F.

2.08 SEISMIC RESTRAINTS

A. GENERAL:

1. Seismic restraint system shall be OSHPD approved for piping in essential facilities, and shall comply with the CBC.

2. Acceptable manufacturers include: Mason Industries Incorporated; Cooper B-Line/TOLCO; or equal.

3. Cable-type seismic bracing will not be acceptable for this project.

PART 3 -- EXECUTION

3.01 GENERAL

A. HANGER AND SUPPORT SELECTION

1. Select pipe hangers and supports as shown on the drawings and as specified here.


40 05 07 - 12

2. Hangers and supports shall withstand all static and specified dynamic conditions of loading to which the piping and associated equipment may be subjected. As a minimum, consider the following conditions:

a. Weights of pipe, valves, fittings, insulating materials, suspended hanger components and normal fluid contents.

b. Weight of hydrostatic test fluid or cleaning fluid if operating fluid contents are lighter. The type of fluids and testing pressure requirements are specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

c. Reaction forces due to the operation of safety or relief valves.

d. Reaction forces at bens and elbows due to internal pressures if the piping system is not fully restrained.

e. Thermal expansion and contraction due to temperature changes in the fluids conveyed by the piping systems.

f. Wind, snow or ice loading on outdoor piping.

3. Where there is horizontal movement at a suspended type hanger location, hanger components shall be selected to allow for swing. The vertical angle of the hanger rod shall not, at any time, exceed 4 degrees.

4. Provide thermal shields at hanger, support and guide locations on pipe requiring insulation. The thermal shield shall be the same thickness as the piping system insulation specified in Process Piping and Equipment Insulation Specification Section.

5. There shall be no contact between a pipe and hanger or support component of dissimilar metals. Prevent contact between dissimilar metals by wrapping the pipe with three layers of UPC-listed 20-mil PVC pipe wrap or 1/8-inch-thick 40 durometer neoprene padding as necessary to ensure the isolation material covers the entire contact surface between the pipe and any metallic portion of the support or hanger. Isolation material must be compatible with the environment.

3.02 INSTALLATION

A. HANGER AND SUPPORTS

1. Locate hangers and supports as near as possible to concentrated loads such as valves, flanges, etc. Locate hangers, supports and accessories within the maximum span lengths specified to support continuous pipeline runs unaffected by concentrated loads.

2. Do not use existing pipes and supports to support new piping.


40 05 07 - 13

3. Do not attach pipe support components to pressure vessels.

4. Provide at least one hanger or support within 2 feet from a pipe change in direction.

5. Locate hangers and supports to ensure that connections to equipment, tanks, etc., are substantially free from loads transmitted by the piping.

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

7. Welded and bolted attachments to the building structural steel shall be in accordance with the requirements of AISC Manual of Steel Construction. Do not drill or burn holes in the building structural steel without written authorization of the structural engineer of record.

8. Do not use hanger components for rigging or erection purposes.

9. Install thermal pipe hanger shields in accordance with the manufacturer's recommendations.

10. Remove burrs and sharp edges from hanger and support components.

11. Rollers shall roll freely without binding. Verify smooth operation prior to placing load on support.

12. Finished floor beneath floor mounted structural attachments and framing channel post bases shall be roughed prior to grouting. Grout between base plate and floor shall be free of voids and foreign material.

13. Provide manufacturer’s plastic or rubber end caps at the exposed ends of all framing channels that are located within 7 feet of the floor or ground. Outside caps shall be UV and weather resistant.

14. Adjust hangers and supports to obtain required pipe slope and elevation. Shims made of material that is compatible with the piping material may be used. Adjust stanchions prior to grouting their baseplates.

15. Seal cut ends of hot dip galvanized after fabrication channel and components with ZRC Galvilite Galvanizing Repair Compound, or equal. Grind all sharp edges off. Solvent clean the surface to remove grease and oils. Apply two coats in accordance with the manufacturer’s instructions.

16. Seal cut ends of FRP channel and components with UV-resistant sealant coating provided by the FRP channel manufacturer. Apply sealant coating in accordance with the manufacturer’s instructions.


40 05 07 - 14

B. SEISMIC RESTRAINT SELECTION AND INSTALLATION:

1. Unless otherwise specified, the Contractor’s design professional shall design, select, and locate seismic restraints for piping to be furnished in accordance with the contract documents.

2. Provide and install seismic restraints in accordance with the Mason Industries Seismic Restraint Guidelines for Suspended Piping, Ductwork and Electrical Systems and the CBC.

3. Piping systems shall not be braced to dissimilar parts of a building or to dissimilar building systems that may respond in a different mode during an earthquake. Examples: wall and a roof; solid concrete wall and a metal deck with lightweight concrete fill.

4. Restraints shall be sized to fit the outside diameter of the pipe, tubing, or, where specified, the outside diameter of insulation.

5. There shall be no contact between a pipe, duct or raceway and restraint component of dissimilar metals.

6. Branch lines shall not be used to brace main lines.

7. Seismic bracing shall not limit the expansion and contraction of the piping system.



**END OF SECTION**


40 05 23 - 1

SECTION 40 05 23

STAINLESS STEEL PROCESS PIPE AND TUBING

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies stainless steel pipe, fittings, and connections.

1.02 REFERENCES


Reference Title

ANSI B16.5 Pipe Flanges and Flanged Fittings NPS ½ Through NPS 24 Metric/Inch Standard

ANSI B31.1 Power Piping

ANSI B31.3 Process Piping

ANSI B1.20.1 Pipe Threads, general purpose

ASME Section IX Boiler and Pressure Vessel Code; Welding and Brazing Qualifications

ASTM A182/A182M Rev A

Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A193/A193M Rev B

Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

ASTM A240/240M Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A312/ A312M Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes


40 05 23 - 2

Reference Title

ASTM A351/ A351M Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

ASTM A380/ A380M Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A403/ A403M Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

ASTM A733 Standard Specification for Welded and Seamless Carbon Steel and Austenitic Stainless Steel Pipe Nipples

ASTM A774/ A774M Standard Specification for As-Welded Wrought Austenitic Stainless Steel Fittings for General Corrosive Service at Low and Moderate Temperatures


1.03 SUBMITTALS



2. Manufacturer’s information and catalog data showing compliance with this specification and a full description of the item.

3. A copy of the ASME Certification of Welders and current work history.

4. Welding procedure for stainless steel.

5. Calculations for proposed alternative anchorage details.

6. The Contractor’s shop drawings (including fabrication), layout drawings and anchorage details.



40 05 23 - 3

PART 2 -- PRODUCTS


2.02 MATERIALS AND EQUIPMENT

A. PIPE:

1. ASTM A312/312M:

a. Sizes 1/8 to 2-1/2 inches. Minimum thickness Schedule 40S seamless. Type TP316L. Yield strength 25,000 psi minimum. Tensile strength 70,000 psi minimum.

2. ASTM A778:

a. Sizes 3 to 48 inches. Wall thickness shall be equivalent to Schedule 10S or 40S as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03). Type 316L. Yield strength 25,000 psi minimum. Tensile strength 70,000 psi minimum.

3. Additional requirements shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03) or as shown on the drawings.

B. PIPE FITTINGS:

1. ASTM A182/A182M Rev A Grade F316L forged stainless steel fittings, ANSI B16.5 Class 150.

2. ASTM A351/A351M Grade CF8M cast stainless steel fittings, Class 150. Threaded or socket weld.

3. ASTM A403/A403M WP-W Type 316 stainless steel fittings. Grooved end. Wall thickness shall equal or exceed pipe wall thickness.

4. ASTM A733 Type TP316L seamless stainless steel nipples, Schedule 40S. Threaded.

5. ASTM A774/A774M TP316L as-welded stainless steel. Butt weld or belled end. Elbows, tees, crosses, laterals, wyes, and reducers shall be fabricated from ASTM A240/A240M plate. Elbows shall be smooth flow style. Wall thickness shall equal or exceed pipe wall thickness.

C. PIPE CONNECTIONS:

1. GENERAL:


40 05 23 - 4

a. Connections shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

2. THREADED CONNECTIONS:

a. Pipe thread dimensions and size limits shall conform to ANSI B1.20.1.

b. PIPE THREAD SEALANT:

1) PRODUCTS FOR OXYGEN PIPING:

Fluoramics LOX-8 oxygen-safe thread sealant for wet locations, or equal.

2) PRODUCTS FOR NON-OXYGEN PIPING:

Rector Seal #5; or equal.

3. PIPE FLANGE CONNECTIONS:

a. FLANGES:

1) ASTM A182/A182M Rev B Grade F316L. ANSI B16.5 Class 150.

2) For piping 3 inches and smaller, provide weld-neck flanges. For piping larger than 3 inches, provide weld-neck or slip-on flanges. Slip-on flanges shall be double welded per ANSI B31.3.

b. FLANGE GASKETS:

1) Gaskets shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

c. FASTENERS:

1) For mild environments less than 200°F and requiring medium strength: SAE J429 Grade 5 hex head zinc-plated carbon steel cap screws, 81 ksi yield strength, with matching washers and nuts, coarse thread.

2) For moderate environments less than 200°F and requiring low strength: ASTM A193 Grade B8 Class 1 stainless steel, Type 304, 30 ksi yield strength, with matching washers and nuts, coarse thread.

3) For moderate environments less than 200°F and requiring medium strength: ASTM A193 Grade B8 Class 2 stainless steel, Type 304, 50+ ksi yield strength, with matching washers and nuts, coarse thread.


40 05 23 - 5

4) For harsh environments less than 200°F and requiring low strength: ASTM A193 Grade B8M Class 1 stainless steel, Type 316, 30 ksi yield strength, with matching washers and nuts, coarse thread.

5) For harsh environments less than 200°F and requiring medium strength: ASTM A193 Grade B8M Class 2 stainless steel, Type 316, 50+ ksi yield strength, with matching washers and nuts, coarse thread.

6) For all environments greater than 200°F or requiring high strength: ASTM A193 Grade B7 zinc-plated, with matching washers and nuts, coarse thread.

D. PIPE OUTLETS:

1. Acceptable Products: Bonney Forge model Threadolet, Sockolet, Weldolet, 3000# half-couplings, or equal.

2. Materials: Outlets shall be Type 316L standard weight stainless steel. Welded outlets shall be socket-weld style or butt-weld style. Threaded outlets shall comply with ANSI B1.20.1.

PART 3 -- EXECUTION


3.02 INSTALLATION

A. PIPE:

1. GENERAL:

a. Pipe shall be installed in as shown on the drawings.

2. ANCHORAGE:

a. Supports and anchorage shall be provided as shown on the drawings and as specified in the HANGERS AND SUPPORTS FOR PROCESS PIPING Section (40 05 07). Calculations and drawings for proposed alternative anchorage shall be submitted in accordance with the SUBMITTAL PROCEDURES Section (01 33 00).

B. FITTINGS:

1. Fittings shall be installed in accordance with the manufacturer’s recommendations.

C. CONNECTIONS:



40 05 23 - 6

a. Pipe cutting, threading, and jointing shall conform to the requirements of ANSI B31.1 and the fitting manufacturer’s installation recommendations.

b. Lubricate pipe threads in accordance with the lubricant manufacturer’s instructions.

2. FLANGED:

a. Pipe cutting, threading, and jointing shall conform to the requirements of ANSI B31.1 and the fitting manufacturer’s installation recommendations.

3. MECHANICAL FLANGE ADAPTER COUPLING:

a. Mechanical couplings shall be installed in accordance with the coupling manufacturer’s installation recommendations.

4. WELDED:

a. PREPARATION OF SURFACES TO BE WELDED:

1) Surfaces of joints to be welded shall be free from mill scale, slag, grease, oil, paint, rust, and other foreign material. Joints to be welded shall be wire-brushed with stainless steel wire brushes and precisely fitted before welding.

2) Nicks, gouges, notches, and depressions in the base metal in the area of the joint shall be repaired before the joint weld is made

b. PROCEDURES:

1) Piping shall be properly beveled and have a root pass with the TIG (GTAW) process followed by subsequent passes with the TIG (GTAW) process. The same technology shall be employed for all welding passes. Filler wire of L grade only shall be added to all welds to provide a cross section at the weld equal to or greater than the parent metal. Weld deposit shall be smooth and evenly distributed and have a crown of no more than 1/16-inch on the I.D. and 3/32-inch on the O.D. of the piping. Concavity, undercut, cracks, or crevices shall not be allowed. Butt welds shall have full penetration to the interior surface, and inert gas shielding shall be provided to the interior and exterior of the joint. Excessive weld deposits, slag, spatter, and projections shall be removed by grinding. Welds on gasket surfaces shall be ground smooth.

2) The welding procedure shall be submitted to engineer for approval prior to performing the work.

3) Only weld procedures that have been qualified under ASME Section IX and only welders who have successfully completed performance qualification tests per ASME Section IX on these qualified procedures shall be utilized.


40 05 23 - 7

4) The whole surface of the piping and welding areas shall be cleaned, descaled, and passivated per ASTM A380.

c. FIELD WELDING:

1) Field welding shall be minimized to the greatest extent possible by use of prefabrication of pipe systems at the shop or factory.

2) Welding shall be done only when the surfaces are completely free of any moisture. Welding of the pipe shall not be done during periods of high winds or rain unless the areas being welded are properly shielded.

3) Joint shall be continuously purged with inert gas during welding procedure.

4) Remove all residue, oxide, and heat stain from the welds and the heat affected areas with stainless steel wire brushes or flexible abrasive pads.

d. TACK WELDS, CLIPS, AND OTHER ATTACHMENTS:

1) Tack welds, clips, and other attachments shall be removed and defects repaired, except where the tack welds occur within the weld area and these tack welds do not exceed the size of the completed weld. Cracked tack welds shall be removed. Areas to be repaired shall be ground to clean metal and then repaired by building up with weld metal. The repaired areas shall be ground smooth to form a plane surface with the base metal.

e. DEFECTS AND REPAIRS:

1) The quality control program for welding and necessary heat treatment shall be submitted for engineer review and approval prior to manufacturing and field installations.

2) Welds with cracks, slag inclusions, porosity, undercutting, incomplete penetration, or which are otherwise deficient in quality or made contrary to any provisions of these specifications shall be removed by chipping or grinding throughout their depth to clean base metal. Caulking or peening of welds to correct defects shall not be done. Welds found deficient in dimension but not in quality shall be enlarged by additional welding after thoroughly cleaning the surface of previously deposited metal and the adjoining plate. Weld deposits, slag, weld spatter, and projections into the interior of the pipe shall be removed by grinding.

3) The heat affected zone of welding shall be free of intergranular defects. A random metallurgical examination shall be completed by the District to ensure the welding procedure is acceptable.


40 05 23 - 8

D. TAKEDOWN COUPLINGS:

1. Takedown couplings shall be installed where indicated on the drawings. They shall be flanged or union type joints as shown on the drawings.

3.03 TESTING

A. Testing of stainless steel pipe shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).


**END OF SECTION**

01/28/19


40 05 24 - 1

SECTION 40 05 24

STEEL PROCESS PIPE

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies steel pipe, fittings, flanges, connections, and coatings.

1.02 REFERENCES


Reference TitleASME B1.1 Unified Inch Screw Threads ASME B1.20.1 Pipe Threads, General PurposeASME B16.3 Malleable Iron Threaded FittingsASME B16.5 Pipe Flanges and Flanged FittingsASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings ASME B16.11 Forged Fittings, Socket-Welding and Threaded ASME B16.39 Malleable Iron Threaded Pipe Unions Classes 150, 250 and 300ASME B31.1 Power PipingASME B31.3 Chemical Plant and Petroleum Refinery Piping ASME Section IX

Certification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators


ASTM A105 Forgings, Carbon Steel, for Piping Components ASTM A193 Alloy-Steel and Stainless Steel Bolting Materials for High-

Temperature ServiceASTM A197 Cupola Malleable IronASTM A234 Pipe Fittings of Wrought Carbon Steel and Alloy Steel for

Moderate and Elevated TemperaturesNSF 61 National Sanitation Foundation, Drinking Water System

Components – Health EffectsSAE J429 Mechanical and Material Requirements for Externally Threaded

Fasteners, Standard

01/28/19


40 05 24 - 2

Reference TitleSSPC-SP 10 Near-White Blast Cleaning


1.03 SUBMITTALS



2. Manufacturer's information and catalog data showing compliance with this specification and a full description of the item.

3. A copy of the ASME Certification of Welders and current work history.

4. Contractor's shop drawings including fabrication and layout drawings.

5. Anchorage and pipe support and calculations and details.


PART 2 -- PRODUCTS


2.02 PIPE MATERIAL

A. ASTM A53:

1. SIZE RANGE: 1/8 to 26 inches. Unless otherwise specified, ASTM A53 pipe shall be Grade A, Type S, seamless pipe. The minimum wall thickness for ASTM A53 pipe shall be Schedule 40 for pipe 10 inch diameter and less and 3/8 inch for pipe 12 inch through 26 inch diameter. Increased shell thickness shall be provided where specified.

2.03 FITTING MATERIAL

A. ASTM A105:

1. Class 3000 forged steel fittings shall conform to ASTM A105 and ASME B16.11. Fittings shall be threaded or socket weld.

01/28/19


40 05 24 - 3

B. ASTM A197:

1. Class 150 malleable iron fittings shall conform to ASTM A197; and ASME B16.3 or B16.39. Yield strength 30,000 psi. Tensile strength 40,000 psi. Fittings shall be threaded.

C. ASTM A234:

1. Wrought steel butt weld fittings shall conform to ASTM A234 Grade WPB or WPB-W; and ASME B16.9. Fitting wall thickness shall match pipe wall thickness.

2. Wrought steel grooved fittings shall conform to ASTM A234 Grade WPB. Fitting wall thickness shall match pipe wall thickness.

2.04 FLANGE MATERIAL

A. ASTM A234:

1. Class 150 forged steel flanges shall conform to ASTM A235; and ASME B16.5.

2. Class 300 forged steel flanges shall conform to ASTM A235; and ASME B16.5.

3. Flanges shall be threaded, weld neck, slip-on, or socket weld.

4. Flanges shall be raised face with continuous spiral groove.

2.05 CONNECTION MATERIAL

A. THREADED CONNECTIONS:

1. Pipe thread dimensions and size limits shall conform to ASME B1.20.1.

B. FLANGED CONNECTIONS:

1. Gaskets shall be as designated in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

C. FASTENERS:

1. For mild environments less than 200F and requiring medium strength: SAE J429 Grade 5 hex head zinc-plated carbon steel cap screws 81 ksi yield strength, with matching washers and nuts, coarse thread.

2. For moderate environments less than 200F and requiring low strength: ASTM A193 Type B8 Class 1 stainless steel cap screws, Type 304, 30 ksi yield strength, with matching washers and nuts, coarse thread.

01/28/19


40 05 24 - 4

3. For moderate environments less than 200F and requiring medium strength: ASTM A193 Type B8 Class 2 stainless steel cap screws, Type 304, 50+ ksi yield strength, with matching washers and nuts, coarse thread.

4. For harsh environments less than 200F and requiring low strength: ASTM A193 Type B8M Class 1 stainless steel cap screws, Type 316, 30 ksi yield strength, with matching washers and nuts, coarse thread.

5. For harsh environments less than 200F and requiring medium strength: ASTM A193 Type B8M Class 2 stainless steel cap screws, Type 316, 50+ ksi yield strength, with matching washers and nuts, coarse thread.

6. For all environments greater than 200F or requiring high strength: ASTM A193 Grade B7 zinc-plated, with matching washers and nuts.

D. INSULATING FLANGE SET:

1. Unless otherwise specified, insulating flange sets shall be as specified in CATHODIC PROCESS CORROSION PROTECTION Section (40 46 42).

2. Flange insulation sets shall be suitable for 225F continuous operating temperature.

3. Insulating gaskets shall be plain phenolic, Type “E” full flange diameter type. Sealing gaskets shall be 1/16” thick, type as specified in the COMMON WORK RESULTS FOR PROCESS PIPING Section (40 05 03).

4. Insulating sleeves and washers shall be either one-piece or two-piece type. Sleeves and washers shall be phenolic or spiral-wound Mylar.

5. Metallic flat washer shall be steel or stainless steel to match the cap screw material.

6. Flange insulation sets shall be manufactured by PSI, or equal.

PART 3 -- EXECUTION


3.02 INSTALLATION

A. PIPE INSTALLATION:

1. Install pipe in accordance with the drawings, the manufacturer’s instructions and recommendations.

01/28/19


40 05 24 - 5

B. FITTING INSTALLATION:

1. Install fittings in accordance with the manufacturer's instructions and recommendations.

C. CONNECTION INSTALLATION:


a. Cut, thread and join in accordance with the fitting manufacturer's instructions and recommendations, and ASME B31.1.

2. FLANGED CONNECTIONS:

a. Cut, thread and join in accordance with the fitting manufacturer's instructions and recommendations, and ASME B31.1.

3. WELDED CONNECTIONS:

a. Weld in accordance with ASME Section IX, ASME B31.1, or ASME B31.3. Welders shall be ASME-certified.

4. TAKEDOWN COUPLINGS:

a. Install screwed unions or flanges where indicated on the drawings. Use flanged joints on pipelines 2-1/2 inches in diameter and larger.

5. DIELECTRIC CONNECTIONS:

a. Provide dielectric connections for dissimilar metal pipe connections.

D. PIPE ANCHORAGE:

1. Anchorage shall be provided as specified in the HANGERS AND SUPPORTS FOR PROCESS PIPING Section (40 05 07) and shown in the drawings.

E. CLEANING AND FLUSHING:

1. The cleaning, disinfection, and flushing of steel pipe shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

3.03 TESTING

A. Pre- Operational Testing:

1. Testing pipe shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

01/28/19


40 05 24 - 6

3.04 TRAINING - (NOT USED)

**END OF SECTION**

01/28/19


40 05 32 - 1

SECTION 40 05 32

POLYETHYLENE PROCESS PIPE

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies high density polyethylene (HDPE) and medium density polyethylene (MDPE) pipe, fittings, and appurtenances for piping 0.5 inches to 36 inches in nominal diameter.

1.02 REFERENCES:

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publication in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed references, the requirements of this section shall prevail.

Reference Title

ASTM A193/A193M

Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

ASTM A774/A774M

Standard Specification for As-Welded Wrought Austenitic Stainless Steel fittings for General Corrosive Service at Low and Moderate Temperatures

ASTM D2513 Rev A

Standard Specification for Polyethylene (PE) Gas Pressure Pipe, Tubing, and Fittings

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

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

ASTM D3350 Standard Specification for Polyethylene Plastics Pipe and Fittings Material

ASTM F2620 Standard Practice for Heat Fusion Joining of Polyethylene Pipe and Fittings

01/28/19


40 05 32 - 2

Reference Title

ASTM F714 Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on Outside Diameter

8CCR462

[CCR Title 8, Chapter 4, Subchapter 1, Article 3, Section 462]

California Code of Regulations for Unfired Pressure Vessel Safety Orders – Air Tanks – Field Inspections and Reports

ISO 9001 Quality Management Systems – Requirements

ISO 9002 Quality Systems – Model for quality assurance in production, installation and servicing.

ISO 12162 Thermoplastics Materials for Pipes and Fittings for Pressure Applications – Classification, designation, and design coefficient

PPI Plastic Piping Institute

SSPC SP 10 Near-White Metal Blast Cleaning


1.03 SUBMITTALS

A. The following submittals shall be provided for review in accordance with the SUBMITTAL PROCEDURES Section (01 33 00):

1. A copy of this specification section, with addendum updates, with each paragraph check-marked to show specification compliance or marked to show deviations.

2. Manufacturer’s information and catalog data showing compliance with this specification and a full description of the item.

3. Contractor’s shop drawings including fabrication, layout drawings and anchorage details.

4. Manufacturer’s equipment certification that the fusion equipment is appropriate for the polyethylene material and pipe size, and complies with ASTM F2620.

5. Qualifications for the equipment operators and fusion inspector including certifications that they have been trained by certified fusion technicians, received training in the manufacturer's recommended procedure within the last 12 months of commencing construction, and have had at least 3 years current experience in the heat fusion butt welding process.

01/28/19


40 05 32 - 3


PART 2 -- PRODUCTS

2.01 ACCEPTABLE PRODUCTS

A. Pipe manufacturers shall be ISO 9001 or 9002 certified.

B. HDPE pipe, ASTM D3035, ASTM F714, shall be Performance Pipe 4100 series and 5100 series; PolyPipe; or equal.

C. HDPE pipe, 8CCR462, shall be Asahi-America Air-Pro; or equal.

D. MDPE pipe shall be Performance Pipe 6500 series; PolyPipe; or equal.

2.02 MATERIALS/EQUIPMENT

A. PIPE

1. HDPE:

a. ASTM D3035:

1) ACCEPTABLE SIZES: SDR11.0 rated 200 psi working pressure.

2) HDPE piping components shall be manufactured from materials that meet or exceed the requirements of the Plastic Piping Institute designation PE4710 and ASTM D3350 cell classification 445474C. Piping shall contain 2% carbon black and shall be UV protected.

b. ASTM D2513:



c. ASTM F714:



01/28/19


40 05 32 - 4

d. 8CCR462:

1) ACCEPTABLE SIZES: ½ to 4 inches nominal; rated 230 psig @ 68°F working pressure, and 150 psig @ 140°F working pressure.

2) HDPE piping components shall be manufactured from materials that meet or exceed the requirements of ISO 12162 designation PE100 and ASTM D3350 cell classification 445474C. Piping color shall be blue.

3) Components shall meet or exceed compliance with Cal-OSHA CCR Title 8, Chapter 4, Subchapter 1, Article 3, Section 462 (8CCR462) for thermoplastic piping used in unprotected compressed air applications.

2. MDPE:

a. ASTM D2513 Rev A:

1) ACCEPTABLE SIZES: ¾ inch IPS SDR11.0; 1 inch IPS SDR11.0; 1¼ inches IPS SDR10; 2 inches IPS SDR11.0; 3 inch IPS SDR11.5; 4 inches IPS SDR11.0; 6 inches IPS SDR11.5.

2) MDPE piping components shall be manufactured from materials that meet or exceed the requirements of the Plastic Piping Institute designation PE2708 and ASTM D3350 cell classification 234373E. Components shall be color coded yellow.

3) Piping components shall be IAPMO listed for yard gas piping and LPG gas service.

B. FITTINGS:

1. HDPE:

a. Fittings shall be injection molded or fabricated from the same material as the pipe and shall meet the same specification as the pipe,

b. Molded butt fittings shall comply with ASTM D3261.

2. MDPE:

a. Fittings shall be injection molded or fabricated from the same material as the pipe, shall meet the same specification as the pipe, and shall be manufactured by the pipe manufacturer.

b. Molded butt fittings shall comply with ASTM D3261.

01/28/19


40 05 32 - 5

C. FLANGE ADAPTERS:

1. HDPE flange adapters shall be long neck HDPE flange adapters with ANSI Class 150 stainless steel backing flange, and flange gasket. Stub ends are not acceptable. Flat face HDPE flanges are not acceptable.

2. Flange Gaskets: Gaskets shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

3. Fasteners:

a. For moderate environments less than 200°F and requiring low strength: ASTM A193 Grade B8 Class 1 stainless steel, Type 304, 30 ksi yield strength, with matching washers and nuts, coarse thread.

b. For moderate environments less than 200°F and requiring medium strength: ASTM A193 Grade B8 Class 2 stainless steel, Type 304, 50+ ksi yield strength, with matching washers and nuts, coarse thread.

c. For harsh environments less than 200°F and requiring low strength: ASTM A193 Grade B8M Class 1 stainless steel, Type 316, 30 ksi yield strength, with matching washers and nuts, coarse thread.

d. For harsh environments less than 200°F and requiring medium strength: ASTM A193 Grade B8M Class 2 stainless steel, Type 316, 50+ ksi yield strength, with matching washers and nuts, coarse thread.

e. For all environments greater than 200°F or requiring high strength: ASTM A193 Grade B7, with matching washers and nuts, coarse thread.

D. FUSION CONNECTIONS:

1. Thermal connections shall be socket fusion or butt fusion. Electrofusion connections are not acceptable.

E. VALVES:

1. See Drawings for required valves to be installed on HDPE pipelines, and refer to applicable Division 40 Section for each valve type.

01/28/19


40 05 32 - 6

PART 3 -- EXECUTION


3.02 INSTALLATION

A. PIPE:

1. Install pipe in accordance with the drawings and the manufacturer's instructions and recommendations.

B. FITTING:

1. Install fittings in accordance with the manufacturer’s instructions and recommendations.

C. CONNECTION:

1. Pipe and fittings shall be joined into continuous lengths on the job site above ground. Joints shall be the butt-fusion method or socket-fusion method performed in accordance with the pipe manufacturer's recommendations and ASTM F2620. Extrusion welding and hot gas welding shall not be used.

2. The pipe manufacturer shall be consulted to obtain machinery and expertise for the joining by butt-fusion and socket-fusion of polyethylene pipe and fittings. No pipe or fittings shall be joined by fusion by any of the Contractor's personnel unless they are adequately trained and qualified in the techniques involved. Fusion joining shall yield a joint strength equal to or greater than the tensile strength of the pipe.

3. The manufacturer shall provide training in the manufacturer's recommended butt and socket fusion procedures to the Contractor's installation personnel, and to the inspector(s) representing the Owner, prior to the start of construction.

4. The Contractor shall certify, in writing, that persons making heat fusion joints have received training in the manufacturer's recommended procedure and have had at least 3 years current experience in the butt-fusion and socket-fusion welding process.

5. The Contractor shall maintain records of trained personnel, and shall certify that training was received not more than 12 months before commencing construction.

6. Flanged joining may be used to make connections to differing piping materials, to equipment, valves and other appurtenances.

01/28/19


40 05 32 - 7

3.03 FIELD QUALITY CONTROL

A. BUTT FUSION TESTING:

1. Every day butt fusions are to be made, the first fusion of the day shall be a trial fusion.

2. The trial fusion shall be allowed to cool completely.

3. Fusion test straps shall be cut out.

4. The test strap shall be 12 inches (minimum) or 30 times the wall thickness in length with the fusion in the center, and 1inch (minimum) or 1.5 times the wall thickness in width.

5. Bend the test strap until the ends of the strap touch.

6. If the fusion fails at the joint, a new trial fusion shall be made, cooled completely and tested.

7. Butt fusion of pipe to be installed shall not commence until a trial fusion has passed the bent strap test.

B. DATA LOGGING:

1. A data logger shall be installed on the fusion heated joining machine. Data on each joint shall be recorded by the data logger. Data to be recorded shall be minimum temperature of joint fusion and interface pressure of the fused joint.

C. ULTRA-SONIC TESTING:

1. Joints smaller than 14 inches diameter shall be tested utilizing ultra-sonic testing.

2. Test results shall be transmitted to District Representative on a daily basis.

3.04 TESTING

A. Testing of HDPE and MDPE piping shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03) using the test pressures specified, and the manufacturer’s instructions and recommendations.


**END OF SECTION**

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40 05 57 - 1

SECTION 40 05 57

ACTUATORS FOR PROCESS VALVES AND GATES

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies manual operators and powered actuators for non-fire-rated valves and gates, and appurtenances.

1.02 REFERENCES


Reference Title

ASTM A276 Stainless Steel Bars and Shapes NEMA ICS2 Industrial Control Devices, Controllers and Assemblies

B. DEFINITIONS:

1. As used in the control valve schedule in the POWER ACTUATED VALVE AND GATE SCHEDULE Section (40 06 60.13) and for manual valves specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03), operator and actuator types are identified by a 3 to 6 digit code. For actuators with digital bus, use the specification for the first 5 digits and include the digital bus field unit specifications in this section.

OPERATOR & ACTUATOR CODES

X X X X X XPower Source M – Manual E – Electric P – Pneumatic H – Hydraulic

Transmission C – Cylinder D – Diaphragm G – Gear L – Lever M – Motor S – Acme Stem

StrokeL – Linear M – Multiturn Q – Quarter turn

(Optional)A – AWWA F – Floor box O – Open/close T – Throttling M – Modulating

(Optional) S – Small M -- Medium L – Large

(Optional)D – Digital fieldbus

2. ANTIFRICTION BEARING: The term “antifriction bearing” shall mean rolling element type bearing.

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40 05 57 - 2

3. OPEN/CLOSE: To move to the fully open or fully closed position.

4. THROTTLING: To move to the fully open or fully closed position, or to move to and maintain an intermediate position between fully open and fully closed in response to a manually initiated control.

5. MODULATING: To move to the fully open or fully closed position, or to move to intermediate positions in response to a variable control signal.

1.03 SUBMITTALS


1. A copy of this specification section, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations

2. Manufacturer's information and catalog data showing compliance with this specification and a full description of the product. The product data shall include control valve schedule per the POWER ACTUATED VALVE AND GATE SCHEDULE Section (40 06 60.13), manual operators, electric, pneumatic, or hydraulic actuators, digital fieldbus network and appurtenances.

3. A copy of the contract document control diagrams and process and instrumentation diagrams that apply to the equipment in this section marked to show specific changes necessary for the supplied equipment. If no changes are required, the drawings shall be marked "No Changes Required."

4. Spare parts listing in accordance with the OPERATION AND MAINTENANCE DATA Section (01 78 23).

5. Application software and complete software manuals for programming field bus master station and valve operator controllers.



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PART 2 -- PRODUCTS

2.01 TYPE MLQ OPERATORS (PROVIDED BY DISTRICT)

A. MATERIALS/EQUIPMENT:

1. GENERAL:

a. Type MLQ operators shall be manual lever quarter turn operators.

2. BALL VALVES:

a. Provide locking lever type with vinyl plastic cover.

3. BUTTERFLY VALVES:

a. Provide latch type lever capable of being locked in at least ten intermediate positions between fully open and fully closed.

4. ECCENTRIC PLUG VALVE:

a. Provide removable lever handle.

2.02 TYPE MGQ OPERATORS (PROVIDED BY DISTRICT)


1. Bray series 04;

2. DynaTorque Inc. series DT;

3. Rotork series AB;

4. Or equal, modified as required to meet the specifications.

B. MATERIALS/EQUIPMENT:

1. GENERAL:

a. Type MGQ operators shall be manual gear quarter turn operators. Torque range: 2000 to 24000 in-lbs, or 160 to 2000 ft-lbs.

2. HOUSING:

a. Cast or ductile iron, gasketed for weatherproof service. Aluminum housings are not acceptable.

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40 05 57 - 4

3. GEARING:

a. Worm and worm gear type reduction gearing.

4. INPUT SHAFT:

a. Stainless steel shaft with antifriction bearings.

5. ROTATION:

a. Nominal 90 degrees, with externally adjustable travel stops. Provide visual position indicators, with permanent labels to show the open and closed positions on aboveground and overhead applications. Clockwise input shaft rotation equals clockwise output. Counterclockwise to open.

6. SIZE:

a. Size operator for the full pressure rating of the valve.

7. OPERATOR:

a. Handwheel, 12 inch diameter maximum unless otherwise indicated.

2.03 TYPE PCQOS ACTUATORS (PROVIDED BY DISTRICT)


1. ACTUATORS:

a. Bray series 92 or 93;

b. Flo-Tite series Air Con C;

c. Max-Air series MT;

d. Valtorc series PA-2000;

e. Or equal, modified as required to meet the specifications.

2. SOLENOID VALVES:

a. Bray series 63;

b. Max-Air series SV;

c. Or equal, modified as required to meet the specifications.

3. VALVE STATUS MONITORS:

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40 05 57 - 5

a. Bray series 50;

b. Max-Air series MS41-2AL;

c. Moniteur series Watchman VPT or Sentinel VPT;

d. Or equal, modified as required to meet the specifications.


1. GENERAL:

a. Type PCQOS actuators are pneumatic cylinder, quarter turn, open/close, small rack and pinion actuators. Torque range for spring return actuators: 15 to 7000 in-lbs. Torque range for double acting actuators: 80 to 21000 in-lbs.

2. ACTUATORS:

a. BODY:

1) Extruded hard anodized aluminum. Body shall be totally enclosed design with no external moving parts. Body shall be rated for 125 psig. Body fasteners shall be stainless steel.

b. PISTON:

1) Cast aluminum alloy, with plastic piston rings and plastic piston guides. Piston seals and o-rings shall be nitrile.

c. RACK AND PINION:

1) Actuators shall be double rack design. Racks shall be constructed of aluminum alloy, with plastic wear bands. The pinion shall be constructed of hardened and tempered alloy steel.

d. BUSHINGS:

1) Plastic bushings shall be provided for the pinion shaft.

e. ROTATION:

1) Nominal 90 degree reversible operation. Provide adjustable mechanical travel stops in both directions, and a visual position indicator.

f. SPRINGS:

1) Springs shall be pre-loaded spring cartridges

g. SIZING:

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1) Step 1: Multiply the valve peak torque requirement times two (Safety Factor = 2.0) at 80 psig supply air. Preliminarily select an actuator meeting or exceeding this requirement. Go to Step 2.

2) Step 2: If the selected actuator pneumatic & spring return torque outputs are ≤ 95% of the valve MAST (Maximum Allowable Stem Torque) value, then use this actuator, and go to Step 5. If not, then go to Step 3.

3) Step 3: If the selected actuator pneumatic or spring return torque outputs are > 95% of the valve MAST (Maximum Allowable Stem Torque) value, then reduce the Safety Factor in increments. Select an actuator with a spring return torque output of approximately 70% to 95% of the valve MAST value. Go to Step 4.

4) Step 4: Reduce the supply air pressure in increments. Select a supply air pressure with a pneumatic torque output of approximately 70% to 95% of the valve MAST value. Record the selected supply air pressure in the actuator documentation. Provide a 16 gauge, 1” x 4” engraved aluminum tag with a hole in one end, and with the label “SET AT XX PSIG” in 3/8” high letters for attachment to the supply air filter pressure regulator valve. Go to Step 5.

5) Step 5: END.

3. SOLENOID VALVES:

a. Solenoid Valve Body:

1) Pilot valves shall attach directly to the actuator body, or via an adapter plate with no external piping. Pilot valves shall be four-way, five-port, two-position, with standard NAMUR or ISO interface. Pilot valves shall be rated for 125 psig air.

b. Solenoid Coil:

1) Coil voltage shall be as required on the control drawings. Coils shall be rated for the ambient temperature where they will be installed. Electrical connections shall be ½” NPT. Provide double solenoids for pilot valves that fail to last position. Provide single solenoids for pilot valves that fail open or close. Solenoids in hazardous areas shall be rated NEMA 7D; solenoids in all other services shall be rated NEMA 4-4X. The actuator manufacturer shall provide pilot valves.

c. Solenoid Accessories:

1) Speed control needles and mufflers on each exhaust port. Manual override levers with screwdriver slots. External filter regulator, as specified below. Include fittings to point the mufflers downward.

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4. VALVE STATUS MONITORS:

a. Provide two adjustable microswitches in accordance with the INSTRUMENTATION OF PROCESS SYSTEMS Section (40 70 00).

b. Provide high visibility position indicator with clear polycarbonate dome. Monitor aluminum enclosure shall be rated NEMA 4-4X-7 for hazardous areas, and NEMA 4-4X for non-hazardous areas. Plastic enclosures are not acceptable.

2.04 TYPE PCQMS ACTUATORS (PROVIDED BY DISTRICT)


1. ACTUATORS:

a. Bray series 92 or 93;

b. Flo-Tite series Air Con C;

c. Max-Air series MT;

d. Valtorc series PA-2000;

e. Or equal, modified as required to meet the specifications.

2. POSITIONERS:

a. Bray series 6A;

b. Moniteur series 50;

c. Siemens model SIPART PS2;



1. GENERAL:

a. Type PCQMS actuators are pneumatic cylinder, quarter turn, modulating, small rack and pinion actuators. Torque range for spring return actuators: 15 to 7000 in-lbs. Torque range for double acting actuators: 80 to 21000 in-lbs.

2. ACTUATORS:

a. BODY:

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40 05 57 - 8

1) Extruded hard anodized aluminum. Body shall be totally enclosed design with no external moving parts. Body shall be rated for 125 psig. Body fasteners shall be stainless steel.

b. PISTON:

1) Cast aluminum alloy, with plastic piston rings and plastic piston guides. Piston seals and O-rings shall be nitrile.

c. RACK AND PINION:

1) Actuators shall be double rack design. Racks shall be constructed of aluminum alloy, with plastic wear bands. The pinion shall be constructed of hardened and tempered alloy steel.

d. BUSHINGS:

1) Plastic bushings shall be provided for the pinion shaft.

e. ROTATION:

1) Nominal 90 degree reversible operation. Provide adjustable mechanical travel stops in both directions, and a visual position indicator.

f. SPRINGS

1) Springs shall be pre-loaded spring cartridges.

g. SIZING:




4) Step 4: Reduce the supply air pressure in increments. Select a supply air pressure with a pneumatic torque output of approximately 70% to 95% of the valve MAST value. Record the selected supply air pressure in the actuator documentation. Provide a 16 gauge, 1” x 4” engraved aluminum tag with a

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40 05 57 - 9

hole in one end, and with the label “SET AT XX PSIG” in 3/8” high letters for attachment to the supply air filter pressure regulator valve. Go to Step 5.

5) Step 5: END.

h. Submit computer sizing program printout reports. Also submit technical data sheets showing torque requirements and torque capacities to verify computer printout reports.

3. POSITIONER:

a. Electro-pneumatic Digital Positioner:

1) Positioner shall be electro-pneumatic, microprocessor controlled with LCD display and keypad. Features shall include: auto calibration, diagnostics, adaptive control, air supply monitor, position indicator, local position adjustment, adjustable flow restrictors, 4-20 mA retransmission module, two limit switches, gauge manifold with pressure gauges. Positioner enclosure shall be NEMA 4-4X for non-hazardous areas, and NEMA 4-4X, 7 & 9 for hazardous areas.

2) Air consumption @ 80 psig: < 0.00035 scfm.

3) Air Supply Pressure: 20-102 psig.

4) Input Signal: 4 to 20 mA.

5) Resolution: < 0.05%

6) Temperature range: -22° to +176°F

b. Positioner Accessories:

1) External filter regulator, as specified below.

2.05 TYPE PCQML ACTUATORS (PROVIDED BY DISTRICT)


1. ACTUATORS:

a. Bray series 98;

b. Bettis series G;

c. Morin model S;


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2. POSITIONERS:

a. Bray series 6A;

b. Moniteur series 50;

c. Siemens model SIPART PS2;


3. ELECTRIC QUICK OPENING EXHAUST VALVE:

a. Asco model EF8210G038; or equal, modified as required to meet the specifications.


1. GENERAL:

a. Type PCQML actuators are pneumatic cylinder, quarter turn, modulating, large scotch yoke actuators. Torque range for spring return actuators: 7000+ in-lbs. Torque range for double acting actuators: 21000+ in-lbs.

2. ACTUATOR INGRESS RATING:

a. Actuator shall be rated ≥ IP66 environmental exposure.

3. ACTUATOR TEMPERATURE RATING:

a. Actuator temperature rating range shall be ≥ 0° to 150°F.

4. ACTUATOR PRESSURE RATING:

a. Actuator shall be rated for ≥ 100 psig.

5. BODY & COVER:

a. Body shall be fabricated from ductile iron or CF8M stainless steel, with ISO 5211 mounting.

6. BODY FASTENERS:

a. Body fasteners shall be stainless steel.

7. SCOTCH YOKE:

a. Scotch Yoke shall be fabricated from ductile iron or 17-4 PH stainless steel, with symmetrical yoke design.

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8. THRUST PIN:

a. Thrust pin shall be bronze or stainless steel.

9. THRUST PIN BEARINGS:

a. Thrust pin bearings shall be bronze or roller bearing stainless steel.

10. STOPS:

a. Stops shall be adjustable in both directions.

11. OUTPUT SHAFT ADAPTER:

a. Output shaft adapter shall be fabricated from Type 17-4 PH stainless steel or Type 304L stainless steel.

12. OUTPUT BEARINGS:

a. Output bearings shall be fabricated from PTFE bronze or PTFE composite.

13. PRESSURE CYLINDER & END CAPS:

a. Pressure cylinder shall be carbon steel, hard chrome plated and honed, or Type 316 stainless steel.

b. End caps shall be ductile iron or Type 316 stainless steel construction, with two 1” FNPT ports.

14. PISTONS:

1) Pistons shall be ductile iron with dual wear bands and nitrile seals, or CF8M stainless steel construction.

15. PISTON ROD:

a. Piston rod shall be alloy steel with PTFE or bronze bushings, or stainless steel construction.

16. SPRING CYLINDER & END CAPS:

a. Spring cylinder shall be carbon steel or stainless steel, all-welded construction.

17. SPRINGS:

a. Springs shall be fabricated from alloy steel or stainless steel.

18. HYDRAULIC DAMPENER:

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a. Hydraulic dampener shall provide an adjustable cushion at the end of the spring-return stroke to prevent damage during the fast opening stroke.

19. COATING:

a. Coating for carbon steel shall be epoxy primer with polyurethane top coat.

b. Coating for stainless steel is not required.

20. SIZING:

a. ACTUATOR SHALL BE SIZED AS FOLLOWS:




4) Step 4: Reduce the supply air pressure in increments. Select a supply air pressure with a pneumatic torque output of approximately 70% to 95% of the valve MAST value. Record the selected supply air pressure in the actuator documentation. Provide a 16 gauge, 1” x 4” engraved aluminum tag with a hole in one end, and with the label “SET AT XX PSIG” in 3/8” high letters for attachment to the supply air filter pressure regulator valve. Go to Step 5.

5) Step 5: END.

b. Submit computer sizing program printout reports. Also submit technical data sheets showing torque requirements and torque capacities to verify computer printout reports.

21. POSITIONER:

a. Electro-pneumatic Digital Positioner:

1) Positioner shall be electro-pneumatic, microprocessor controlled with LCD display and keypad. Features shall include: auto calibration, diagnostics, adaptive control, air supply monitor, position indicator, local position adjustment, adjustable flow restrictors, 4-20 mA retransmission module, two

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limit switches, gauge manifold with pressure gauges. Positioner enclosure shall be NEMA 4-4X for non-hazardous areas, and NEMA 4-4X, 7 & 9 for hazardous areas.

2) Air consumption @ 80 psig: < 0.00035 scfm.

3) Air Supply Pressure: 80 psig.

4) Input Signal: 4 to 20 mA.

5) Resolution: < 0.1%

6) Temperature range: ≥ 0° to 150°F

C. ELECTRIC QUICK OPENING EXHAUST VALVE:

1. GENERAL:

a. Quick opening valve shall be an electric solenoid valve, two-way, normally open when de-energized.

2. FLOW WAY:

a. Flow way shall be two-way, normally open when de-energized.

b. Orifice shall be 5/8” diameter.

c. CV shall be ≥ 3.0.

3. BODY:

a. Body shall be Type 304 stainless steel, with ¾” NPT ends.

b. Body shall be rated ≥ 150 psig.

4. SPRING:

a. Spring shall be stainless steel.

5. SEALS:

a. Seals shall be Buna-N, rated for 150 psig @ 180°F.

6. COIL:

a. Coil shall be RedHat II, rated for NEMA 4-4X-7D, 110 VAC-1Ø-60Hz.

b. Ambient temperature rating range shall be ≥ 32°F to 125°F.

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c. Maximum shutoff pressure rating for air shall be ≥ 150 psig.

7. ADDITIONAL ITEMS:

a. Provide a 1” x ¾” Type 304 stainless steel bushing and an ASTM A312 ¾” Schedule 40 Type 304 stainless steel nipple for connection to the second pressure cylinder end cap port.

b. Provide an ASTM A312 ¾” Schedule 40 Type 304 stainless steel nipple, ASTM A182 Schedule 40 Type 304 stainless steel elbow, and Nitra Pneumatics model HVM-34N-H high capacity (CV = 13.5) aluminum exhaust silencer for connection to the exhaust side of the quick opening valve.

2.06 MOUNTING ADAPTERS (PROVIDED BY DISTRICT)

A. MATERIALS/EQUIPMENT:

1. Mounting adapters shall include operator or actuator housing, stem and bonnet extensions, adapter plates, and connections to the valve. Design and fabricate stem and bonnet extensions according to the general details shown on the drawings. Adjust dimensions as required to comply with sizing criteria. Submit mounting adapter design calculations and shop drawings.

2. For mounting adapter sizing purposes, assume the valve is jammed. Size mounting adapters to withstand the maximum operating torque of the operator or actuator, and for a minimum safety factor of 5 based on the yield strength of the material used.

3. Do not attach mounting adapter utilizing valve bonnet bolts, thereby providing for removal of the adapter without taking the valve out of service.

2.07 APPURTENANCES

A. DECLUTCH OVERRIDE MECHANISM (PROVIDED BY DISTRICT):

1. Where specified, provide manual declutch override mechanisms between the valve and actuator to provide emergency manual override operation of the valve.

B. STEM EXTENSIONS:

1. Buried quarter turn manual valves with the operating nut more than 6” below grade shall be provided with a stem extension, valve box with extensions, debris shield, and the valve box lid. The stem extension shall include a 2” AWWA nut with the flow alignment engraved into the top of the nut. Valve boxes shall be cast iron or concrete, Christy G05T, Brooks 3-RT, or equal. Valve box extensions shall be AWWA C900 PVC DR 18 pipe. Hot-dip galvanize covers. Label box covers with the symbol of the particular service, as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

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C. AIR FILTER REGULATORS (PROVIDED BY DISTRICT):

1. AIR FILTER REGULATOR TYPE 050AFR+O:

a. ACCEPTABLE PRODUCTS:

1) FILTER REGULATOR: McMaster-Carr model 4910K23 (½” NPT); Norgren model B73G-4AK-AD1-RMG (½” NPT); or equal, modified as required to meet the specifications.

2) OIL REMOVAL FILTERS: McMaster-Carr model 8282K63 with model 4910K98 bracket; Norgren Excelon model F74H-4AD-AD0 with model 4324-50 bracket; or equal, modified as required to meet the specifications.

b. MATERIAL/EQUIPMENT:

1) Filter regulators shall be “piggyback” style relieving units, with aluminum body and ½ inch FNPT connections, aluminum bowl, sight gauge, automatic drain, 5 micron filter, secondary pressure gauge, and T-handle or knob adjustment. Primary pressure rating shall be minimum 175 psig. Secondary pressure range shall be 5 to 150 psig. Flow rate shall be ≥ 55 scfm @ 10 psig droop. Set regulator @ 80 psig. Filter element shall be 5 microns. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the inlet of the oil removal filter.

2) Oil removal filters shall be aluminum body with ½” FNPT connections, with aluminum bowl, sight gauge, automatic drain, visual service life indicator, and mounting bracket. Pressure rating shall be minimum 250 psig. Flow rate shall be ≥ 55 scfm saturated air @ 80 psig inlet and 6 psig pressure drop. Filter element shall be 0.01 microns.

2. AIR FILTER REGULATOR TYPE 050AFR+O+D+F+O:


1) SUPPLY CHECK VALVE: DFT Valves model SCV; or equal, modified as required to meet the specifications.


3) OIL REMOVAL FILTER: McMaster-Carr model 8282K63 with model 4910K98 bracket; Norgren Excelon model F74H-4AD-AD0 with model 4324-50 bracket; or equal, modified as required to meet the specifications.

4) DESICCANT DRYER: Van Air Systems model ID15-SW; or equal, modified as required to meet the specifications.

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5) POST FILTER: McMaster-Carr model 4958K42; Norgren Excelon model F74G-4AN-QD1; Speedaire model 4Zl49; or equal, modified as required to meet the specifications.

6) RESTRICTION ORIFICE UNION: HART Industrial Unions model Sure Seal Orifice O-Ring Union; Lamda Square Inc. model Restriction Orifice Union; or equal, modified as required to meet specifications.


1) Check valve shall be spring assisted in-line type, fabricated from ASTM A351 CF8M stainless steel with ½” FNPT ends. Disc shall be fabricated from ASTM A351 stainless steel. Spring shall be fabricated from Type 316 stainless steel. Valve cracking pressure range shall be approximately 0.25 to 0.75 psig. O-ring shall be nitrile. Check valve pressure shall be rated ≥ 150 psig @ 200°F. Flow capacity CV = 7. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the inlet of the filter regulator housing.

2) Filter regulators shall be “piggyback” style relieving units, with aluminum body ½ inch FNPT connections, aluminum bowl, sight gauge, automatic drain, 5 micron filter, secondary pressure gauge, and T-handle or knob adjustment. Primary pressure rating shall be minimum 175 psig. Secondary pressure range shall be 5 to 150 psig. Flow rate shall be ≥ 55 scfm @ 10 psig droop. Set regulator @ 80 psig. Filter element shall be 5 microns. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the inlet of the oil removal filter.

3) Oil removal filters shall be coalescing type fabricated with aluminum body with ½” FNPT connections, with aluminum bowl, sight gauge, automatic drain, visual service life indicator, and mounting bracket. Pressure rating shall be minimum 250 psig. Flow rate shall be ≥ 55 scfm saturated air @ 80 psig inlet and 6 psig pressure drop. Filter element shall be 0.01 microns. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the desiccant filter housing.

4) Desiccant dryer housing shall be fabricated from powder-coated aluminum, end connections shall be ½” FNPT. Desiccant shall be replaceable color indicating silica gel cartridge type with color change-out sight window. Loose fill silica is NOT ACCEPTABLE. Desiccant capacity shall be ≥ 23 ounces of silica gel. Pressure dew point shall be ≤ - 40 °F @ 15 scfm. Flow capacity shall be ≥ 15 scfm @ 80 psig. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the post filter.

5) Post Filter shall be fabricated from aluminum, end connections shall be ½” FNPT, with aluminum bowl with liquid level indicator and ¼ turn manual drain valve. Filter element shall be 5 micron sintered polypropylene. Flow capacity shall be ≥ 25 scfm @ 80 psig and < 1 psig pressure drop. Pressure

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rating shall be minimum 250 psig. Temperature range shall be > 0°F to 150°F. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the restriction orifice union.

6) Restriction Orifice Union shall be fabricated from ASTM A182 Type 316 stainless steel with ½” FNPT end connections. Body shall be rated Class 3000 and shall be double O-ring style for sealing against both sides of the restriction orifice plate. O-rings shall be fabricated from nitrile. Restriction orifice plate shall be Type 316 stainless steel and diameter shall be 0.0995 to 0.100 inches. Approximate flow capacities are 10.9 scfm at 80 psig in, 0 psig out; 10.8 scfm at 80 psig in, 20 psig out; 10.1 scfm at 80 psig in, 40 psig out; 8.0 scfm at 80 psig in, 60 psig out; 4.3 scfm at 80 psig in, 75 psig out. Restriction orifice union shall limit the supply air flow to < 15 scfm in order to stay within the capacity of the desiccant dryer and maintain the - 40°F pressure dewpoint performance rating.

2.08 NAMEPLATES (PROVIDED AND MOUNTED BY THE DISTRICT)

A. Nameplates shall be provided on each item of equipment. Equipment nameplates shall be 16-gauge aluminum bearing the equipment name and equipment number legibly engraved in ½ inch high letters. Nameplates shall be attached to the equipment in an accessible location with stainless steel screws.

PART 3 -- EXECUTION


3.02 INSTALLATION

A. Equipment specified in this section shall be installed in accordance with the manufacturer's instructions.

B. MANUAL OPERATORS:

1. ACCESSIBILITY:

a. Position operators so that they can readily be operated.

b. Provide specified handle for operators with centerlines up to 7 feet 6 inches above the operating level. Where these operators are not readily accessible, provide either rigid shaft extensions with universal joints, or flexible shaft extensions so that the handles can be remotely mounted in an accessible location.

c. Unless otherwise shown on the plans, replace specified handwheels with chain wheels for operators with centerlines more than 7 feet 6 inches above the operating level. Where these chain wheels are not accessible, provide either rigid

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shaft extensions with universal joints, or flexible shaft extensions so that the chain wheels can be remotely mounted in an accessible location.

2. AWWA NUTS & STEM EXTENSIONS:

a. Quarter-turn operators: Install 2 inch AWWA nuts and stem extensions where shown or specified. Engrave top of nuts to indicate flow way. Locate nuts to within 6 inches of the valve box cover.

3. CHAIN WHEELS:

a. Provide chain guides for chain wheels. Loop operating chains to 4 feet above the operating level. Provide hooks on adjacent piping for chain storage where chain hangs in foot traffic.

b. Provide hammer blow devices for plug valves 8 inches and larger.

C. POWERED ACTUATORS:

1. Control valves with powered actuators are specified in the POWER ACTUATED VALVE AND GATE SCHEDULES Section (40 06 60.13).

3.03 TESTING

A. Testing of powered actuators shall be as specified in the COMMISSIONING Section (01 91 00).

1. Inspect valve actuators covered by this Specification Section.

2. Supervise adjustments and installation checks:

a. Open and close valves electrically under local manual and demonstrate that all limit switches are properly adjusted, valve actuator is configured correctly and the valve is functioning properly by verifying the inputs are received at the PLC panels.

b. Position modulating valves electrically under local manual control and demonstrate that the valve position feedback is properly adjusted and that the feedback signal is received at the PLC.

c. Simulate a valve position command signal at the PLC or local control panel as appropriate and demonstrate that the valve is controlled to the desired position without excessive hunting.

3. Provide Owner with a written statement that the valve actuator manufacturer has verified that the actuators have been installed properly, that all limit switches and position potentiometers have been properly adjusted and that the valve actuator responds correctly to the valve position command.

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3.04 TRAINING

A. Training shall conform to TRAINING Section (01 79 10). The number of training session and hours for each craft shall conform to the requirements of TRAINING Section (01 79 10).

**END OF SECTION**

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40 05 63 - 1

SECTION 40 05 63

BALL VALVES

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies non-fire-rated ball valves.

1.02 REFERENCES


Reference Title

ASME B16.5 Pipe Flanges and Flanged Fittings

ASTM A276 Stainless and Heat-Resisting Steel Bars and Shapes

ASTM A351 Castings, Austenitic, Austenitic-Ferritic (Duplex), for Pressure-Containing Parts

B. DEFINITIONS:

Valve Type Description

SS-3P Stainless Steel, 3-Piece Ball Valve.

SS-F Stainless Steel, Flanged Ball Valve.

SS-F-V Stainless Steel, Flanged, V-port Ball Valve.

1.03 SUBMITTALS (NOT USED)


1.05 UNIT RESPONSIBILITY (NOT USED)


40 05 63 - 2

PART 2 -- PRODUCTS


2.02 TYPE SS-3P VALVES (PROVIDED BY DISTRICT)

A. GENERAL:

1. Type SS-3P valves are stainless steel three-piece ball valves, rated 1000 psig WOG for bi-directional bubbletight shutoff. Size Range: ¼ inch to 3 inch.

B. ACCEPTABLE PRODUCTS:

1. Apollo Series 86A-100-76 & 86A-100-77; Bray Flow-Tek series 7000; Flo-Tite series 300; FNW Figure 320A, Valtorc Series 140; or equal, modified as required to meet the specifications.

C. MATERIALS:

1. BODY: The body shall be three-piece, ASTM A351 Grade CF8M stainless steel construction, with ISO 5211 actuator pad. End connections shall be NPT.

2. BALL: The ball shall be constructed from ASTM A351 Grade CF8M stainless steel or ASTM A276 Type 316 stainless steel.

3. SEAT: The seats shall be multi-seal, reinforced PTFE, rated for 1000 psig WOG and for 150 psig saturated steam.

4. STEM: The stem shall be constructed from ASTM A276 or A479 Type 316 stainless steel.

5. STEM SEAL: The stem seal shall be reinforced PTFE, live-loaded with stainless Belleville spring washers.

6. FLOW WAY: The valves shall be full port design.

2.03 TYPE SS-F VALVES (PROVIDED BY DISTRICT)

A. GENERAL:

1. Type SS-F valves are two-piece stainless steel flanged ball valves, ANSI /ASME Class 150, rated 250 psig for bi-directional bubbletight shutoff. Size Range: ½ inch to 6 inches.


1. Apollo Series 87A-200-76 & 87A-200-77; Flow-Tek series F-15; or equal, modified as required to meet the specifications.


40 05 63 - 3

C. MATERIALS:

1. BODY: The body shall be ASTM A351 Grade CF8M stainless steel two-piece construction with integral ISO 5211 mounting pad. End connections shall be ANSI /ASME Class 150 flanges.

2. BALL: The ball shall be ASTM A351 Grade CF8M stainless steel or ASTM A276 Type 316 stainless steel.

3. SEAT: The seats shall be multi-seal, TFM or reinforced PTFE, rated for 250 psig at 150 degrees F and for 150 psig saturated steam.


5. STEM SEAL: The stem seal shall be TFE or reinforced PTFE, live-loaded with stainless Belleville spring washers.

6. DIRECTION: Counterclockwise to open.

7. FLOW WAY: Valves shall be full port design.

2.04 TYPE SS-F-V VALVES (PROVIDED BY DISTRICT)

A. GENERAL:

1. Type SS-F-V valves are two-piece stainless steel flanged V-port ball valves, ANSI /ASME Class 150, rated 250 psig for bi-directional bubbletight shutoff. Size Range: ½ inch to 6 inches.


1. Flow-Tek series F-15; Flo-Tite model F-150; or equal, modified as required to meet the specifications.

C. MATERIALS:

1. BODY: The body shall be ASTM A351 Grade CF8M stainless steel two-piece construction with integral ISO 5211 mounting pad. End connections shall be ANSI /ASME Class 150 flanges.

2. BALL: The ball shall be ASTM A351 Grade CF8M stainless steel or ASTM A276 Type 316 stainless steel.

3. SEAT: The seats shall be TFM, rated for 250 psig at 150 degrees F and for 150 psig saturated steam.


40 05 63 - 4


5. STEM SEAL: The stem seal shall be TFE or reinforced PTFE, live-loaded with stainless Belleville spring washers.

6. DIRECTION: Counterclockwise to open.

7. FLOW WAY: Valves shall be V-port design. V-port angle per Control Valve Schedule as specified in the POWER ACTUATED VALVE AND GATE SCHEDULES Section (40 06 60.13).

2.05 VALVE OPERATORS

A. Manual valve operators shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03), and ACTUATORS FOR PROCESS VALVES AND GATES Section (40 05 57).

PART 3 -- EXECUTION


3.02 INSTALLATION

A. Valves and operators shall be installed in accordance with the manufacturer's recommendations.

B. Manual operators shall be positioned so that they can readily be operated.

C. Powered operators shall be installed so that the position indicator can be easily read from floor level.

3.03 TESTING

A. Testing for the valves and associated operators shall be in accordance with the ACTUATORS FOR PROCESS VALVES AND GATES Section (40 05 57). The installed gate and operator assemblies shall be tested for proper alignment, balancing, and smooth operation.

B. Valves shall be tested with the piping system test as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).


**END OF SECTION**


40 05 64 - 1

SECTION 40 05 64

BUTTERFLY VALVES

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies non-fire-rated butterfly valves.

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed publications, the requirements of this section shall prevail.

Reference Title

ASTM A126 Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

ASTM A167 Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet and Strip

ASTM A182 Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A240/A240M

Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A276 Standard Specification for Stainless Steel Bars and Shapes

ASTM A351/A351M

Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

ASTM A536 Standard Specification for Ductile Iron Castings

ASTM A564/A564M

Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A743/A743M

Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Applications


40 05 64 - 2

Reference Title

ISO 5211 Industrial Valves – Part-Turn Actuator Attachments

B. DEFINITIONS:

Type Description

GP-XXX-XXXX General purpose butterfly valve. HPDO High performance double offset butterfly valve.



1.05 UNIT RESPONSIBILITY (NOT USED)

PART 2 -- PRODUCTS

2.01 TYPE GP-XXX-XXXX (PROVIDED BY DISTRICT)

A. GENERAL:

1. Type GP valves shall be general-purpose butterfly valves, ANSI Class 150, rated for 150 psig minimum bi-directional bubbletight shutoff and for bubbletight dead-end service with one flange removed as shown in the following table. Type GP valves shall be identified by a 3-section code as follows:

General Purpose Butterfly Valve Codes

Type Dead End Pressure (psig)

Seat

xx ― xxx ― xxxx

GP 150 Buna

GP 150 EPDM

GP 150 FKM


1. GP-150-Buna & GP-150-EPDM & GP-150-FKM:


40 05 64 - 3

a. Bray Series 31 (2 inches to 20 inches) with bonded seat and Series 36 (22 inches to 120 inches) with bonded seat;

b. Valtorc Resilient Seated Lugged Butterfly Valves series 1000 (2 inches to 24 inches) and Resilient Seated Flanged Butterfly Valves (26 inches to 40 inches);

c. Or equal, modified as required to meet the specifications.

C. MATERIALS:

1. BODY:

a. Valves shall be full lugged or flanged body. The body shall be constructed of ASTM A126, Class B cast iron, or ASTM A536, ductile iron with integral ISO 5211 mounting pad.

2. DISC:

a. The inline disc shall be constructed of ASTM A351/A351M or A743/A743M, CF8M Type 316 stainless steel, spherically machined and polished. Offset discs are not acceptable.

3. SEAT:

a. The seat shall provide complete isolation of the media from the valve body. The seat shall also incorporate integral flange seals to eliminate the requirement for flange gaskets or O-rings. Seat material per Valve Code. Cartridge style seats are not acceptable.

4. SHAFT:

a. The shaft shall be constructed of ASTM A182 or A276 Type 316 stainless steel.

b. Shaft-to-disc connection shall be an internal double-D or spline connection. External screws, bolts, taper pins, etc. are not acceptable.

c. Shafts retained from blowout using pins or similar devices in the neck or body are not acceptable.

5. BEARINGS:

a. Upper shaft bearing shall be heavy duty acetal.

6. DIRECTION:

a. Counterclockwise to open.


40 05 64 - 4

7. COATINGS:

a. The interior and exterior body surfaces shall be coated with the manufacturer’s standard epoxy finish.

2.02 TYPE HPDO VALVES (PROVIDED BY DISTRICT)

A. GENERAL:

1. Type HPDO valves shall be high performance double offset butterfly valves, ANSI Class 150, rated 200 psig at 375°F for bi-directional bubbletight shutoff, and 200 psig at 375°F for bubbletight dead-end service with one flange removed. Size range: 3 inches to 48 inches.


1. Bray/McCannalok High Performance Zero Leakage Butterfly Valves (3 inches to 60 inches);

2. Crane Flowseal High Performance Butterfly Valve (3 inches to 48 inches);

3. Or equal, modified as required to meet the specifications.

C. MATERIALS:

1. BODY:

a. Valves shall be full lugged or flanged body. The body shall be constructed of ASTM A351 CF8M stainless steel.

2. DISC:

a. Valves shall utilize the double offset eccentric disc design. The disc shall be constructed of ASTM A351 CF8M stainless steel.

3. SEAT:

a. The seat shall be a 360 degree uninterrupted seal and shall be retained in the body by means of a bolted ASTM A240 Type 316 or ASTM A351 CF8M stainless steel ring. The seat shall be reinforced PTFE with an elastomeric O-ring energizer. Seats without an energizer feature are not acceptable.

4. SHAFT:

a. The shaft shall be constructed of ASTM A276 Type 316 stainless steel or A564 Type 630 17-4 PH stainless steel, and shall be turned, ground and polished. Shaft bearings shall be constructed of Type 316 stainless steel with a TFE/glass fabric liner.


40 05 64 - 5

5. SHAFT SEAL:

a. The shaft seal shall be adjustable PTFE packing rings.

6. BEARINGS:

a. Upper and lower shaft bearings shall be Type 316 stainless steel with TFE/glass fabric liner.

7. DIRECTION:

a. Counterclockwise to open.

2.03 OPERATORS AND ACTUATORS

A. Manual operators and powered actuators shall be as specified in this specification section, the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03), and the ACTUATORS FOR PROCESS VALVES AND GATES Section (40 05 57).

B. Powered actuators shall be as specified in the POWER ACTIVATED VALVE AND GATE SCHEDULES Section (40 06 60.13) and the ACTUATORS FOR PROCESS VALVES AND GATES Section (40 05 57).

PART 3 -- EXECUTION


3.02 INSTALLATION

A. Coordinate butterfly valve installation with HDPE piping installation. Where butterfly valve disc travel may be impaired by HDPE wall thickness, use HDPE beveled flange adapters. Field shaving is not permitted.

B. Valves and operators shall be installed in accordance with the manufacturer's recommendations.

3.03 TESTING

A. Valves shall be tested with the piping system test per the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).


**END OF SECTION**


40 05 64 - 6



40 05 66 - 1

SECTION 40 05 66

FIRE-RATED FIRE ISOLATION VALVES

PART 1 -- GENERAL

1.01 DESCRIPTION

A. SCOPE:

1. This section specifies fire-rated fire isolation valves for use in the GMS piping systems, including valves, pneumatic actuators, valve status monitors, solenoid valves, etc. and actuator air supply assemblies.

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed publications, the requirements of this section shall prevail.

Reference Title

ANSI B16.5 Pipe Flanges and Flanged Fittings: NPS ½ through 24 Metric/Inch Standard

API 598 Valve Inspection and Testing

API 607 Fire Test for Quarter-turn Valves and Valves Equipped with Nonmetallic Seats

ASTM A276 Standard Specification for Stainless Steel Bars and Shapes

ASTM A351/A351M

Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

ASTM A564/A564M

Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM B241 Standard Specification for Aluminum and Aluminum-Alloy Seamless Pipe and Seamless Extruded Tube

ASTM B670 Standard Specification for Precipitation-Hardening Nickel Alloy (UNS N07718) Plate, Sheet, and Strip for High-Temperature Service


40 05 66 - 2

Reference Title

ISO 5211 Industrial Valves – Part-Turn Actuator Attachments

B. DEFINITIONS:

Type Description

HPDO-FS High performance double offset fire safe butterfly valve.

SS-F-FS Stainless Steel Flanged Fire Safe Ball Valve

1.03 DESIGN REQUIREMENTS

Design Requirements

Digester gas composition Approximately 60% methane, 35% carbon dioxide, balance of nitrogen, up to 300 ppm H2S, trace gases

Gas inlet shutoff pressure 30 psig Failure position on loss of signal CLOSE Failure position on loss of motive power CLOSE Valve allowable seat leakage, per API 598 Zero Certification API 607 < 6” Valve/actuator closing speed Approximately 2 to 5 seconds6” Valve/actuator closing speed Approximately 5 to 10

seconds 8” Valve/actuator closing speed Approximately 5 to 10





seconds


40 05 66 - 3

1.04 SUBMITTALS

A. The following information shall be submitted for review:

1. Manufacturer’s information and catalog data showing compliance with this specification and a full description of the product. Product data sheets shall be marked to indicate proposed specific features and options.

2. A copy of this specification section, and all referenced sections, with each paragraph check marked to show specification compliance or marked to show deviation.

3. Certified shop drawings.

4. Computer sizing program printout reports, and technical data sheets listing torque requirements and torque capacities.

5. Installation, operation and maintenance (IOM) instructions.

PART 2 -- PRODUCTS

2.01 TYPE SS-F-FS BALL VALVES (PROVIDED BY THE DISTRICT)

A. GENERAL:

1. Type SS-F-FS valves shall be fire-rated, flanged, two-piece, stainless steel, full port ball valves.

B. BODY:

1. Body shall be fabricated from ASTM A351 CF8M stainless steel. Body shall be two-piece with integral ISO 5211 mounting pad. Ends shall be ANSI Class 150 raised flanges.

C. BALL:

1. Ball shall be fabricated from ASTM A351 CF8M or ASTM A276 Type 316 stainless steel.

2. Port shall be full-port design.

D. PRIMARY SEATS:

1. Seats shall be fabricated from TFM 1600.


40 05 66 - 4

2. Seats shall be rated for 200 psig @ 400°F.

3. Seats shall be rated for ≥ 15” WC vacuum.

4. Seat leakage shall be zero, per API 598.

E. FIRE SAFE SEATS:

1. Fire safe seats shall be machined into the valve body.

F. STEM:

1. Stem shall be fabricated from ASTM A564 Type 630 17-4 PH Type 316 stainless steel.

G. STEM SEALS:

1. Stem seals shall be live-loaded graphite stem packing.

H. ACCEPTABLE PRODUCTS:

1. Bray Flow-Tek model F15; Flo-Tite model F150; or equal, modified as required to meet the specifications.

2.02 TYPE HPDO-FS BUTTERFLY VALVES (PROVIDED BY THE DISTRICT)

A. GENERAL:

1. Butterfly valves shall be fire-rated, high performance, double offset, ANSI Class 150 butterfly valves.

B. BODY:

1. Body shall be fabricated from ASTM A351 CF8M stainless steel.

2. Body shall be full-lugged or flanged body design.

C. DISC:

1. Disc shall be fabricated from ASTM A351 CF8M stainless steel.

2. Disc shall be double offset style.

D. PRIMARY SEAT:


40 05 66 - 5

1. Seat shall be reinforced PTFE with elastomeric O-ring energizer with bolted ASTM A276 Type 316 or A351 CF8M stainless steel retaining ring. Seats without O-ring energizer feature are not acceptable.

2. Seat shall be rated for 200 psig at 375°F minimum for bi-directional bubble tight shutoff and 200 psig at 375°F minimum bubble tight dead-end service with one flange removed.

3. Seat shall be rated for bi-directional seating without the aid of line pressure.

4. Seat shall be rated for ≥ 15” WC vacuum.

E. FIRE SAFE SEAT:

1. Fire safe seat shall be fabricated from ASTM B670 Inconel 718.

2. Fire safe seat shall be rated for bi-directional seating without the aid of line pressure.

F. SHAFT:

1. Shaft shall be fabricated from ASTM A564 Type 630 17-4 PH stainless steel, turned, ground, and polished.

G. SHAFT SEAL:

1. Shaft seal shall be live-loaded flexible graphite rings.

H. DIRECTION:

1. Valve direction shall be counterclockwise to open.

I. ACCEPTABLE VALVES:

1. Bray series 41 High Performance Zero Leakage Butterfly Valve with Fire Safe Seat; Crane model Flowseal High performance Butterfly Valve with Fire Safe Seat; or equal, modified as required to meet the specifications.

2.03 TYPE PCQOS DOUBLE RACK & PINION ACTUATORS (PROVIDED BY THE DISTRICT)

A. GENERAL:

1. Actuators shall be pneumatic cylinder, quarter turn, open-close, spring-return, double rack and pinion actuators.


40 05 66 - 6

B. FAILURE POSITIONS:

1. Signal Failure: FCS. Fails CLOSE on loss of control signal.

2. Motive Power Failure: FCP. Fails CLOSE on loss of motive power.

C. ACTUATOR PRESSURE RATING:

1. Actuator shall be rated for ≥ 125 psig.

D. BODY:

1. Body shall be fabricated from extruded hard aluminum, with ISO 5211 mounting.

E. BODY FASTENERS:

1. Body fasteners shall be stainless steel.

F. PISTONS:

1. Pistons shall be cast aluminum alloy with plastic piston rings, plastic piston guides, and nitrile O-ring seals.

G. RACKS:

1. Rack shall be fabricated from aluminum alloy with plastic wear bands.

H. PINION:

1. Pinion shall be fabricated from hardened, tempered alloy steel.

I. STOPS:

1. Stops shall be adjustable in both directions.

J. SPRINGS:

1. Springs shall be pre-loaded spring cartridges.

K. SIZING:

1. Actuators shall be sized as follows:

a. Step 1: Multiply the valve peak torque requirement times two (Safety Factor = 2.0) at 80 psig supply air. Preliminarily select an actuator meeting or exceeding this requirement. Go to Step 2.


40 05 66 - 7

b. Step 2: If the selected actuator pneumatic & spring return torque outputs are ≤ 95% of the valve MAST (Maximum Allowable Stem Torque) value, then use this actuator, and go to Step 5. If not, then go to Step 3.

c. Step 3: If the selected actuator pneumatic or spring return torque outputs are > 95% of the valve MAST (Maximum Allowable Stem Torque) value, then reduce the Safety Factor in increments. Select an actuator with a spring return torque output of approximately 70% to 95% of the valve MAST value. Go to Step 4.

d. Step 4: Reduce the supply air pressure in increments. Select a supply air pressure with a pneumatic torque output of approximately 70% to 95% of the valve MAST value. Record the selected supply air pressure in the actuator documentation. Provide a 16 gauge, 1” x 4” engraved aluminum tag with a hole in one end, and with the label “SET AT XX PSIG” in 3/8” high letters for attachment to the supply air filter pressure regulator valve. Go to Step 5.

e. Step 5: END.

2. Submit computer sizing program printout reports. Also submit technical data sheets showing torque requirements and torque capacities to verify computer printout reports.

L. SOLENOID VALVE:

1. Solenoid pilot valves shall have aluminum bodies that attach directly to the actuator body, or via an adapter plate with no external piping. Solenoid valves shall be 3-way, five ¼” NPT ports, two-position style with manual override and standard NAMUR interface. Flow configuration shall vent treated air to the non-pressurized side of the piston to reduce corrosion. Valves shall be rated for 30 psig to 116 psig minimum range.

2. Provide single solenoid coil. Coil shall be rated NEMA 4-4X-7, Class 1, Division 1, Group D. Coil ambient temperature range shall be 0°F to +122°F minimum. Coil Voltage shall be 120 VAC-60Hz.

3. Provide spring-loaded check valves and speed control needles and mufflers on each exhaust port. Pneumatic check valves shall prevent atmospheric air contamination of the unpressurized air chamber.

a. Spring-loaded check valves shall be ¼” NPT brass body, rated for 250 psig and 0 to 180°F. Seal shall be nitrile. Flow rate shall be 30 scfm @ 100 psig pressure drop. Cracking pressure shall be 1 to 2 psig. Parker model 3047; Schrader Bellows model 3047; or equal.


40 05 66 - 8

b. Combination speed control needle valve and muffler shall be ¼” NPT brass body.

M. SOLENOID VALVE ACTUATOR SPEED CONTROL BLOCK:

1. Solenoid valve actuator speed control block shall provide adjustable opening and closing speed control for spring-return actuator applications.

2. Speed control block body shall be designed for NAMUR sandwich mounting in between the solenoid pilot valve and the NAMUR mounting block. Speed control block body shall be fabricated from anodized aluminum. Body seals shall be nitrile.

3. Two speed control needles, fabricated from brass, with knurled knobs and locknuts.

4. Speed control block shall be rated NEMA 4-4X.

N. VALVE STATUS MONITORS:

1. Provide two adjustable SPDT micro-switch position switches.

2. Visual position indicators shall be high visibility type, with clear polycarbonate or Ektar domes or cylinders. Covers with decals or paint are not acceptable.

3. Enclosure shall be aluminum, and shall be rated NEMA 4-4X-7, Class 1, Division 1, Group D. Plastic enclosures are not acceptable.

O. ACCESSORIES:

1. Include ISO 5211 Type 304 stainless steel mounting brackets, shaft couplings, etc.

P. ACCEPTABLE PRODUCTS:

1. Actuators: Bray series 93; Flo-Tite model Air Con C; Max-Air series MT; Valtorc series PA-2000; or equal, modified as required to meet the specifications.

2. 3-Way Solenoid Valves: Bray series 63; Valtorc series 9AAG-EXP; or equal, modified as required to meet the specifications.

3. Solenoid Valve Actuator Speed Control Block: Valworx model 529600; UniTorq model UT-SC-SR; MaxAir model CF3; or equal, modified as required to meet the specifications.

4. Valve Status Monitors: Bray series 50-0700; Moniteur series Sentinel VPT; or equal, modified as required to meet the specifications.


40 05 66 - 9

2.04 TYPE PCQOL SCOTCH YOKE ACTUATORS (PROVIDED BY THE DISTRICT)

A. GENERAL:

1. Actuator shall be pneumatic cylinder, quarter turn, open-close, spring-return, scotch yoke type.

B. FAILURE POSITIONS:

1. Signal Failure: FCS. Fails CLOSE on loss of control signal.

2. Motive Power Failure: FCP. Fails CLOSE on loss of motive power.

C. ACTUATOR INGRESS RATING:

1. Actuator shall be rated ≥ IP66 environmental exposure.

D. ACTUATOR TEMPERATURE RATING:

1. Actuator temperature rating range shall be ≥ 0° to 150°F.

E. ACTUATOR PRESSURE RATING:

1. Actuator shall be rated for ≥ 100 psig.

F. BODY & COVER:

1. Body shall be fabricated from ductile iron or CF8M stainless steel, with ISO 5211 mounting.

G. BODY FASTENERS:

1. Body fasteners shall be stainless steel.

H. SCOTCH YOKE:

1. Scotch Yoke shall be fabricated from ductile iron or 17-4 PH stainless steel, with canted yoke design.

I. THRUST PIN:

1. Thrust pin shall be bronze or stainless steel.

J. THRUST PIN BEARINGS:

1. Thrust pin bearings shall be bronze or roller bearing stainless steel.


40 05 66 - 10

K. STOPS:

1. Stops shall be adjustable in both directions.

L. OUTPUT SHAFT ADAPTER:

1. Output shaft adapter shall be fabricated from Type 17-4 PH stainless steel or Type 304L stainless steel.

M. OUTPUT BEARINGS:

1. Output bearings shall be fabricated from PTFE bronze or PTFE composite.

N. PRESSURE CYLINDER & END CAPS:

1. Pressure cylinder shall be carbon steel, hard chrome plated and honed cylinders with ductile iron end caps, or Type 316 stainless steel construction.

O. PISTONS:

1. Pistons shall be ductile iron with dual wear bands and nitrile seals, or CF8M stainless steel construction.

P. PISTON ROD:

1. Piston rod shall be alloy steel with PTFE or bronze bushings, or stainless steel construction.

Q. SPRING CYLINDER & END CAPS:

1. Spring cylinder shall be carbon steel or stainless steel, all-welded construction.

R. SPRINGS:

1. Springs shall be fabricated from alloy steel or stainless steel.

S. SIZING:

1. Actuators shall be sized as follows:

a. Step 1: Multiply the valve peak torque requirement times two (Safety Factor = 2.0) at 80 psig supply air. Preliminarily select an actuator meeting or exceeding this requirement. Go to Step 2.


40 05 66 - 11

b. Step 2: If the selected actuator pneumatic & spring return torque outputs are ≤ 95% of the valve MAST (Maximum Allowable Stem Torque) value, then use this actuator, and go to Step 5. If not, then go to Step 3.

c. Step 3: If the selected actuator pneumatic or spring return torque outputs are > 95% of the valve MAST (Maximum Allowable Stem Torque) value, then reduce the Safety Factor in increments. Select an actuator with a spring return torque output of approximately 70% to 95% of the valve MAST value. Go to Step 4.

d. Step 4: Reduce the supply air pressure in increments. Select a supply air pressure with a pneumatic torque output of approximately 70% to 95% of the valve MAST value. Record the selected supply air pressure in the actuator documentation. Provide a 16 gauge, 1” x 4” engraved aluminum tag with a hole in one end, and with the label “SET AT XX PSIG” in 3/8” high letters for attachment to the supply air filter pressure regulator valve. Go to Step 5.

e. Step 5: END.

2. Submit computer sizing program printout reports. Also submit technical data sheets showing torque requirements and torque capacities to verify computer printout reports.

T. COATING:

1. Coating for carbon steel shall be epoxy primer with polyurethane top coat.

2. Coating for stainless steel is not required.

U. SOLENOID VALVE:

1. Solenoid pilot valves shall have aluminum bodies. Solenoid valves shall be 3-way, five ¼” NPT ports, two-position style with manual override and standard NAMUR interface. Flow configuration shall vent treated air to the non-pressurized side of the piston to reduce corrosion. Valves shall be rated for 30 psig to 116 psig minimum range.

2. Provide single solenoid coil. Coil shall be rated NEMA 4-4X-7, Class 1, Division 1, Group D. Coil ambient temperature range shall be 0°F to +122°F minimum. Coil Voltage shall be 120 VAC-60Hz.

3. Provide spring-loaded check valves and speed control needles and mufflers on each exhaust port. Pneumatic check valves shall prevent atmospheric air contamination of the unpressurized air chamber.


40 05 66 - 12

a. Spring-loaded check valves shall be ¼” NPT brass body, rated for 250 psig and 0 to 180°F. Seal shall be nitrile. Flow rate shall be 30 scfm @ 100 psig pressure drop. Cracking pressure shall be 1 to 2 psig. Parker model 3047; Schrader Bellows model 3047; or equal.

b. Combination speed control needle valve and muffler shall be ¼” NPT brass body.

V. SOLENOID VALVE ACTUATOR SPEED CONTROL BLOCK:

1. Solenoid valve actuator speed control block shall provide adjustable opening and closing speed control for spring-return actuator applications.

2. Speed control block body shall be designed for NAMUR sandwich mounting in between the solenoid pilot valve and the NAMUR mounting block. Speed control block body shall be fabricated from anodized aluminum. Body seals shall be nitrile.

3. Two speed control needles, fabricated from brass, with knurled knobs and locknuts.

4. Speed control block shall be rated NEMA 4-4X.

W. NAMUR TO ¼” NPT ADAPTER:

1. Adapter block shall convert NAMUR connection to two ¼” NPT connections for remote mounting of the solenoid pilot valve. ¼” BSP connections are not acceptable.

2. Adapter block shall be fabricated from aluminum.

X. VALVE STATUS MONITORS:

1. Provide two adjustable SPDT micro-switch position switches.

2. Visual position indicators shall be high visibility type, with clear polycarbonate or Ektar domes or cylinders. Covers with decals or paint are not acceptable.

3. Enclosure shall be aluminum, and shall be rated NEMA 4-4X-7, Class 1, Division 1, Group D. Plastic enclosures are not acceptable.

Y. ACCESSORIES:

1. Include ISO 5211 Type 304 stainless steel mounting brackets, shaft couplings, etc.

Z. ACCEPTABLE PRODUCTS:

1. Actuators: Bray series 98; Bettis series G; Morin model S; or equal, modified as required to meet the specifications.


40 05 66 - 13

2. 3-Way Solenoid Valves: Bray series 63; Valtorc series 9AAG-EXP; or equal, modified as required to meet the specifications.

3. Solenoid Valve Actuator Speed Control Block: Valworx model 529600; UniTorq model UT-SC-SR; MaxAir model CF3; or equal, modified as required to meet the specifications.

4. NAMUR to ¼” NPT Adapter: Flow Line Controls, Inc. model NP1/4; or equal, modified as required to meet the specifications.

5. Valve Status Monitors: Bray series 50-0700; Moniteur series Sentinel VPT; or equal, modified as required to meet the specifications.

2.05 TYPE 050AFR + O ALUMINUM DOUBLE RACK & PINION ACTUATOR AND STAINLESS STEEL SCOTCH YOKE ACTUATOR SUPPLY AIR ASSEMBLY (PROVIDED BY THE DISTRICT)



2) OIL REMOVAL FILTERS: McMaster-Carr model 8282K63 with model 4910K98 bracket; Norgren Excelon model F74H-4AD-AD0 with model 4324-50 bracket; or equal, modified as required to meet the specifications.


1) Filter regulators shall be “piggyback” style relieving units, with aluminum body and ½ inch FNPT connections, aluminum bowl, sight gauge, automatic drain, 5 micron filter, secondary pressure gauge, and T-handle or knob adjustment. Primary pressure rating shall be minimum 175 psig. Secondary pressure range shall be 5 to 150 psig. Flow rate shall be ≥ 55 scfm @ 10 psig droop. Set regulator @ 80 psig. Filter element shall be 5 microns. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the inlet of the oil removal filter.

2) Oil removal filters shall be aluminum body with ½” FNPT connections, with aluminum bowl, sight gauge, automatic drain, visual service life indicator, and mounting bracket. Pressure rating shall be minimum 250 psig. Flow rate shall be ≥ 55 scfm saturated air @ 80 psig inlet and 6 psig pressure drop. Filter element shall be 0.01 microns.

2.06 TYPE 050AFR + O + D + F + O STEEL SCOTCH YOKE ACTUATOR SUPPLY AIR ASSEMBLY (PROVIDED BY THE DISTRICT)



40 05 66 - 14

1) SUPPLY CHECK VALVE: DFT Valves model SCV; or equal, modified as required to meet the specifications.


3) OIL REMOVAL FILTER: McMaster-Carr model 8282K63 with model 4910K98 bracket; Norgren Excelon model F74H-4AD-AD0 with model 4324-50 bracket; or equal, modified as required to meet the specifications.

4) DESICCANT DRYER: Van Air Systems model ID15-SW; or equal, modified as required to meet the specifications.

5) POST FILTER: McMaster-Carr model 4958K42; Norgren Excelon model F74G-4AN-QD1; Speedaire model 4Zl49; or equal, modified as required to meet the specifications.

1) RESTRICTION ORIFICE UNION: HART Industrial Unions model Sure Seal Orifice O-Ring Union; Lamda Square Inc. model Restriction Orifice Union; or equal, modified as required to meet specifications.


1) Check valve shall be spring assisted in-line type, fabricated from ASTM A351 CF8M stainless steel with ½” FNPT ends. Disc shall be fabricated from ASTM A351 stainless steel. Spring shall be fabricated from Type 316 stainless steel. Valve cracking pressure range shall be approximately 0.25 to 0.75 psig. O-ring shall be nitrile. Check valve pressure shall be rated ≥ 150 psig @ 200°F. Flow capacity CV = 7. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the inlet of the filter regulator housing.

2) Filter regulators shall be “piggyback” style relieving units, with aluminum body ½ inch FNPT connections, aluminum bowl, sight gauge, automatic drain, 5 micron filter, secondary pressure gauge, and T-handle or knob adjustment. Primary pressure rating shall be minimum 175 psig. Secondary pressure range shall be 5 to 150 psig. Flow rate shall be ≥ 55 scfm @ 10 psig droop. Set regulator @ 80 psig. Filter element shall be 5 microns. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the inlet of the oil removal filter.

3) Oil removal filters shall be coalescing type fabricated with aluminum body with ½” FNPT connections, with aluminum bowl, sight gauge, automatic drain, visual service life indicator, and mounting bracket. Pressure rating shall be minimum 250 psig. Flow rate shall be ≥ 55 scfm saturated air @ 80 psig inlet and 6 psig pressure drop. Filter element shall be 0.01 microns. Include


40 05 66 - 15

ASTM B241 Schedule 80 aluminum pipe nipple for connection to the desiccant filter housing.

4) Desiccant dryer housing shall be fabricated from powder-coated aluminum, end connections shall be ½” FNPT. Desiccant shall be replaceable color indicating silica gel cartridge type with color change-out sight window. Loose fill silica is NOT ACCEPTABLE. Desiccant capacity shall be ≥ 23 ounces of silica gel. Pressure dew point shall be ≤ - 40 °F @ 15 scfm. Flow capacity shall be ≥ 15 scfm @ 80 psig. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the post filter.

5) Post Filter shall be fabricated from aluminum, end connections shall be ½” FNPT, with aluminum bowl with liquid level indicator and ¼ turn manual drain valve. Filter element shall be 5 micron sintered polypropylene. Flow capacity shall be ≥ 25 scfm @ 80 psig and < 1 psig pressure drop. Pressure rating shall be minimum 250 psig. Temperature range shall be > 0°F to 150°F. Include ASTM B241 Schedule 80 aluminum pipe nipple for connection to the restriction orifice union.

6) Restriction Orifice Union shall be fabricated from ASTM A182 Type 316 stainless steel with ½” FNPT end connections. Body shall be rated Class 3000 and shall be double O-ring style for sealing against both sides of the restriction orifice plate. O-rings shall be fabricated from nitrile. Restriction orifice plate shall be Type 316 stainless steel and diameter shall be 0.0995 to 0.100 inches. Approximate flow capacities are 10.9 scfm at 80 psig in, 0 psig out; 10.8 scfm at 80 psig in, 20 psig out; 10.1 scfm at 80 psig in, 40 psig out; 8.0 scfm at 80 psig in, 60 psig out; 4.3 scfm at 80 psig in, 75 psig out. Restriction orifice union shall limit the supply air flow to < 15 scfm in order to stay within the capacity of the desiccant dryer and maintain the - 40°F pressure dewpoint performance rating.

PART 3 -- EXECUTION

3.01 INSTALLATION

A. Valves, actuators, solenoid valves, valve status monitors and supply air filter regulator dryer assemblies shall be installed, connected, aligned, adjusted, and tested in accordance with the manufacturer's instructions.

B. Flanged fire-rated valves must be installed with fire-rated flange gaskets in order to maintain the API 607 rating. Use Fire-rated Stainless Steel/Graphite flange gaskets, per COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).


40 05 66 - 16

C. Adjust the scotch yoke actuator supply air flow rate into the actuator to approximately 10 scfm, using the solenoid actuator speed control block supply needle valve.

D. Adjust actuator closing speeds per paragraph 1.03 Design Requirements Table, using both the solenoid actuator speed control block exhaust needle valve and the speed control needle valve/muffler.

**END OF SECTION**

01/28/19


40 06 60.13 - 1

SECTION 40 06 60.13

POWER ACTUATED VALVE AND GATE SCHEDULES

PART 1 -- GENERAL


A. SCOPE:

1. This section is a schedule of the control valves for this work.

1.02 REFERENCES (NOT USED)

1.03 SUBMITTALS


1. Power actuated valve and gate schedule shall be submitted as specified in the ACTUATORS FOR PROCESS VALVES AND GATES Section (40 05 57).


PART 2 -- PRODUCTS

2.01 VALVE SIZING

A. Where the specific valve is smaller or larger than the connected pipe, the Contractor shall provide reducers and increasers.

PART 3 -- EXECUTION

3.01 GENERAL

A. Valve types are defined in their respective specification sections.

B. Actuator types are defined in the ACTUATORS FOR PROCESS VALVES AND GATES Section (40 05 57).

C. For schedule, see next page.

01/28/19


40 06 60.13 - 2




01/28/19


40 06 60.13 - 3

CONTROL VALVE & GATE SCHEDULE Valve

Number Service Valve Size,

(inches) Valve Type Actuator Type OPEN

Stroke Time, (seconds)

CLOSE Stroke Time,

(seconds)

Failure Positiona

Dutyb Notes

CV87314A GF 1 Isolation 12 GP-150-FKM PCQOS 2-5 10-15 FCP-FCS O/C CV87315A GF 2 Isolation 12 GP-150-FKM PCQOS 2-5 10-15 FCP-FCS O/CCV87316A GF 3 Isolation 12 GP-150-FKM PCQOS 2-5 10-15 FCP-FCS O/CCV87318 FSG Flow to GF 1 12 GP-150-FKM PCQMS 2-5 10-15 FLP MCV87319 FSG Flow to GF 2 12 GP-150-FKM PCQMS 2-5 10-15 FLP MCV87320 FSG Flow to GF 3 12 GP-150-FKM PCQMS 2-5 10-15 FLP M

CV870007A WGB Backpressure Valve 24 HPDO PCQML 1 20-30 FOP-FOS MCV87521A Scrubber Inlet Fire Valve 24 HPDO-FS PCQOL 5-10 20-30 FCP-FCS O/CCV87522A Scrubber Inlet Fire Valve 24 HPDO-FS PCQOL 5-10 20-30 FCP-FCS O/CCV87523A Scrubber Outlet Fire Valve 24 HPDO-FS PCQOL 5-10 20-30 FCP-FCS O/CCV87524 MSG Building Fire Valve 24 HPDO-FS PCQOL 5-10 20-30 FCP-FCS O/C

POP870012 FSG Fire Valve 12 HPDO-FS PCQOS 2-5 10-15 FCP-FCS O/CPOP870013 FSG Fire Valve 12 HPDO-FS PCQOS 2-5 10-15 FCP-FCS O/CCV87068 MSG Building Fire Valve 12 HPDO-FS PCQOS 2-5 10-15 FCP-FCS O/CCV87069 MSG Building Fire Valve 12 HPDO-FS PCQOS 2-5 10-15 FCP-FCS O/CCV87007 Recycle Valve 6 SS-F-30°V PCQMS 5-10 5-10 FCP-FCS MCV80110 Dump Valve 6 SS-F-60°V PCQMS 5-10 5-10 FCP-FCS M

CV870015A FSG PRV 1 6 SS-F-30°V PCQMS 5-10 5-10 FCP-FCS MCV870017A FSG PRV 2 6 SS-F-60°V PCQMS 5-10 5-10 FCP-FCS MCV870018A FSG High Pressure Bleed 1 SS-F PCQOS 1 2-5 FCP-FCS O/CCV870019A FSG High Pressure Bleed 1 SS-F PCQOS 1 2-5 FCP-FCS O/C

V80201A WGB 1 Isolation 8 GP-150-FKM PCQOS 1-2 5-10 FOP-FOS O/CV80202A WGB 2 Isolation 8 GP-150-FKM PCQOS 1-2 5-10 FOP-FOS O/CV80205A WGB 5 Isolation 8 GP-150-FKM PCQOS 1-2 5-10 FOP-FOS O/CV80206A WGB 6 Isolation 8 GP-150-FKM PCQOS 1-2 5-10 FOP-FOS O/CV80207A WGB 7 Isolation 8 GP-150-FKM PCQOS 1-2 5-10 FOP-FOS O/CV80208A WGB 8 Isolation 8 GP-150-FKM PCQOS 1-2 5-10 FOP-FOS O/C

aFailure position: FCP = Fail close on loss of power FCS = Fail close on loss of signal FOP = Fail open on loss of power

FOS = Fail open on loss of signal FLP = fail to last position

bDuty: M = modulating

O/C = open-close T = throttling (open-stop-close) N/A = not applicable

**END OF SECTION**

01/28/19


40 06 60.13 - 4



40 06 70 - 1

SECTION 40 06 70

SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS

PART 1 -- GENERAL


A. SCOPE:

1. This schedule describes instruments and devices furnished and installed under this contract. Scheduled instruments shall be provided as described in the schedule and in the referenced specification. The list is ordered by instrument loop number.

2. These schedules shall not be interpreted as a set of complete data sheets for the instruments but only as a listing of instruments with certain salient features described. Additional elements such as power supplies, or isolators, mounting hardware, cord sets, and other such elements as may be required by a particular vendor in order to complete the system shall be provided even though not listed.




PART 2 -- PRODUCTS (NOT USED)

PART 3 -- EXECUTION

3.01 GENERAL

A. SCHEDULE COLUMN DESCRIPTIONS:

1. TAG NO: Instrument tag numbers include the instrument loop numbers and individual instrument prefixes and suffixes as described on the contract drawings.

2. DESCRIPTION: Identifies the common name for the individual instrument or device.

3. SPEC: Lists the specification section where the instrument or device is specified. For INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 70 00) references, the paragraph number is also referenced.


40 06 70 - 2

4. VOLTS: The required voltage for an instrument or the voltage limit of the instrument.

5. RANGE: The normal operating range of the instrument or device.

6. SET PTS: The alarm and trip set points for instruments and devices.

7. UNITS: Engineering units for specified range or set points.

8. SIZE: Line size if significant or probe length or other significant size factor.

9. P&ID DWG: References the Process and Instrumentation Diagram where the instrument or device is functionally diagrammed.

10. INTER DWG: Interconnect drawing, instrument loop sheet or wiring drawing where power and terminations reference drawing.

11. DETAIL: Installation Detail drawing reference

12. PLAN: Plan or location drawing

13. NOTES: Specific information on the instrumentation or device not covered in the other columns. Specific functions, process parameters, materials, input and output signals and construction shall be provided as listed.

B. INSTRUMENTATION FOR PROCESS SYSTEMS SCHEDULE (attached).




**END OF SECTION**

INSTRUMENTATION FOR PROCESS SYSTEMS SCHEDULE

ITEM TAG NO PREFIX AREA NUMBER SUFFIX DESCRIPTION SPEC TYPE PWR SOURCE RANGE SETPOINT UNITS SIZE P&ID INTER DWG DETAIL PLAN NOTES1 PI870022 PI 87 0022 LSG-1 SCRUBBER INLET PRESSURE GAGE 40 70 00 - 2.02(B) ---- ---- "0-20" ---- "WC ---- 66X2813 PIT870022 PIT 87 0022 LSG-1 SCRUBBER INLET PRESSURE TRANSMITTER 40 70 00 - 2.02(A) 4 - 20mA LOOP POWERED "0-20" ---- "WC ---- 66X2812 PI830021 PI 83 0021 LSG-2 SCRUBBER INLET PRESSURE GAGE 40 70 00 - 2.02(B) ---- ---- "0-20" ---- "WC ---- 66X2814 PIT830021 PIT 83 0021 LSG-2 SCRUBBER INLET PRESSURE TRANSMITTER 40 70 00 - 2.02(A) 4 - 20mA LOOP POWERED "0-20" ---- "WC ---- 66X2815 PI870020A PI 87 0020A LSG SCRUBBER OUTLET HEADER PRESSURE GAGE 40 70 00 - 2.02(B) ---- ---- "0-20" ---- "WC ---- 66X2826 PI870020A PI 87 0020A LSG SCRUBBER OUTLET HEADER PRESSURE GAGE 40 70 00 - 2.02(B) ---- ---- "0-20" ---- "WC ---- 66X2827 PIT870020B PIT 87 0020B LSG SCRUBBER OUTLET HEADER PRESSURE TRANSMITTER 40 70 00 - 2.02(A) 4 - 20mA LOOP POWERED "0-20" ---- "WC ---- 66X2828 PIT870020B PIT 87 0020B LSG SCRUBBER OUTLET HEADER PRESSURE TRANSMITTER 40 70 00 - 2.02(A) 4 - 20mA LOOP POWERED "0-20" ---- "WC ---- 66X282

13 PI870000 PI 87 0000 MSG COMPRESSED GAS PRESSURE GAGE 40 70 00 - 2.02(B) ---- ---- "0-20" ---- PSI ---- 66X400

9 FE870010 FE 87 0010 RECYCLE VALVE CONTROL STATION FLOW ELEMENT 40 70 00 - 2.03(A) ---- VIA TRANSMITTER SEE TRANSMITTER ---- ---- 6" 66X400

11FIT870010 FIT 87 0010 RECYCLE VALVE CONTROL STATION FLOW TRANSMITTER 40 70 00 - 2.03(A) 4 - 20mA 120VAC 0-3000 ---- SCFM ---- 66X400

INTEGRALLY MOUNTED TO FLOW ELEMENT

10 FE870011 FE 87 0011 DUMP VALVE CONTROL STATION OUTLET FLOW ELEMENT 40 70 00 - 2.03(A) VIA TRANSMITTER SEE TRANSMITTER ---- ---- 6" 66X400

12FIT870011 FIT 87 0011 DUMP VALVE CONTROL STATION TRANSMITTER 40 70 00 - 2.03(A) 4 - 20mA 120VAC 0-3000 ---- SCFM ---- 66X400


PI870014 PI 87 0014 FLARE HEADER PRESSURE GAGE 40 70 00 - 2.03(b) ---- ---- "0-40" ---- "WC ---- 66X40014 PIT870014 PIT 87 0014 FLARE HEADER PRESS 40 70 00 - 2.02(A) 4 - 20mA LOOP POWERED "0-40" ---- "WC ---- 66X400

PI870016 PI 87 0016 FLARE PRESSURE REDUCING INTERMEDIATE PRESSURE GAGE 40 70 00 - 2.03(b) ---- ----"0-5"

----PSIG

---- 66X400

15 PIT870016 PIT 87 0016 FLARE PRESS REDUCING INTERMEDIATE PRESS 40 70 00 - 2.02(A) 4 - 20mA LOOP POWERED "0-5" ---- PSIG ---- 66X400

16PIT8759 PIT 87 59 LSG COMPERSSOR SUCTION HEATER PRESSURE TRANSMITTER 40 70 00 - 2.02(A) 4 - 20mA LOOP POWERED

"0-20"----

"WC---- 66X400

17 PI870008 PI 87 0008 WGB VALVE STATION OUTLET PRESSURE GAGE 40 70 00 - 2.02(B) ---- ---- "0-20" ---- "WC ---- 66X40118 PIT870009 PIT 87 0009 WGB VLV STA INLET PRESS TRANS 40 70 00 - 2.02(A) 4 - 20mA LOOP POWERED "0-20" ---- "WC ---- 66X401

19 FE8112 FE 81 12 WGB VALVE STATION FLOW ELEMENT 40 70 00 - 2.03(A) ---- VIA TRANSMITTER SEE TRANSMITTER ---- ---- 24" 66X401

20FIT8112

FIT 81 12 WGB VALVE STATION FLOW TRANSMITTER40 70 00 - 2.03(A) 4 - 20mA 120VAC 0-3000 ---- SCFM ---- 66X401


21TE80201

TE 80 201 WASTE GAS BURNER No.1 PILOT TEMERATURE TRANSMITTER40 70 00 - 2.04(A) 4 - 20mA LOOP POWERED 32-2400 ---- DEG F ---- 66X402

MOUNT PER BURNER VENDOR REQUIREMENTS

22TE80202



23TE80205



24TE80206



25TE80207



26TE80208



CALIBRATION DRAWINGS

01/28/19Gas Management SystemRehabilitation and Improvements 40 06 70 - 1



40 61 13 - 1

SECTION 40 61 13

PROCESS CONTROL SYSTEM GENERAL PROVISIONS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies general requirements which are applicable to providing a complete, functional process control, instrumentation, communication, and signal system for the Plant Computer Control System (PCCS) expansion. The PCCS consists of Emerson Ovation distributed controllers, workstations, servers providing HMI and supervisory functions, and Rockwell Automation programmable logic controllers and I/O subsystems providing machine and process control functions.

2. The section applies to all Division 40 specification sections numbered 40 06 70, and 40 61 13 through 40 79 00, and where referenced from additional specification sections.

3. Electrical requirements applicable to this work are specified in the Division 26 Electrical Specifications.

B. DESCRIPTION OF THE CONTROL SYSTEM WORK:

1. New instrumentation and valve actuators associated with the MSG compressor building as shown on the Contract Drawings will be programmed by the Contractor as additions and revisions to an existing District supplied Rockwell RSLogix 500 program. Contractor shall provide the completed RSLogix 500 program a minimum of 60 days prior to loading the program on the “live” PLC-5. This will allow the District to test the program on the software development system prior to loading on the PCCS.

2. New instrumentation and valve actuators associated with the waste gas burners (WGBs) ControlLogix PLC will be programmed by the Contractor using the Contractor supplied Rockwell Studio 5000 programs.

3. New instrumentation and valve actuators associated with the ground flares ControlLogix PLCs will be programmed by the ground flare Vendor using the Vendor supplied Rockwell Studio 5000 programs.

4. CONTROL PANELS:

The control panels required are shown on the Contract Drawings, and specified in CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00).


40 61 13 - 2

1) The ControlLogix PLC equipment is specified in PROGRAMMABLE LOGIC CONTROLLER Section (40 63 43).

2) The PLC-5 I/O modules are show on the drawings.

The instruments, instrument valves, and fittings required are shown on the Contract Drawings, listed in SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70), and specified in the INSTRUMENTATION OF PROCESS SYSTEMS Section (40 70 00).

Furnished Allen-Bradley PLC-5 I/O subsystems components are shown on the Contract Drawings and specified in PROGRAMMABLE LOGIC CONTROLLER Section (40 63 43). New PLC-5 inputs and outputs are specified in the PLC INPUT/OUTPUT LIST Section (40 61 93.20).

Programming modifications to the existing PLC-5 program are required as part of this work and are specified in the PLC CONTROL NARRATIVES Section (40 61 96.20).

New Allen-Bradley ControlLogix PLC controllers and I/O subsystems components are shown on the Contract Drawings and specified in PROGRAMMABLE LOGIC CONTROLLER Section (40 63 43). New ControlLogix PLC inputs and outputs are specified in the PLC INPUT/OUTPUT LIST Section (40 61 93.20).

Programming of the new ControlLogix PLC is required as part of this work and are specified in the PLC CONTROL NARRATIVES Section (40 61 96.20).

5. CONTRACTOR RESPONSIBILITIES: Contractor shall manage and be contractually responsible to the District for all System Integrator and Subsystem Manufacturer activities and responsibilities listed below.

SYSTEM INTEGRATOR:

1) Provide services that include project management, submittal development, equipment supply, control and instrument panel manufacturing, PLC programming, integration, instrument configuration, installation and installation supervision, training, testing, startup, and maintenance during warranty period as specified.

2) Be the single point of contact responsible for coordination and communications among the Contractor, District and the subsystem providers (vendor package systems).

3) Select equipment make and model for PLC modules and cabling, and instrumentation that meet the requirements of the specifications, specified application, and the installation environment.

4) Be responsible for the PLC hardware and software for the communications interface between the Ovation control system and the new ControlLogix PLCs.


40 61 13 - 3

5) Be responsible for the PLC programming required to provide the monitoring and control specified in the PLC CONTROL NARRATIVES (40 61 96.20).

6) Coordinate with Contractor on the selection of instruments to verify that they meet the requirements of the INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 70 00).

7) Be responsible for correct installation of all instruments that meet the requirements of the instrument manufacturer, INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 70 00), and standard installation detail drawings

8) Produce instrumentation and controls submittals, other than those required by the various subsystems (vendor supplied package systems).

9) Submit Rockwell Studio 5000 based PLC program and RSLogix 500 revised PLC program.

10) Program the Studio 5000 application software to customize the control logic and alarms to provide regulatory control and operator interfaces required in the equipment specifications. PLC Studio 5000 program shall conform to the Regional San EchoWater Project Allen-Bradley Programmable Logic Controller Programming Standards. Local panel OIT (HMI) program shall conform to the Regional San EchoWater HMI Programming Standards.

11) Coordinate with and provide support to the District programming team for completion of a PLC-PCCS IO data map and HMI graphic interface development for monitoring and controlling the provided PLC programs.

12) Provide field commissioning staff for manufacturer equipment installation, pre-commissioning and commissioning activities as specified in the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and the COMMISSIONING Section (01 91 00).

13) Prepare process control, equipment, and instrument test plan submittals as required in the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and COMMISSIONING Section (01 91 00)

14) Participate in all testing specified in PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and COMMISSIONING Section (01 91 00).

15) Provide services including panel modifications, instrument calibration, testing, startup, troubleshooting, corrective actions, preventive maintenance, and training. Services shall be provided by qualified personnel. Necessary test equipment shall be provided to complete all testing specified in the


40 61 13 - 4

PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and the COMMISSIONING Section (01 91 00).

16) Be responsible for the successful installation, testing, and commissioning of furnished control panels and instruments as specified in the PROCESS CONTROL SYSTEM TESTING Section (40 61 21).

17) Collaborate with and support the District Emerson Ovation programming team, and the subsystem manufacturers throughout testing and commissioning of the PCCS.

SUBSYSTEM MANUFACTURERS (VENDOR SUPPLIED PACKAGE SYSTEMS)

1) Submit Rockwell Studio 5000 based PLC program(s) which monitor and control the vendor package equipment for review.

2) Program the Studio 5000 application software to customize the control logic and alarms to provide regulatory control and operator interfaces required in the equipment specifications. PLC Studio 5000 program shall conform to the Regional San EchoWater Project Allen-Bradley Programmable Logic Controller Programming Standards. Local panel OIT (HMI) program shall conform to the Regional San EchoWater HMI Programming Standards.

3) Install approved fully configured and tested PLC control logic application programs for integration with the PCCS.

4) Submit annotated printouts of standard vendor supplied HMI displays to the District programming team. Annotation shall identify online functionality and HMI options. Coordinate with and provide support to the District programming team for completion of PCCS IO interface and HMI graphic development for monitoring and controlling the subsystem PLC program.

5) Provide field commissioning staff for manufacturer equipment installation, pre-commissioning and commissioning activities as specified in the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and the COMMISSIONING Section (01 91 00).

1.02 REFERENCES


Reference Title


40 61 13 - 5

Reference Title

ANSI/IEEE S121 Comprehensive Dictionary of Measurement & Control, STD 100

API RP 551 Process Measurement Instrumentation

FM Factory Mutual

ISA RP7.1 Pneumatic Control Circuit Pressure Test

ISA S5.4 Instrument Loop Diagrams

ISA S7.4 Air Pressures for Pneumatic Controller and Transmission Systems

ISA S20 Specification Forms for Process Measurement and Control Instrumentation, Primary Elements, and Control Valves

ISA 50.1 Compatibility of Analog Signals for Electronic Industrial Process Instruments

ISA S51.1 Process Instrumentation Terminology

MILSPEC

MIL-I-46058C

Electrical Insulating Compound

NEC National Electrical Code (NFPA 70)

NEMA ICS 1 Industrial Control and Systems: General Requirements

UL Underwriters Laboratories

B. DEFINITIONS:

1. GENERAL: Definitions of terminology related to Instrumentation and Industrial Electronic Systems used in the specifications as defined in IEEE 100, ISA S51.1, and NEMA ICS.

2. AREA CONTROL CENTER (ACC): ACC consists of a control room, control system room, electrical room, and several offices and meeting areas for operations staff and supervisors.

3. CONTROL CIRCUIT: Any circuit operating at 80 volts AC or DC or more, whose principal purpose is the conveyance of information and not the conveyance of energy for the operation of an electrically powered device.

4. DATA SHEETS: Data sheets as used in this specification shall include all information shown in the latest version of ISA S20.

5. DISCRETE CONTROL LOOP: Discrete control circuit or circuits, along with all associated switches, instruments, relays, timers, and other control devices, and including related logic in a programmable controller or other programmable devices. A "discrete" control circuit conveys two-state (ON/OFF, TRUE/FALSE,


40 61 13 - 6

etc.) information. The function of a discrete control loop is usually to monitor and control one or more pieces of mechanical equipment. For the purposes of the contract, the circuits and logic shown on each Control and Logic Diagram and circuits and logic contained within panels depicted on these diagrams, shall be considered a single discrete control loop, unless the diagrams represent multiple pieces of equipment, in which case each piece of equipment on the diagram shall be considered to have its own discrete control loop.

6. FOUR-WIRE TRANSMITTER (EXTERNALLY POWERED): A transducer which derives operating power from separate power supply connections. A four-wire transmitter produces a 4 to 20 milliampere current regulated signal in a series circuit with a maximum circuit resistance of 600 ohms. Four-wire transmitters typically require 120Vac or 24Vdc input power supply.

7. GALVANIC ISOLATION: Pertaining to an electrical node having no direct current path to another electrical node. As used in this specification, galvanic isolation refers to a device with electrical inputs and/or outputs which are galvanically isolated from ground, the device case, the process fluid, and any separate power supply terminals, but such inputs and/or outputs are capable of being externally grounded without affecting the characteristics of the device or providing a path for circulation of ground currents. The terms "electrical isolation", "isolation", or similar terms shall mean galvanic isolation whenever used in Division 40, or whenever used in specifications for electrical control and instrumentation equipment in any other Divisions of these contract documents. Unless otherwise specified, galvanic isolation for analog signal devices shall be rated 250 volts AC continuous, and fully isolated, in accordance with ISA S50.1.

8. INSTRUMENT AND CONTROL PANEL: An instrument support system which may be a flat surface, a partial enclosure, or a complete enclosure for instruments and other devices used in process control systems including consoles, cabinets and racks. Panels provide mechanical protection, electrical isolation, and protection from dust, dirt, moisture, and chemical contaminants which may be present in the atmosphere.

9. INSTRUMENT INSTALLATION DRAWINGS: Instrument installation drawings shall show the mounting and piping details of field mounted instruments and instrument racks.

10. PCCS: Plant Computer Control System which consists of the Emerson Ovation distributed control system for all HMI and supervisory control, and Allen-Bradley PLC-5 (existing) and ControlLogix PLCs for all field equipment interfaces and regulatory control. All area and subsystem operator workstations and panel mounted personal computer HMI displays are configured in the Emerson Ovation software, unless specified otherwise.

11. SIGNAL CIRCUIT: Any circuit operating at less than 80 volts AC or DC that conveys analog or digital information or communications.


40 61 13 - 7

12. SIGNAL TYPES: The following types of signals are used in systems specified in this division. All definitions below are for circuits operating at less than 80 volts DC or AC.

LOW LEVEL ANALOG: A signal that has a full output level of 100 millivolts or less. This group includes thermocouples and resistance temperature detectors.

HIGH LEVEL ANALOG: Signals with full output level greater than 100 millivolts but less than 50 volts, including 4-20 milliamps DC transmission.

DIGITAL CODE: Coded information such as that derived from the output of an analog to digital converter or the coded output from a digital computer or other digital transmission terminal. This type includes those cases where direct line driving is utilized and not those cases where the signal is used to modulate a carrier.

PULSE FREQUENCY: Counting pulses such as those emitted from speed transmitters.

DISCRETE CONTROL OR EVENTS: Isolated contact closures and signals monitored by solid state equipment, relays, or control circuits operating at less than 30 volts and 250 milliamperes.

HIGH LEVEL AUDIO SIGNALS: Audio signals exceeding plus 4 dBm, including loudspeaker circuits.

13. SUBSYSTEM CONTROL SYSTEM: A system of equipment and hardware provided by a manufacturer or vendor used to monitor and control an associated package equipment system, and which is connected to the PLC network and communicates using EtherNet/IP protocol. The subsystem communicates with the Emerson Ovation system for remote monitoring and supervisory control.

14. TWO-WIRE TRANSMITTER (LOOP POWERED): A transducer which derives its operating power supply from the signal transmission circuit and therefore requires no separate power supply connections. As used in this specification, two-wire transmitter refers to a transmitter which provides a 4 to 20 milliampere current regulation of signal in a series circuit with an external 24 volt direct current driving potential and a maximum external circuit resistance of 600 ohms.

1.03 SUBMITTALS

A. Schedule, organize, and attend a process control submittal requirements review meeting (assume a duration of 4–8 hours) with the Engineer no earlier than 30 days and no later than 90 days after Notice to Proceed.

B. Coordinate submittals for all instrument, control system, fieldbus networking, and equipment suppliers to provide the required information in the operation and maintenance manual submittal for this specification section.


40 61 13 - 8

C. The instrumentation and control system functions are shown on the drawings and specified in Division 40. The System Integrator drawings and integration practices shall be as defined in IEEE 100, ISA S51.1, and NEMA ICS 1.

D. All equipment with power, control and/or signal electrical interconnections shall have required drawings submitted as specified in Section 01 33 00.

Diagrams shall carry a uniform and coordinated set of wire numbers and terminal block numbers in compliance with panel wiring specified in the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00), to permit cross-referencing between contract documents and the drawings prepared by the Contractor.

Drawings shall conform to District drawing and database standards, available from the District upon request.

Drawings shall conform to the common contract standard drawings and the requirements of the PROJECT RECORD DOCUMENTS Section (01 78 39).

Individual drawings for all furnished instruments and equipment are required. No typical drawings shall be accepted.

Include in the submittal all applicable data used to develop the drawings.

E. Approved instrumentation and control submittals.

F. Hardcopy and electronic copy of final configuration files for PLC-5 program, new ControlLogix PLC program, and vendor supplied ControlLogix PLC programs.

G. Operation and maintenance (O&M) instructions as specified herein.

H. Approved as-built drawings and schedules


A. Submit operation and maintenance (O&M) instructions in accordance with the OPERATION AND MAINTENANCE DATA Section (01 78 23) by submitting a copy of the OPERATION AND MAINTENANCE DATA Section (01 78 23) with each paragraph check marked to show compliance. O&M instructions shall be submitted after all submittals specified above have been returned mark “No Exceptions Taken” or “Make Corrections Noted.” O&M instructions shall reflect the approved materials and equipment. O&M instructions shall include (at a minimum):

1. Manufacturer’s operation and maintenance instructions, edited for this project.

1.05 SEQUENCE OF WORK

A. Coordination meetings with Contractor, District, and subsystem manufacturers.


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B. Testing and commissioning as specified in the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and the COMMISSIONING Section (01 91 00).

PART 2 -- PRODUCTS

2.01 MATERIALS AND QUALITY

A. GENERAL:

1. Material shall be new, free from defects, and of the quality specified.

B. ELECTRONIC EQUIPMENT:

1. Be solid-state construction.

2. Designed for industrial environments.

3. Listed by and bearing the label of Underwriters’ Laboratories Incorporated (UL) or of an independent testing laboratory acceptable to the District.

2.02 ENVIRONMENTAL REQUIREMENTS

A. GENERAL:

1. All communication and process control equipment provided under this contract as a minimum shall be suitable for operation in the ambient conditions specified below:

B. ALL AREAS:

1. Atmospheric contaminants:

Hydrogen sulfide: 0.1 ppm (by weight)/0.1 mg/l

Chlorine: 0.01 ppm (by weight)/0.01 mg/l

Ammonia: 0.5 ppm (by weight)/0.5 mg/l

Dust: 50.0 ug/m3

Electromagnetic radiation

(27 Hz-500 MHz):

5 volts/m


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C. CONTROL ROOMS AND MCC ROOMS:

Temperature: 18 to 40 degrees C

Humidity: 20 to 80 percent

D. OTHER INDOOR LOCATIONS:

Temperature: 5 to 50 degrees C


E. OUTDOOR FIELD LOCATIONS:

Temperature: -7 to 50 degrees C


Instruments mounted outdoors will be subjected to direct sun radiation, wind driven rain, dust, and ice accumulation.

PART 3 -- EXECUTION

3.01 GENERAL

A. FIELD INVESTIGATION:

1. The "as-built" drawings of previous work presented in these contract documents or provided by the District during construction are not certified to be correct. Field-investigate all existing facilities to ascertain the exact physical and electrical conditions in each case.

B. DOCUMENT REVIEW:

1. Review the following contract documents and submittals to determine the integration work required for a complete and operable system.

Electrical drawings for power connections.

Mechanical drawings for pneumatic signal lines and process connections to verify the size, orientation and location of the process connections.

Process & Instrument Diagrams.


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Panel, instrument, and PLC IO schedules.

Control Strategies (programmed in the Emerson Ovation DCS) and Control Narratives (programmed by the Contractor or Vendor).

Cable and raceway schedule.

Approved submittals.

C. REVISIONS TO EXISTING DRAWINGS:

1. GENERAL: Where work is in existing panels, or otherwise interfaces with existing control system components, revise existing panel layout, connection, interconnection, loop, DCSA assembly and schematic diagrams, control & logic diagrams, schematic and other drawings as necessary to show all work. The District will provide electronic copies of applicable existing drawings. Submittals of modified District-provided drawings shall clearly delineate new work. New wires shall be drawn with lines thicker than the existing wire lines, and all new work shall be outlined with a "cloud" of connected half circles. Entries shall be made in the revision blocks giving the date and a brief description of the revisions.

D. TEST PROCEDURE:

1. Submit for review detailed test procedure and test forms in accordance with the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and the COMMISSIONING Section (01 91 00). The test procedures shall be submitted at least 60 days prior to the scheduled test.

E. AS-BUILT DOCUMENTS:

1. As-built documents shall be prepared as specified in the PROJECT RECORD DOCUMENTS Section (01 78 39)

3.02 INSTALLATION

A. GENERAL:

1. The process control system construction must be carefully coordinated with other work to avoid any interference with normal operation of on-line plant equipment and processes. Refer to the WORK RESTRICTIONS Section (01 14 00) requirements and construction schedules and constraints.

2. Manufacturer's installation instructions and the contract documents shall be strictly adhered to in the erection of all instrumentation and equipment. Where conflicts arise between the requirements of the contract documents and the manufacturer's installation instructions, the District Representative shall be consulted for resolution.


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3. Where installation procedures are not available from the manufacturer or specified, (API RP551) shall be used as a guide.

B. ELECTRICAL POWER CONNECTIONS:

1. Electrical equipment, disconnect switches, and wiring is specified in Division 26.

C. CONTROL AND INSTRUMENT AIR CONNECTIONS:

1. GENERAL: Control and instrument air connections are specified in the MISCELLANEOUS INSTRUMENTS, CALIBRATION EQUIPMENT, INSTRUMENTATION VALVES, AND FITTINGS Section (40 79 00).

2. PNEUMATIC SIGNAL TRANSMISSION: Each field transmitter or receiver which requires an air supply shall be provided with Instrument Air as specified in the Instrument Schedule section. Pneumatic tubing, fittings, and installation shall be in compliance with the MISCELLANEOUS INSTRUMENTS, CALIBRATION EQUIPMENT, INSTRUMENT VALVES, AND FITTINGS Section (40 79 00). Tubing runs shall not be tied to or supported by process piping or electrical conduit. Individual tubing runs exceeding 3 feet or where mechanical damage may occur shall be continuously supported by running in steel channels. Runs exceeding four single tubes shall be supported in raceway tracks. Unless otherwise shown, or specified, pneumatic signals shall be 3-15 psig in accordance with ISA Standards S7.4.

D. HAZARDOUS AREAS: Instruments and equipment located in hazardous areas shall be made suitable for the specified conditions by use of intrinsic safety equipment and barriers approved by Underwriters Laboratories Inc. (UL) or Factory Mutual (FM). Dual barriers shall be used in such loops. Four-wire transmitters and indicators, pilot devices, and limit or process switches shall be made suitable for the specified conditions by the use of explosion proof enclosures.

E. WIRE NUMBER: Wire numbers shall consist of four parts.

1. The prefix of the wire number shall be single letter from the following list:

a. Analysis

b. Burner (Flame)

c. Conductivity

d. Density

e. Voltage

f. Flow Rate


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g. Fire, Smoke

h. Current (Elec)

i. Power

j. Time, Time Sch.

k. Level

l. Moisture

m. Pressure, Vacuum

n. Quantity

o. Radiation

p. Speed, Frequency

q. Temperature

r. Multivariable

s. Vibration, Mech. Analysis

t. Weight, Force

u. Unclassified

v. Position

2. The second part shall be the area and core equipment number as shown on P&ID’s (existing instruments may only have the core equipment number). If an instrument loop number is not available, the lowest mechanical equipment number of all final drives in the circuit shall be used.

3. The third part shall be a signal code from the following list:

D Networked Data (Fieldbus)

S Signal, Analog

C Discrete Events and Low Voltage Control

24 VDC 24 VDC Power Supply

COM Signal Common


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4. The fourth part shall be a unique sequential.

Example of wire number without area designation (i.e. PIT8133):

Tag Number = P8133S-25

Where:

P = Pressure

8133 = Loop number

S = Signal code

25 = Unique sequential wire number

Example of wire number with area designation (i.e. FIT048283):

Tag Number = F048283S-15

Where:

F = Flow

048283 = Loop number with area designator

S = Signal code

15 = Unique wire number

Example of 24V power supply wire number (i.e. LIT3122):

Tag Number = L3122+24VDC

Where:

L = Level

3122 = Loop number

24VDC = Power supply

3.03 TESTING

A. All instrument and control system equipment provided as part of work shall be tested as specified in the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and COMMISSIONING Section (01 91 00).


40 61 13 - 15


**END OF SECTION**


40 61 13 - 16



40 61 21 - 1

SECTION 40 61 21

PROCESS CONTROL SYSTEM TESTING

PART 1 -- GENERAL


A. SCOPE:

1. This section supplements the COMMISSIONING Section (01 91 00) with testing requirements for the Plant Computer Control System (PCCS) connections, communications, integration, custom applications, and user interfaces.

2. The testing specified in this section is in addition to the system component requirements specified in the following sections:

a. The PCCS HMI screens and control logic specified in the PROGRAMMABLE LOGIC CONTROLLER CONTROL NARRATIVES Section (40 61 96.20).

b. The process instruments are specified in the INSTRUMENTATION OF PROCESS SYSTEMS Section (40 70 00) and scheduled in the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70).

c. The PLC control system equipment specified in the PROGRAMMABLE LOGIC CONTROLLERS Section (40 63 43) and the PLC control logic specified in the PROGRAMMABLE LOGIC CONTROLLER CONTROL NARRATIVES Section (40 61 96.20).

d. The control panel lights, switches and pushbuttons specified in the CONTROL PANEL Section (40 67 00).

e. The communication networks between the Contractor supplied equipment and District network equipment as shown on the drawings.

3. The Contractor shall provide labor, tools, materials, power, and services necessary to complete the systems inspection, testing, and troubleshooting specified herein.

4. The PCCS shall successfully complete all tests specified in the COMMISSIONING Section (01 91 00) and the following tests specified herein as part of the COMMISSIONING tests:

a. PRE-COMMISSIONING FACTORY ACCEPTANCE TESTING (FAT):

1) Hardware Test


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2) Software Test

3) Functional Test

4) Performance Test

5) Discrepancy Corrections

b. PRE-COMMISSIONING SITE ACCEPTANCE TESTING (SAT):

1) Network Inspection and Testing

2) Instrument Installation Inspection

3) Instrument Calibration

4) I/O Checkout

5) Loop Testing

c. PRE-COMMISSIONING SYSTEMS INTEGRATION TESTING (SIT):

1) PLC Control Narrative Testing and Remaining Loop Tuning

2) PCCS Control Strategy Testing and Remaining Loop Tuning

d. COMMISSIONING SITE INTEGRATION TESTING (SIT):

1) System Testing

2) Loop Tuning

3) PLC Control Narrative Testing

4) PCCS Control Strategy Testing

5) Performance Test

e. COMMISSIONING START-UP TESTING:

1) Reliability Acceptance Test (RAT)

B. COMMISSIONING COORDINATOR:

1. The Contractor shall provide a commissioning coordinator as specified in the COMMISSIONING Section (01 91 00).


40 61 21 - 3

1.02 REFERENCES


Reference Title

ANSI American National Standards Institute

ASTM American Society for Testing and Materials

EIA Electronics Industries Association

IEEE Institute of Electrical and Electronic Engineers

IES Illuminating Engineering Society

IEC International Electrotechnical Commission

ISA International Society of Automation

NEC National Electric Code

NFPA National Fire Protection Association

NFPA 70 National Electrical Code

NFPA 72 Fire Alarm Signaling

NFPA 820 Standard for Fire Protection in Wastewater Treatment and Collection Facilities

NFPA 101 Life Safety Code

TIA Telecommunications Industry Association

UBC Uniform Building Code

UFC Uniform Fire Code

UL Underwriters Laboratory


1.03 SUBMITTALS

A. The following information shall be submitted for review in accordance with SUBMITTAL PROCEDURES Section (01 33 00) and be submitted as part of the COMMISSIONG Section (01 90 00):



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2. GENERAL: Supplemental descriptions for test plans including SAT plans, SIT plans, and RAT plans for incorporation into the introductory section of the Commissioning Plan as specified in the COMMISSIONING Section (01 91 00). Alternatively, supplemental descriptions can be incorporate directly into the Commissioning Plan submittal and referenced for the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) submittal.

3. TEST PROCEDURES: Supplemental procedures for FAT, SAT, SIT, and RAT additional process control system testing to the procedures provided as part of the COMMISSIONING Section (01 91 00). Alternatively, supplemental procedures can be incorporated directly into the Commissioning Plan submittal and referenced for the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) submittal.

4. TEST RESULTS: Supplemental test results for the additional process control system testing to the test results provided as part of the COMMISSIONING Section (01 91 00). Alternatively, test results can be incorporated directly into the Commissioning Plan submittal and referenced for the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) submittal.


PART 2 -- PRODUCTS

2.01 TESTING DOCUMENTATION

A. The Contractor shall provide all testing documentation in accordance with the COMMISSIONING Section (01 91 00).

2.02 TEST PLANS

A. FACTORY ACCEPTANCE TEST PLAN. Individual Factory Acceptance Tests shall be required for the Waste Gas Burner PLC equipment and the Ground Flare packaged control systems. The MSG Compressor Building PLC will not have a separate FAT. Each FAT test plan shall be structured in a step-by-step manner with checkpoints at critical points.

1. As a minimum, the following information shall be included in the Factory Acceptance Test Plan for each test:

a. Test identification number

b. Test name and description

c. List of all equipment to be tested including any special test equipment required. Test displays are to be developed by the Contractor or subsystem provider for FAT testing.


40 61 21 - 5

d. FAT application program testing:

1) The PLC control logic and OIT monitoring and control will be tested as part of the FAT.

e. Description of test procedure in logical steps for testing:

1) PLC control system functionality and performance testing including PLC Networks and equipment, PLC regulatory control logic, Ethernet Fieldbus network and equipment, PLC I/O subsystems, and OIT to PLC interface.

f. Description of expected response verifying the completion of each logical step

g. Space for recording results of the test, time, date, and signature lines for approval by District and Contractor or subsystem supplier.

2. The final draft of the software and hardware documentation shall be used during these tests to ascertain the accuracy and completeness of the documentation.

B. PRE-COMMISSIONING INSPECTION AND TEST PLAN: Pre-Commissioning inspection and testing shall be required for the complete installed PCCS control system including the PLC equipment; each subsystem packaged control system; the PCCS, PLC, and Ethernet networks; systems interfaces; and instruments, valve actuators, VFDs, and motor starters. The inspection and test procedures shall be structured in a step-by-step manner with checkpoints and gates at critical milestones.

1. As a minimum, the following information shall be included in the Pre-Commissioning Test Plan for each test:

a. Description of test procedure in logical steps

1) Test procedures for each analog and discrete loop in the process control system shall be organized and assembled in separate volumes for each process area. Final test records shall be submitted in electronic form by scanning and converting the records and files to Adobe PDF format, to preserve actual signatures and signoffs

2) Test procedure documentation shall include a detailed, step-by-step description of the required test procedure, panel and terminal block numbers for points of measurement, input test values, expected resultant values, test equipment required, process setup requirements, and safety precautions

3) Test report forms for each loop, including forms for wiring, piping, and individual component tests, shall be included with the test procedure documentation. The actual test results shall be recorded on these forms and a included in the Pre-Commissioning test results


40 61 21 - 6

b. Test report forms shall be preprinted and completed to the extent possible prior to commencing testing. Test report forms that document the field test procedures shall include the following information:

1) Project Name

2) Test identification number

3) Test name and description

4) Process area associated with the equipment being tested

5) Instrument loop description

6) Instrument loop identification number

7) Instrument loop nameplate data

8) Instrument setup and configuration parameters

9) Time and data of test

10) Inspection checklist and results

11) Applicable test procedure reference

12) Test equipment used

13) Expected and actual test results

14) Space for remarks regarding test procedure or results

15) Name, date, and signature of testing personnel

16) Name and signature of District witness personnel


C. FUNCTIONAL TEST PLAN: Functional testing shall be required for the complete installed PLC equipment, instruments, and motor starters. The inspection and test procedures shall be structured in a step-by-step manner with checkpoints and gates at critical milestones.

1. As a minimum, the following information shall be included in the Functional Test Plan for each test:

a. Test identification number


40 61 21 - 7

b. Test name and description

c. List of all equipment to be tested including any special test equipment required

d. Description of test procedure in logical steps that include the requirements

e. Description of expected response verifying the completion of each logical step

f. Space for recording results of the test and the time and date of the test

g. Approval signed by the District and the Contractor or subsystem supplier.


3. Copies of all referenced and applicable contract and submittal drawings with addenda updates included and marked to indicate requested deviations from specified requirements.

2.03 TEST RESULTS

A. Provide testing documentation as required in the COMMISSIONING Section (01 91 00) as well as the testing results for testing specified herein.

B. Upon completion of each test, provide the following documentation:

1. Factory Acceptance Test Results Form

2. Site Acceptance Test Results Form

3. Functional Test Results Form

4. Site Integration Test Results Form

5. Reliability Acceptance Test Results Form

PART 3 -- EXECUTION


A. Materials, equipment, and construction included under this specification shall be inspected and tested in accordance with this section and the COMMISSIONING Section (01 91 00).

B. No required test shall be applied without prior notice to the District Representative as specified in the COMMISSIONING Section (01 91 00). Contractor shall provide a detailed test plan with step-by-step test procedures, forms for recording test results, list of testing equipment, and test result forms.


40 61 21 - 8

C. TECHNICAL QUALIFICATIONS:

1. Field instruments and analyzers shall be calibrated and set up by a certified instrument technician qualified to calibrate the instrumentation.

2. Field instrument technician shall be qualified by completion and certification from training courses offered by the International Society for Automation (ISA), the instrumentation and analyzer manufacturer, or a recognized trade school or community college that specializes in instrumentation calibration.

D. TEST EQUIPMENT AND MATERIALS:

1. Provide all tools, reference fluids, standards, and equipment required to calibrate each instrument and test each loop. Test instruments used to simulate inputs and read outputs shall be suitable for the purpose and shall have a rated accuracy of 0.1 percent of span and the measured value shall be greater than the required accuracy of the instrument being tested or calibrated. Each test instrument shall be certified by an established calibration laboratory and have a current calibration sticker showing date of calibration, deviation from standard, name of calibration laboratory and technician, and date recalibration is required. Certified calibration reports traceable to the National Institute of Standards and Technology shall be included with the final test report.

2. Provide an instrument calibration system such as Fluke 743B with Fluke DPC/Track Instrumentation Management software or similar system. The instrument calibration system captures the calibration results and electronically documents instrument data, date of calibration, calibration procedures, and as-found and as-left instrument calibration data. Completed calibration results shall be submitted with the final test results in hard copy and electronic format that does not require specialized equipment or software to read and print the files.

3. Provide buffer solutions and reference fluids for tests of analytical equipment.

4. Provide a communications and software package to record final configuration parameters and settings for smart devices including: variable frequency drives, motor starters, power quality meters, valve actuators, instruments, and analyzers with the device parameters acquired by connection of a host device to the network and record the device configuration settings without manual data entry or transcription of values.


40 61 21 - 9


3.03 PRE-COMMISSIONING SITE ACCEPTANCE TEST (SAT)

A. GENERAL:

1. REVIEW MEETING: Schedule, organize and attend a test requirement review meeting (4 to 8 hours) with the District not earlier than 30 days prior to commencement of Pre-Commissioning SAT testing. The purpose of this meeting shall be to review the SAT test plan and identify any potential conflicting work or risks posed to operations during the testing period. As a minimum, the District Representative, Contractor, and Commissioning Coordinator for the system being tested shall attend.

2. RESPONSIBILITIES OF PARTIES: The District will operate the PCCS control system, issue all control commands, and verify receipt of signals in the PCCS. District will verify the proper operation of instruments, mechanical equipment and final control elements, and provide any injected or simulated signals. Contractor personnel shall be responsible for communicating during the test, by radio or telephone with District staff stationed at PCCS operator workstations in the Plant Control Center (PCC), or other location designated by the District Representative. For any signals that do not function properly, the Contractor shall locate and correct the cause of the failure. The circuits shall then be retested and proper I/O signal functionality verified. If the test failure is due to District-installed equipment, the equipment will be corrected by the District. The District may, at its option, waive the loop test for individual PCCS or PLC I/O points.

3. TESTING SEQUENCE: Testing of wiring and piping, and individual components shall be successfully completed with certified test reports submitted to the District prior to commencement of individual loop testing. Individual loop testing shall be successfully completed with certified test reports submitted to the District prior to commencement of loop tuning.

4. TEST REPORTS: Record all test results on the appropriate test forms. If these forms are not applicable, modify these forms as necessary to document all required tests. Test reports shall be compiled by the Contractor and shall be submitted in accordance with the SUBMITTAL PROCEDURES Section (01 33 00). Include Test Reports in Pre-Commissioning Test Results submittal.

B. INSTRUMENT PIPING TESTING:

1. PNEUMATIC PIPING SYSTEMS: Pneumatic piping systems shall be tested for leaks in compliance with ISA RP7.1, except that the test shall be performed at the maximum normal operating pressure.

2. LIQUID PIPING SYSTEMS: Liquid piping systems shall be tested for leaks.


40 61 21 - 10

C. WIRING TESTING:

1. TEST PROCEDURES: Electrical power and signal cable ring-out and resistance testing shall be conducted as specified in the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00) and the ACCEPTANCE TESTING OF ELECTRICAL SYSTEMS Section (26 08 10). Wiring tests shall not be conducted until cables have been properly terminated, tagged, and inspected.

2. Manufacturer’s specifications and guidelines may supersede the specifications of the applicable governing body for the associated network but at a minimum must meet all of the governing body’s requirements

a. All node devices physically disconnected from the network

b. Manufacturer’s data and specifications for all installed network components, available on-site for use by the network testing firm

c. All qualification and testing activities will be conducted by the Contractor.

d. Manufacturer’s data and specifications for all installed network components, available on-site for use by the network testing firm.

e. A complete set of construction drawings and specifications with all addenda and change orders are available on-site for use by the network testing firm

3. INSTALLATION QUALIFICATION AND TEST PROCEDURES:

D. INSTRUMENTATION INSTALLATION INSPECTION:

1. Inspect the instrumentation installation for adherence to manufacturer’s recommendations and industry best practices. Identify deficiencies that are not acceptable to the District and must be modified or replaced prior to any instrument calibration or testing.

2. Validate instrument has correct tag name and nameplate data.

3. Confirm instrument installation conforms to the drawings, specifications, and manufacturer’s instructions.

4. Visually check instrument for physical damage, dirt accumulation, and corrosion.

5. Verify isolation amplifiers, surge protection, and safety barriers are properly installed.

6. Report deficiencies identified within 24 hours of discovery to the District Project Manager or designated representative. All deficiencies shall be addressed prior to any instrument calibration.


40 61 21 - 11

E. INSTRUMENT CALIBRATION:

1. GENERAL:

a. Calibrate all instruments furnished under this contract. Each instrument listed in the instrument schedule and all instruments supplied with mechanical (including pressure gauges) or electrical equipment shall be calibrated on site prior to installation in accordance with the manufacturer's recommended procedure. Instruments shall then be tested in compliance with ISA S51.1 and this paragraph and the data entered on the applicable test form. Alarm trips, control trips, and switches listed in the instrument schedule shall be set to initial values at this time. Final elements shall be checked for range, deadband, and speed of response.

b. Any component which fails to meet the required tolerances shall be repaired by the manufacturer or replaced, at no expense to the District, and the above tests repeated until the component is within tolerance. Systems not accessible for standard calibration shall be furnished with the manufacturer's verification of factory calibration. Proper manufacturer's reports will be acceptable as evidence of calibration when field testing is not possible.

c. If an item of existing equipment cannot be calibrated to the specified tolerances, immediately notify the District, who will have the subject item repaired or replaced or will waive the tolerances for that item.

d. At the District's discretion, existing magmeters and other existing devices which require factory calibration and cannot reasonably be field calibrated may be checked for proper calibration in lieu of full recalibration. The Contractor's method of checking for proper calibration shall be approved by the District.

2. CALIBRATION PROCEDURE: Each analog instrument shall be calibrated at 0 percent, 10 percent, 50 percent, 90 percent and 100 percent of its specified full scale. Each signal sensing trip and process sensing switch shall be adjusted to the required setting(s). All instrument calibration test data shall be entered on applicable test forms. A report shall be delivered to the District containing all instruments, listed by instrument number, certifying that each instrument has been calibrated and meets contract requirements.

F. I/O TESTING:

1. As specified in the COMMISSIONING Section 01 90 00. This will include validating the I/O from field instruments and equipment to Vendor packaged systems control panels.


40 61 21 - 12

G. LOOP TESTING:

1. Each instrument loop shall be tested as an integrated system. Check operation from field instruments to transmitter to receiving components to control panel. Test signals shall be injected at the process input to the instruments where possible, otherwise at the most primary signal access point.

2. Testing of loops with an interface to the PLC shall include verification of the PLC I/O assignment. If output control or input monitoring device fails to indicate properly, make corrections to the loop circuitry, device, or PLC program and repeat until device operates as required.

3. Each analog loop shall be tested for accuracy by injecting calibrated signals at the primary sensing element's output signal connection. Measure and record the response at each device in the loop. Where applicable, loops shall be tested for accuracy by manually setting the output of the loop controller and measuring the response at the final control element. All analog loops shall be tested at 0, 10, 50, 90 and 100 percent of span. Also, alarms, current signal trips, and other analog-to-discrete trip devices shall be tested at their set point to verify the trip point is within published tolerances.

4. The difference between the signal injected at the primary sensing element and the value displayed in the PLC shall not exceed the acceptable instrument tolerance (stated in the appropriate units or as 0-100 percent). Also, the difference between the controller output setting and the final control element response shall not exceed the calculated tolerance. If the observed difference is greater than the allowable tolerance, corrections to the loop circuitry shall be made as necessary and the test repeated until the difference is within the allowable tolerance. If any final element moves in the wrong direction or fails to move over the required range, corrections shall be made as necessary and the test repeated until final element action is correct.

5. Measure and record the resistance of each loop. For loops powered by 4-wire transmitters, this shall be accomplished by disconnecting the loop transmitter and injecting a 20mA signal with a loop calibrator. Measure and record the loop voltage at 20mA and calculate the resistance. For loops with 2-wire transmitters in the field and powered from the ACC, disconnect the transmitter and regulate (simulate) loop current to 20mA with a loop calibrator. Measure the voltage at the transmitter at 0 and 20mA and calculate the resistance at 20mA. For powered signal isolators, use the 4-wire transmitter test. Non-powered signal isolators are included in the 2-wire transmitter test. Where signal isolators are used, disconnect the output leads on the isolator and measure the loop resistance.

6. Each analog signal circuit leaving the PLC control panel connected to field transmitters and final control elements shall be tested to verify that the circuit is isolated from electrical ground. This test shall be performed after the individual component calibration and test, after all circuit components have been connected,


40 61 21 - 13

and may be performed prior to, or as part of, the loop test. The field signal leads of the circuit under test shall be disconnected from the field terminals in the PLC panel and connected together. Connect a 25-volt DC (Maximum) ohmmeter between the (joined) signal leads and the panel ground bus and measure the resistance. Values of resistance less than 2 million ohms are not acceptable. If the loop fails the test, troubleshoot and modify the circuit to achieve isolation from ground greater than 2 million ohms. Test shall be repeated until the circuit passes.

7. Digital control and logic end-to-end testing shall demonstrate proper operation of each discrete control loop to insure the proper operation of hand switches, interlocks, solenoid valves, other auxiliary devices, status lights, and alarms.

a. LOGIC TEST: For each Control and Logic Diagram demonstrate, in a step-by-step fashion, that the PLC program operates according to the PROGRAMMABLE LOGIC CONTROLLERS CONTROL NARRATIVES Section (40 61 96.20) and the depicted logic on the “X” drawings.

b. DISCRETE I/O TEST: Discrete inputs shall be tested to verify proper state when the field device is switched between states. Discrete outputs shall be tested to verify field equipment responds properly (start, stop, etc.). Record the successful completion of points by annotating the PROGRAMMABLE LOGIC CONTROLLER INPUT/OUTPUT Section (40 61 93.20).

c. MODIFICATIONS: All circuit modifications required to pass the tests shall be incorporated into the as-built drawings. A completed legible set of Control & Logic diagrams shall be attached to the test form and filed with the Master Test Log.

3.04 PRE-COMMISSIONING FUNCTIONAL TESTING

A. PLC CONTROL NARRATIVE TESTING:

1. Pre-Commissioning Function Testing shall not commence until the Pre-Commissioning SAT testing has been completed and documented to the satisfaction of the District.

2. Each PLC regulatory control application program shall demonstrate the functionality specified in the PROGRAMMABLE LOGIC CONTROLLERS CONTROL NARRATIVES Section (40 61 96.20). Control Narrative Testing consists of installing and debugging the PLC control logic program, verifying the interface points between the PLCs and field devices and equipment, and exercising the control narrative control logic and interlocks. Control Narrative Testing will be performed on one PLC at a time.

3. Provide qualified personnel to immediately correct any deficiencies in Contractor provided work that may be encountered during Control Narrative Testing.


40 61 21 - 14

B. PCCS CONTROL STRATEGY TESTING:

1. Each PCCS Emerson Ovation supervisory control application program shall demonstrate the functionality required HMI displays and reports. Control Strategy Testing is performed by the District PCCS Programmer and consists of installing and debugging the Ovation HMI, database, and control sheets, verifying the interface points between the PLCs and field devices and equipment, and exercising the control strategies. Control Strategy Testing will be performed on one PLC at a time.

2. Provide qualified personnel to immediately correct any deficiencies in Contractor-provided work that may be encountered during Control Strategy Testing. Failure of the Contractor to provide such personnel in a timely manner may prolong the time allotted to complete Control Strategy Testing

3.05 ACTIVATION TESTING

A. As specified in the COMMISSIONING Section (01 91 00).

B. LOOP TUNING TEST:

1. All control loops that could not be tuned during the SIT testing are tuned during Activation Testing.

2. Control loop tuning tests shall demonstrate stable operation of a control loop under actual operating conditions. This test shall include adjustment of closed loop tuning parameters.

a. Tuning parameters (such as proportional gain, integral time constant, and derivative time constant) for each control loop shall be adjusted to provide 1/4-amplitude damping (subsidence ratio of 4).

b. The loop response to a step disturbance shall be provided for each loop. Two graphs shall be made for cascaded control loops, one showing the secondary loop response with its set point in manual, and the second showing overall loop response.

c. Control loops with "batch" features shall be adjusted to provide optimum response following start-up from an integral action saturation condition.

d. Graph recording shall be provided showing the response and made at sufficient speed and amplitude to show 1/4 amplitude damping. Label to show loop number and title, and settings of parameters and set point.

e. Where a loop is controlled under the direction of a programmable logic controller, the District will perform the necessary adjustment of loop tuning parameters and setpoints; Contractor shall record the loop response, adjusting final elements, and assuring total integrated loop performance as specified.


40 61 21 - 15

C. PLC CONTROL NARRATIVE TESTING:

1. Each PLC regulatory control application program shall be tested during Activation Testing. Demonstrate the functionality specified in the PROGRAMMABLE LOGIC CONTROLLERS CONTROL NARRATIVES Section (40 61 96.20).

D. PCCS HMI DISPLAY TESTING:

1. Each PCCS Emerson Ovation supervisory control application program shall be tested during Activation Testing. Demonstrate the required HMI displays and reports.

E. PERFORMANCE 48-HOUR TEST:

1. After the successful completion of the functional testing, a 48-hour continuous run of the system shall be performed. The test shall be passed if no system function is lost, no hardware or software failure occurs.

2. During this test, the System shall be exercised (with simulated inputs, events, and conditions) in a manner which attempts to approximate an operational environment. Unstructured testing by District Representatives shall be included during this test to further exercise the system.

3. No software "patches" or changes will be allowed to bypass failed modules during this test. Any software and/or hardware correction made to the System shall result in the mandatory rerun of the entire 48-hour test.

F. RELIABILITY AVAILABILITY TEST (RAT):

1. After completion of the preceding testing and calibration requirements specified herein, a Reliability Availability Test (RAT) shall be run as specified in the COMMISSIONING Section (01 91 00). The RAT shall demonstrate that all functional requirements specified herein have been satisfied including:

a. Each component of the system operates correctly with all other components of the system

b. Analog control loops operate in a stable manner

c. Hard-wired and software equipment interlocks perform correctly

d. Process control descriptions in the PLC Control Narratives perform correctly

e. Operator interface graphics represent the monitoring and control functions correctly

2. The RAT will be conducted concurrently with normal system operations without special test equipment or procedures. During the test, District personnel will


40 61 21 - 16

perform the normal functions using the computer system according to the procedures described in the supplier documentation.

G. TEST SATISFACTION:

1. Success criteria for completing the Activation Testing are as specified in the COMMISSIONING Section (01 91 00).

**END OF SECTION**


40 61 26 - 1

SECTION 40 61 26

PROCESS CONTROL SYSTEM TRAINING

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies Allen-Bradley PLC applications control logic training for the O&M staff.

2. This section also includes field device operation and maintenance courses for instruments connected to the PCCS.


1.03 SUBMITTALS



2. Training course syllabuses

3. Instructor qualifications

4. Training schedules


1.05 TRAINING INSTRUCTOR QUALIFICATIONS

A. The training instructor shall submit a statement of qualifications that provides documented proof that he or she meets the following requirements:

1. Has a minimum of 2 years of experience as a technical instructor

2. Has proof of completion from the manufacturer that the instructor has been trained on the content to be presented during the course they are to teach.


40 61 26 - 2

PART 2 -- PRODUCTS – NOT USED

PART 3 -- EXECUTION

3.01 GENERAL – NOT USED

3.02 INSTALLATION – NOT USED

3.03 TRAINING

A. GENERAL:

1. This training shall be conducted at District facilities in accordance with the TRAINING Section (01 79 10).

2. Training shall be conducted by a qualified training instructor. All necessary training material shall be provided by the supplier of the training. Each trainee shall receive individual copies of the technical manuals and pertinent documents. All training materials, including the course outline, shall be sent to the trainee at least one week before the scheduled start of the particular training course. Training materials and software required for training shall be provided by the supplier. All courses shall include and emphasize the appropriate deliverable system documenta-tion defined. All hardware and software required for training shall be provided by the supplier. All courses shall be 50 percent lecture and 50 percent hands-on training unless otherwise approved by the District.

3. Supplier of training shall provide all documentation, hardware, software, and networking equipment required to train a class size of 12 students.

4. Supplier of training shall coordinate with the District for the availability of training equipment required, and provide necessary equipment if not available.

B. INSTRUMENTS TRAINING:

1. System Integrator or manufacturer shall provide minimum of 4 instruction hours for operations and maintenance of all instruments.

a. Instrument setup and configuration

b. Instrument diagnostics and maintenance

c. Instrument calibration

C. PLC APPLICATION PROGRAM TRAINING:

1. Contractor and Vendor PLC application program trainers shall provide 24 instruction hours for training on the application control logic program operations


40 61 26 - 3

and maintenance (which includes 8 hours for ground flare program, 8 hours for waste gas burner program, and 8 hours for revised compressor building PLC program). Training shall include all control logic implement including configured I/O, ladder logic configuration (as well as function block, structured text or other programming language used), hardwired interlocks, system diagnostics, maintenance, and operator interface.

**END OF SECTION**


40 61 26 - 4


01/28/19


40 61 93.20 - 1

SECTION 40 61 93.20

PROGRAMMABLE LOGIC CONTROLLER INPUT/OUPUT LIST

PART 1 -- GENERAL


A. SCOPE:

1. This schedule lists the regulatory input and output (I/O) points for the Area Programmable Logic Controllers (PLCs) and Subsystem vendor PLCs. These points are also shown on the control and logic and Process and Instrumentation Drawings (P&IDs). All listed spares shall be provided fully implemented with installed modules, required memory, and any other hardware or software necessary for use.

1.02 REFERENCES - NOT USED

1.03 SUBMITTALS - NOT USED

1.04 OPERATION AND MAINTENANCE INSTRUCTIONS - NOT USED

PART 2 -- PRODUCTS - NOT USED

PART 3 -- EXECUTION

3.01 GENERAL

A. SCHEDULE HEADER DESCRIPTIONS:

1. Panel: Panel number where the PLC is located.

2. PLC: PLC equipment number.

B. SCHEDULE COLUMN DESCRIPTIONS:

1. POINT ID: Defines the tag number (point ID). Each I/O will be assigned in the PLC.

2. DESCRIPTION: Functional description of the point.

3. TYPE: Point type, either discrete input (DI), discrete output (DO), relay discrete output (RO), analog input (AI), or analog output (AO).

01/28/19


40 61 93.20 - 2

4. VOLT: Voltage level of the module.

5. ADDRESS: Internal Address of register used to transfer data between PCCS and PLC module. ‘N’ indicates the integer file location. ‘F’ indicates floating point. To be completed by the Systems Integrator

6. CHASS: Chassis Physical enclosure containing all PLC modules.

7. SLOT: I/O module number within a given rack.

8. POS: Position Point number on a given I/O module.

9. P&ID: Process and Instrument Drawing reference

10. INTER DWG: Interconnect, loop, or wiring drawing for termination information. To be completed by the Systems Integrator

11. PLAN: Plan or location drawing showing location of fields device

12. CONTROL: Control Strategy or Control Specification

13. NOTES: Additional information as required.

C. PROGRAMMABLE LOGIC CONTROLLER (PLC) INPUT/ OUTPUT SCHEDULE (attached)

3.02 INSTALLATION - NOT USED

3.03 TESTING - NOT USED

3.04 TRAINING - NOT USED

PROGRAMMABLE LOGIC CONTROLLER (PLC) INPUTS / OUTPUTSPANEL: PNL87708

PLC:

POINT ID DESCRIPTION TYPE VOLT ADDRESS CHASS SLOT POS P&ID INTER DWG PLAN CONTROL NOTES

CV87521 OPEN/CLOSED_COMMADO 120AC 66X281

CV87521 OPEN_INDICATE DI 120AC 66X281

CV87521 CLOSED_INDICATE DI 120AC 66X281

PIT870021 PRESSURE_INDICATE AI 66X281 BBB




PIT870022 PRESSURE_INDICATE AI 66X281 AAA

PIT870020A PRESSURE_INDICATE AI 66X282 DDD

PIT870020B PRESSURE_INDICATE AI 66X282 CCC




CV87068 OPEN/CLOSED_COMMADO 120AC 66X284A

CV87068 OPEN_INDICATE DI 120AC 66X284A

CV87068 CLOSED_INDICATE DI 120AC 66X284A

01/28/19Gas Management System Rehabilitation and Improvements

40 61 93.20


PLC:


CV87069 OPEN/CLOSED_COMMADO 120AC 66X284A

CV87069 OPEN_INDICATE DI 120AC 66X284A

CV87069 CLOSED_INDICATE DI 120AC 66X284A













PIT8759 PRESSURE_INDICATE AI 66X400


40 61 93.20


PLC:






FIT870010 FLOW_INDICATE AI 66X400

FIT870011 FLOW_INDICATE AI 66X400

CV870017 POSITION_CONTROL AO 66X400

CV870017 POSITION_INDICATE AI 66X400









40 61 93.20


PLC:


CV87318 POSITION COMMAND AO 66X288

CV87318 POSITION INDICATE AI 66X288

CV87314 OPEN/CLOSED COMMAND DO 120AC 66X288

CV87314 OPEN INDICATE DI 120AC 66X288

CV87314 CLOSED INDICATE DI 120AC 66X288


40 61 93.20


PLC:




CV87315 OPEN/CLOSED COMMAND DO 120AC 66X289



01/28/19Gas Management System Rehabilitation and Improvements 40 61 93.20


PLC:




CV87316 OPEN/CLOSED COMMANDO 120AC 66X290




40 61 93.20

PROGRAMMABLE LOGIC CONTROLLER (PLC) INPUTS / OUTPUTSPANEL: CPNL80200

PLC: PLC80200C



CV870007 POSITION INDICATOR AI 66X401

FIT8112 FLOW INDICATOR AI 66X401

PIT870009 PRESSURE INDICATOR AI 66X401

SV870007 WGB EMR DUMP VLV DO 120AC 66X402

TE80201 TEMPERATURE INDICATO AI 66X402






V80201 OPEN COMMAND DO 120AC 66X402

V80201 CLOSE COMMAND DO 120AC 66X402

V80201 OPEN INDICATOR DI 120AC 66X402

V80201 CLOSED INDICATOR DI 120AC 66X402

V80201A OPEN COMMAND DO 120AC 66X402


40 61 93.20


PLC: PLC80200C


V80201A CLOSE COMMAND DO 120AC 66X402

















40 61 93.20


PLC: PLC80200C

















END OF SECTION


40 61 93.20


01/28/19

Gas Management System

Rehabilitation and Improvements

40 61 96.10 - 1

SECTION 40 61 96.10

PLANT COMPUTER CONTROL SYSTEM CONTROL STRATEGIES

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies control strategies for the Emerson Ovation supervisory

control system for the Plant Computer Control System (PCCS). Control strategies

describe sequential and interlocking control functions, analog control functions,

and color graphic video display operator interfaces including alarm and event

logging.

2. PCCS programming will be completed by the District.

3. Contractor shall provide labor and equipment necessary to test the specified control

strategies as specified in the COMMISSIONING Section (01 91 00) and

4. PROCESS CONTROL SYSTEM TESTING Section (40 61 21).

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of

this specification to the extent referenced. The publications are referred to in the text by

the basic designation only. The latest edition of referenced publications in effect at the

time of the bid shall govern. In case of conflict between the requirements of this section

and the listed references, the requirements of this section shall prevail.

Reference Title

SRCSD PCCS Programming Design Standards

1.03 SUBMITTALS

A. NOT USED


1.05 CONTROL STRATEGIES SCHEDULE

A. CS1020 Ground Flare Gas Supply

B. CS1021 Gas Management System Fire Valves

C. CS1022 LSG Recycle Valve/ MSG Dump Valve Control, and Miscellaneous

Scrubbers and Compressor Monitoring

01/28/19



40 61 96.10 - 2

D. CS1023 LSG Header Pressure Relief Supervisory Control

E. CS1024 Scrubber Pressures and MSG Compressor Low Suction Pressure Cutoff

1.06 GENERAL REQUIREMENTS FOR OPERATION

A. HMI DISPLAYS: The PCCS control system HMI displays will include common

controller interface displays which follow District HMI display standards.

B. CONTROLS: The operator can adjust most values thru the PCCS control system which

is the graphical user interface running on either desk mounted workstations or panel

mounted operator interface terminals. The PCCS control system is networked with the

PLCs as specified in the PROCESS CONTROL SYSTEM GENERAL PROVISIONS

Section (40 61 13) and the PROGRAMMABLE LOGIC CONTROLLERS Section (40

63 43). PLC modes, statuses and alarms are specified herein and function in conjunction

with the control strategies developed by the District. PLC adjustable parameters are also

identified within the control narratives and typically initial values are set during startup

and commissioning.

1. LOCAL CONTROLS:

a. Most equipment is provided with HOA switches which are at the starter, VFD

or instrument control station located near the equipment. With this switch in

HAND, the equipment runs. With the switch in AUTO, the equipment is

controlled through the PLC and monitored from the PCCS control system.

b. If the equipment is run with a variable or adjustable speed drive, then speed

control at the VFD is active when the switch is in HAND.

2. PCCS CONTROLS:

a. START AND STOP: Start and stop control START/STOP allows an operator

to start and stop equipment sequence or equipment directly.

b. SEQUENCE: Sequence control DUTY/STANDBY allows an operator to

select equipment in an order to start and stop. The equipment selected in

DUTY runs when a sequence is started. The equipment selected in STANDBY

runs when the DUTY cannot run. The PCCS only allows one of the sequenced

equipment to run at any time. The current SEQUENCE ORDER is displayed

on PCCS control system.

c. For more than two pieces of equipment, the Sequence control

LEAD/LAG/STANDBY allows an operator to select equipment in an order to

start and stop. The equipment selected as LEAD runs first when a sequence is

started. The equipment selected as LAG runs second when a sequence is

started. The equipment selected in STANDBY runs when either the LEAD or

LAG equipment cannot run. The current SEQUENCE ORDER is displayed on

PCCS control system

01/28/19



40 61 96.10 - 3

d. ALTERNATOR: Alternating sequence control ON/OFF ALT allows the PCCS

to change a sequence order based on a SCHEDULED TIME interval when set

ON. SCHEDULE TIME is an adjustable value and entered from PCCS control

system in days (1 to 30). When the SCHEDULE TIME has elapsed (PCCS

counts the elapsed time and the PCCS control system displays a time count

when set ON), the PCCS changes the sequence order and restarts the

SCHEDULE TIME automatically for the next sequence alternation.

e. FLOW CONTROL: Flow control options with VFDs or VSD is also provided

with a graphic speed adjustment for changing the speed of the equipment thru

the PCCS control system screen in MANUAL.

f. FLOW PACING: Flow pacing is used for automatic samplers, chemical

feeders, and other process applications. The PCCS provides an analog output

signal of 4-20 mA to the sampler. The sampler’s control strategy lists the

process variable that is used for flow pacing. For the flow pace analog output

signal, 4 mA represents zero flow and 20 mA represents that maximum flow for

the flow pacing signal. A process variable with SIGNAL BAD alarm is set to 4

mA until not SIGNAL BAD.

g. PROPORTIONAL-INTEGRAL-DERIVATIVE (PID): PCCS PID logic shall

have PCCS control system access to set PID parameters and monitor active PID

logic.

h. EQUIPMENT SOFTWARE INTERLOCKS: All equipment software interlocks

shall reside in the PCCSs controller unless provided with a subsystem (vendor)

package system or specified as part of a PLC control narrative.

C. STATUS:

1. Most equipment is monitored by the PCCS control system for AUTO mode

selection which enables PCCS control system automatic control logic to be in

control. In LOCAL mode, the PCCS control system control is not in AUTO and

only local manual control of the equipment is active.

2. All equipment with starters, VFDs or VSDs has TOTALIZED RUN TIMES

calculated in the PCCS in 1/10-hour increments and displayed in PCCS graphics.

TOTALIZED RUN TIME RESET shall be initiated from the PCCS graphics to

reset the totalizer run time to zero.

3. Equipment is monitored for RUNNING by the PCCS and the running status is

displayed on PCCS operator graphics.

4. All VFDs are monitored for frequency or SPEED by the PCCS and is the frequency

or SPEED is displayed on PCCS per the PCCS Programming Design Standards.

5. Any equipment that cycles on and off (i.e., Pumps for level control) shall have the

PCCS count starts and display the counts on PCCS operator graphics.

6. Motor Operated Valves/Gates:

01/28/19



40 61 96.10 - 4

a. MODULATING: Position is monitored by the PCCS and displayed on PCCS

graphics as 0 to 100 percent open.

b. NON-MODULATING: Open, travel position and closed status is monitored by

the PCCS and displayed on PCCS graphics. TRAVEL is displayed when there

is no motor operated valve/gate position feedback and the valve/gate is neither

open nor closed.

7. RECORDING: PCCS control system shall generate reports based upon monitored

process variables (pressure, flow, temperature, level and analytical) and equipment

status (speed, and motor current) in real time and from recent historical data. The

exact report requirements shall be determined and shall be configured during the

project construction period.

8. TRENDING: PCCS control system shall graphically plot trends of process

variables (pressure, flow, temperature, level and analytical) monitored, controller

set points and outputs, and equipment status (speed and motor current) in real-time

and from historical data. The operator shall be able to select the plotting interval,

within the limits of the actual data collection. The exact trending requirements

shall be determined and shall be configured during the project construction period.

In addition to the plotted data, a trend shall include:

a. Time

b. Date

c. Tag number

d. Plotting interval

e. Time at start

f. Time at latest value

9. PLC HARDWARE: All PLC hardware is monitored for health status and displayed

in PCCS control system in the same layout as the PLC hardware has been

physically installed.

10. NETWORKING: All PLC and PCCS network communication is monitored and is

displayed to view the health and traffic rate of the data links on the PCCS control

system.

01/28/19



40 61 96.10 - 5

D. ALARMS:

1. General:

a. For self-resetting alarms, an analog point which is in alarm status will not be

changed to normal status until the point value changes by the predetermined

deadband value for the point, initial setting of 5 percent of full-scale range.

b. For manual-resting alarms, an analog point which is in alarm status will not be

changed to normal status until reset by the PCCS Operator and the point value

changes by the predetermined deadband value for the point, initial setting of

5 percent of full-scale range.

2. Power Failure:

a. All PCCS I/O racks are monitored for power fail from the source power input

to the I/O rack power supply.

b. All PCCS power supplies are monitored for power fail from the source power

input.

3. EQUIPMENT DISCREPANCY ALARM: A discrepancy alarm is generated when

a PCCS control system issued command does not match the feedback. The

following are discrepancy alarms:

a. RUN FAULT: The discrepancy alarm is called RUN FAULT when equipment

with no active alarms that prevent running is called by the PCCS to run or to

start and there is no running status feedback within 30 seconds. The RUN

FAULT alarm sets the PCCS command to stop and requires reset at PCCS

control system to clear the alarm.

b. POSITION FAULT:

c. NON-MODULATING ACTUATOR: The discrepancy alarm is called

POSITION FAULT when a non-modulating valve/gate with no active alarms

that prevent opening or closing is called by the PCCS to open or to close and

there is no open or closed status feedback within travel time + 30 seconds. The

POSITION FAULT alarm is set.

b. Modulating Actuator: The discrepancy alarm is called POSITION FAULT

when a modulating valve/gate with no active alarms that prevent opening or

closing is called by the PCCS to a control position and the feedback position does

not match the PCCS control system output signal by +/- 2 percent within 30

seconds. The POSITION FAULT alarm is set.

d. SPEED FAULT: The discrepancy alarm is called SPEED FAULT when

equipment with no active alarms that prevent running is called by the PCCS to

an output speed to the VFD and the speed feedback does not match within

01/28/19



40 61 96.10 - 6

30 seconds +/- 5 percent for more than 30 seconds. The SPEED FAULT alarm

is set.

e. SIGNAL BAD: All analog inputs are monitored by the PCCS for the input

signal to be within the 4-20 mA range (current). If the input signal is outside the

range by 5 percent for more than 30 seconds, PCCS control system displays a

SIGNAL BAD alarm.

f. CONTROL BAD: All PCCS PID functions are monitored for deviation

between set point and the process variable feedback. If the deviation is outside

of the PID control dead band for more than 30 seconds then alarm discrepancy

as [CONTROL BAD]. Separate deviation, dead band and time delay are

provided for each PCCS PID controller.

4. INSTRUMENT ANALOG ALARM: All analog signals shall be able to have the

PCCS generate any or all of the following alarms and display in PCCS control

system: LOW LOW, LOW, HIGH, HIGH HIGH, and HIGH RATE CHANGE.

HIGH RATE CHANGE is an alarm generated when the difference between two

consecutive measurements exceeds a predetermined value and may be interlocked

with other conditions in the PCCS logic. Separate trip value and time delay are

provided for each analog alarm. The control narratives specified herein include

lists of required analog alarms, and the control strategies specified in PLANT

COMPUTER CONTROL SYSTEM CONTROL STRATEGIES Section (40 61

96.10) includes lists of additional required analog alarms.

5. MOTOR HI CURRENT ALARM AND SHUTDOWN

a. If the current sensed by the current monitor on any motor has a value

110 percent of the rated running amps for more than 10 seconds then alarm in

the PCCS and display on the PCCS.

b. On motor overload, hardwired interlock shuts down equipment.

6. NETWORK LOSS: If equipment connects to the PCCS networks and the

communication data signal is lost for greater than a time delay of 60 seconds then

alarm COMM LOSS is set and is display on the PCCS. When communication is

restored then clear the PCCS control system alarm. Equipment action on COMM

LOSS varies.

a. If the equipment PLC commands and statuses are via networked data and there

is a COMM LOSS set the equipment in the field to stop and set the PLC to

force a STOP command. The operator restarts equipment at PCCS control

system when the alarm is cleared and communication is restored. Note: the

equipment is also monitoring communication loss and there is a time delay

parameter for communication loss which should be the same as the PLC or

PCCS control system time delay value.

01/28/19



40 61 96.10 - 7

b. If the equipment is networked to the PCCS, the equipment is a vendor package

control system that can operate independently and there is a COMM LOSS set

the equipment to the last received data from PCCS control system until

communication is restored. PCCS control system stops monitoring, trending

and recording data until communication is restored.

PART 2 -- PRODUCTS


PART 3 -- EXECUTION

3.01 GENERAL

A. The following PCCS control strategies shall be coordinated with the PROCESS

CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13), the PLANT

COMPUTER CONTROL SYSTEM INPUT/OUTPUT Section (40 61 93.10), the

PROGRAMMABLE LOGIC CONTROLLER INPUT/OUTPUT Section (40 61 93.20),

and the PROGRAMMABLE LOGIC CONTROLLER CONTROL NARRATIVES

Section (40 61 96.20).

B. The control strategies and control narratives are meant to be guidelines in the

requirements of the PCCS and PLC programming requirements. Changes in the PLC

and PCCS programming may be required to meet additional requirements of the

dynamics of the processes including how equipment interact during startup, shutdown,

emergency shutdown, equipment fault conditions, and electrical blackout and brownout

conditions. The control strategies and control narratives shall be redlined with changes

as necessary to document the PLC and PCCS programming for RECORD.

3.02 CONTROL STRATEGIES

A. The control strategies are attached to this Section.

3.03 TESTING

A. Testing shall conform to COMMISSIONING Section (01 91 00) and the PROCESS

CONTROL SYSTEM TESTING Section (40 61 21).


**END OF SECTION**

01/28/19



40 61 96.10 - 8

CONTROL STRATEGY CS1020

GROUND FLARE GAS SUPPLY

DATE: REVISION DESCRIPTION:

11/13/2017 A DS-2

7/12/2018 / 8/21/2018 B DS-3 Review Comments / Bid Set

Review Meeting


TITLE: GROUND FLARE GAS SUPPLY

PCCS: DROP 10/60

PLC: None

INSTRUMENTS

PIT 8766

PIT 870016

PIT 870014

FIT 8767

MSG Pressure (PCCS Existing)

Flare Pressure Reducing Intermediate Pressure

Flare Header Pressure

Flare Header Gas Flow (PCCS Existing)

FINAL CONTROL ELEMENTS

CV870015

CV870017

CV870018

CV870019

Flare Pressure Reducing Control Valve 1

Flare Pressure Reducing Control Valve 2

Flare Pressure Bleed Valve 1, Fire Rated


DIAGRAMS

66X400 Compressor Room Control Valve Stations

ASSOCIATED CONTROL NARRATIVES AND CONTROL STRATEGIES

CN8001

CN8701

CS1010

CS1011

SCP202

Waste Gas Burners

Ground Flares

Flare Flow Control

MSG Compressors and Gas Holders

Flare Compliance Program (Records and Archives)

01/28/19



40 61 96.10 - 9


GROUND FLARE GAS SUPPLY

DESCRIPTION

The gas supply for the ground flares comes from the MSG system through a set of two pressure

reducing valves in series to produce Flare Supply Gas (FSG). The first pressure reducing valve,

CV870015, reduces MSG pressure to the intermediate pressure utilizing pressure set at 3 psi and

monitored in the PCCS by PIT870016. The second pressure reducing valve, CV870017, reduces

pressure from the intermediate pressure down to the FSG pressure of approximately 20“WC and

monitored in the PCCS by PIT870014. Should PIT870016 or PIT870014 fail (is in alarm); the

pressure reducing valves CV870015 and CV870017 are closed.

If PIT870016, CV870015 and CV870017 are operational but PIT870014 fails (is in alarm),

either available downstream pressure transmitter PIT8768A or PIT8768B can be automatically

assigned to the control CV870017 or manually selected by the operator to replace PIT870014.

Downstream from the pressure reducing valves are bleed valves (CV870019A and CV870018A)

which open to prevent the flare headers from being over pressurized, a critical safety function.

This occurs during no or low flow conditions, or in the event the MSG Compressor Building fire

isolation valves must close. When the bleed valves are open FSG gas is sent upstream of V87524

to the LSG compressor suction header. These bleed valves also fail closed on loss of power or

loss of signal from the PIT870014 and the backup FSG pressure transmitter, either PIT8768A or

PIT8768B.

CONTROL FROM THE PCCS

PCCS HMI

The following I/O points are monitored at the PCCS HMI:

1. Monitor pressure transmitters and pressure alarms

2. Monitor control valve positions and valve alarms

PCCS MANUAL MODE CONTROL LOGIC

The following manual mode control logic is to be programmed in Ovation DCU Drop 10 of the

PCCS:

1. MSG Pressure Reducing Control:

a. Put the intermediate pressure reducing valve CV870015 in manual mode and

modulate to change the intermediate pressure PIT870016.

b. Put the FSG pressure reducing valve CV870017 in manual mode and modulate

to change the FSG pressure PIT870014.

01/28/19



40 61 96.10 - 10

c. Generate a high pressure alarm when FSG pressure exceeds 23”H2O. Alarm set

point is operator adjustable.

d. Operator selectable to assign either PIT8768A or PIT8768B to automatically

backup FSG pressure transmitter PIT870014 if it is in alarm, or to be manually

selectable to backup PIT870014.

2. FSG Bleed Valve Control:

a. Bleed valves CV870018A and CV870019A are controlled by solenoid valves

SV870018 and SV870019. Each bleed valve can be placed in manual mode and

opened or closed.

b. Utilize PIT8768A or PIT8768B as selected above as FSG pressure to control

bleed valves CV870018A and CV870019A should transmitter PIT870014 be in

alarm.

PCCS AUTOMATIC MODE CONTROL LOGIC

The following automatic mode control logic is to be programmed in Ovation DCU Drop 10 of

the PCCS:

1. MSG Pressure Reducing Control:

a. PID control modulates CV870015 to maintain the desired intermediate pressure

based on PIT870016. The initial setpoint for intermediate pressure is 3 psig.

b. PID control modulates CV870017 to maintain the desired FSG pressure based

on PIT870014. Initial setpoint for FSG pressure is 20”H2O.

c. Should PIT870014 go into alarm, the Operator may select between PIT8786A

and PIT8786B to be the backup pressure transmitter to monitor FSG pressure.

The selected backup transmitter automatically replaces PIT870014 as the

process variable for MSG pressure reducing control and FSG bleed valve

control.

2. FSG Bleed Valve Control:

a. High FSG pressure greater than 23”H2O, calls for both bleed valves

CV870018A and CV870019A to open. They remain open until the FSG

pressure drops below 20”H2O. The open and close command pressure setpoints

are operator adjustable.

b. Utilize PIT8768A or PIT8768B as selected above as FSG pressure to control

bleed valves CV870018A and CV870019A should transmitter PIT870014 be in

alarm

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40 61 96.10 - 11

PCCS INTERLOCKS

The following interlocks are programmed in Ovation DCU Drop 10:

1. When CV870015 or CV870017 is in alarm, shut both valves.

2. When PIT870014 is in alarm and no FSG pressure transmitter has been selected to

replace it, close pressure reducing valves CV870015 and CV870017.

HARDWIRED INTERLOCKS

1. None.

FIELD CONTROL

The pressure reducing valves CV870016 and CV870014 have a local (L/R switch) which allows

the user to take control of the valve locally and modulate as desired using a local indicator of

valve position for feedback.

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40 61 96.10 - 12


GAS MANAGEMENT SYSTEM FIRE VALVES


11/13/2017 A DS-2

12/4/2017 B Post DS-2

01/10/2019 C Bid Set

01/28/19



40 61 96.10 - 13


TITLE: GAS MANAGEMENT SYSTEM FIRE VALVES

PCCS: DROP 10

PLC: None

INSTRUMENTS

??? Flame detecting sensors and LEL gas analyzers


V87521

V87522

V87523

V87524

V87068

V87069

V870012

V870013

CV870018

CV870019

Scrubber Inlet Fire Valve, LSG-2

Scrubber Inlet Fire Valve, LSG-1

Scrubber Outlet Fire Valve

MSG Compressor Suction Fire Valve

MSG Fire Valve 1 at Compressor Building

MSG Fire Valve 2 at Compressor Building

Ground Flare Fire Valve at Compressor Building, FSG-2

Ground Flare Fire Valve at Compressor Building, FSG-1



DIAGRAMS

66X281

66X282

66X284A

66X400

Scrubbers 1

Scrubbers 2

Gas Compressors

Compressor Room Control Valve Stations


CN8001

CN8701

CS1020

CS1010

CS1011

SCP202

Waste Gas Burners

Ground Flares

Ground Flare Gas Supply

Flare Flow Control



01/28/19



40 61 96.10 - 14

CONTROL NARRATIVE CS1021

GAS MANAGEMENT SYSTEM FIRE VALVES

DESCRIPTION

When a flame is detected in an area, the associated fire rated valves close. The applicable areas

include the MSG Compressor Building, scrubber area, and the ground flare area. When the MSG

Compressor Building LEL/H2S gas detectors alarms, the building inlet and outlet fire rated

valves are closed. The scrubber UV-IR scanners will trip the gas scrubber valves and the ground

flare UV-IR scanners will trip the FSG valves.


PCCS HMI


1. The gas detectors and UV-IR scanners.

2. Fire valve open/close status and alarms



PCCS:

1. None



the PCCS:

1. Upon detection of a fire or LEL alarm, close the fire rated valves for that area.

2. Upon detection of a Plant Emergency Trip (PET) alarm, close all fire rated valves.

PCCS INTERLOCKS

The following interlocks are programmed in the PLC (regardless of the pump HOA position):

1. None.

01/28/19



40 61 96.10 - 15


LSG RECYCLE VALVE/ MSG DUMP VALVE CONTROL, AND

MISCELLANEOUS SCRUBBERS AND COMPRESSOR MONITORING


11/13/2017 A DS-2

12/4/2017 B Post DS-2

7/12/2018 / 8/21/2018 C DS-3 Review Comments / Bid Set

Review Meeting

01/10/2019 D Bid Set

01/28/19



40 61 96.10 - 16


TITLE: LSG RECYCLE VALVE/ MSG DUMP VALVE CONTROL, AND


PCCS: DROP 10

PLC: None

INSTRUMENTS

PIT8391 LSG-2 Header Pressure

PIT8392 LSG-1 Header Pressure

PIT8759 MSG Compressor Suction Pressure

PIT8766 MSG Compressor Discharge Pressure

PIT87022 LSG-1 Scrubbers Inlet Pressure

PIT870020A LSG-1 Scrubbers Outlet Pressure

PIT87021 LSG-2 Scrubbers Inlet Pressure

PIT870020B LSG-2 Scrubbers Outlet Pressure


CV87007

CV87110

MSG Recycle Valve

MSG Dump Valve

DIAGRAMS

66X281

66X282

66X284A

66X400

Scrubbers 1

Scrubbers 2

Gas Compressors



CN8001

CN8701

CS1020

CS1010

CS1011

SCP202

Waste Gas Burners

Ground Flares


Flare Flow Control



01/28/19



40 61 96.10 - 17


LSG RECYCLE VALVE/ MSG DUMP VALVE CONTROL, AND


DESCRIPTION

The boiler backpressure valve (V22775) maintains an operator adjustable MSG header pressure

feeding the boilers. The MSG header pressure is monitored through PIT8766 at the MSG

compressor discharge.

The Recycle Valve (CV87007) is used to recycle some of the compressor discharge flow and

transfer gas from medium-pressure MSG to low-pressure LSG in order to maintain the

compressor suction line pressure (LSG pressure), initially set to 7”WC.

The Dump Valve (CV80110) is used to blow-off excess compressor discharge flow and transfer

gas from medium-pressure MSG to low-pressure LSG in order to maintain the compressor

discharge line pressure (MSG pressure), initially set to 10.5 psig.


PCCS HMI


1. Recycle valve percent closed position, local/remote status, and alarms

2. Dump valve percent open position, local/remote status, and alarms

3. Pressure transmitters:

LSG-2 header pressure (PIT8391)

LSG-1 header pressure (PIT8392)

Which is selected (PIT8391 or PIT8392) as LSG pressure PID controller process

variable.

MSG header pressure (PIT8766)

4. LSG Scrubbers Differential Pressure Monitoring:

LSG-1 scrubbers differential pressure which is equal to the inlet pressure minus

the outlet pressure (PIT870022 - PIT870020A).

LSG-2 scrubbers differential pressure which is equal to the inlet pressure minus

the outlet pressure (PIT870021 - PIT870020B).

5. MSG Compressor Suction Header Pressure Monitoring

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40 61 96.10 - 18

MSG compressor suction header pressure transmitter PIT8759 replaces PSL8759

and it will be configured with a low pressure setpoint initially set to 1.0”WC. The

low pressure setpoint will be programmed in the PCCS to stop the compressor if

the pressure is equal to or less than that value. The setpoint will be operator

adjustable.



PCCS:

1. Manually adjust the Recycle Valve percent closed position

2. Manually adjust the Dump Valve percent open position

a.



the PCCS:

1. Recycle Valve Control:

a. A PID controller modulates the Recycle Valve (CV87007) to maintain a

minimum LSG pressure. The operator adjustable LSG pressure setpoint is

initially set to 7”WC.

b. The LSG pressure process variable is operator selected from either LSG-2

header pressure (PIT8391) or LSG-1 header pressure (PIT8392).

c. When the LSG gas pressure process variable rises above the LSG pressure

setpoint, the Recycle Valve closes.

d. When the LSG gas pressure process variable falls below the LSG pressure

setpoint, the Recycle Valve opens.

2. Dump Valve Open:

a. A PID controller modulates the Dump Valve (CV80110) to maintain a

maximum MSG pressure.

b. The operator adjustable MSG pressure setpoint is initially set to 11.5 psig.

c. The PID process variable is MSG discharge header pressure (PIT8766).

d. When the MSG gas pressure process variable rises above the MSG pressure

setpoint, the Dump Valve opens.

e. When the MSG gas pressure process variable falls below the MSG pressure

setpoint, the Dump Valve closes.

01/28/19



40 61 96.10 - 19

PCCS INTERLOCKS

The following interlocks are programmed in the PCCS:

1. None.

01/28/19



40 61 96.10 - 20


LSG HEADER PRESSURE RELIEF SUPERVISORY CONTROL


9/14/2018 A Bid Set

1/17/2019 B Bid Set Final

01/28/19



40 61 96.10 - 21


TITLE: LSG HEADER PRESSURE RELIEF SUPERVISORY CONTROL

PCCS: DROP 10

PLC: None

INSTRUMENTS

PIT87009 Waste Gas Burners LSG Header Pressure

PIT8391 LSG Header Pressure at Digesters (LSG-1)

PIT8392 LSG Header Pressure at Digesters (LSG-2)


MME87301 Ground Flare 1



MME80201A Waste Gas Burner Pilot Unit for WGB MME80201






DIAGRAMS

66X288

66X289

66X290

ZTOF Enclosed Flare System BRN87301




CN8001

CN8701

CS1020

CS1010

SCP202

Waste Gas Burners

Ground Flares


Existing Flare Flow Control


01/28/19



40 61 96.10 - 22


LSG HEADER PRESSURE RELIEF

DESCRIPTION

The Waste Gas Burners (WGB) and Ground Flares (GF) are coordinated to relieve pressure and

to dispose of excess digester gas in the Low Pressure Sludge Gas (LSG) system. Both systems

play a critical role in preventing an uncontrolled digester gas release through the digester

pressure relief valves. The WGBs and GF are called to start at the same operator adjustable LSG

pressure. The WGBs can accept and start burning LSG immediately while the GFs have to

warmup before they can meet their air quality permit. The Duty GF burns higher pressure and

scrubbed Flare Supply Gas (FSG) that burns cleaner than unscrubbed LSG and therefore is the

preferred method for relieving high LSG pressure. The WGBs burn LSG and Duty GF burns

FSG until a low LSG pressure setpoint is reached. CN8001 provides the required control logic

for the WGB PLC, and CN8701 and Section 43 13 43.01 Ground Flares provide the required

control logic for the GFs.

The purpose of this control narrative is to provide the supervisory control to start and stop the

Waste Gas Burners and Ground Flares to safely dispose of digester gas. This supervisory control

strategy is to replace CS1010 for Ground Flare control.

The PCCS monitors all WGB and GF I/O points and provides supervisory control. A change

from CS1010 control is that now the GF vendor PLC controls the isolation and modulating Flare

Supply Gas (FSG) valve and not the PCCS. This is optimizes the GF warmup time and shutdown

cycle.

The PLC limits the GF flow so that it remains within 500 to 3000 cfm (operator adjustable).

Programmed within the vendor PLC, if the flare temperature falls below the minimum

temperature required by the air quality permit or the flow drops below the minimum flow of 500

SCFM, the flare will shut down.

The supervisory control strategy assigns the duty-standby1-standby2 flares in the PCCS. This

strategy cannot be disabled and has no enable/disable control because it is critical to preventing a

violation.


Supervisory Control Logic

The PCCS supervisory control logic includes the following:

1. Send calculated LSG header pressure to the WGB PLC and GF PLCs to use as the

process variable for controlling gas flow to be burned in the Pressure Mode.

2. Send commands to the WGB PLC to operate in either Pressure Mode or Flow

Mode of control.

3. Select which GF is Duty, which is Standby1 and which is Standby2.

01/28/19



40 61 96.10 - 23

4. Call for the Duty GF to start when the calculated LSG header pressure drops below

its operator adjustable setpoint.

PCCS HMI


1. All WGB I/O points

2. All GF I/O points.

PCCS HMI COMMANDS (AUTOMATIC AND MANUAL MODES)

The following commands are available from the PCCS HMI when the equipment is in either the

Automatic or Manual mode:

1. Select Flow Mode or Pressure Mode for WGBs

2. Select Duty, Standby1, Standby2 for GFs

PCCS HMI COMMANDS (MANUAL MODE ONLY)

The following commands are available from the PCCS HMI when the equipment is in the

Manual mode:

1. Start Duty GF

2. Stop Duty GF

PCCS HMI COMMANDS (AUTOMATIC ONLY)


Automatic mode:

3. Adjust WGB flow setpoint in Flow Mode

4. Adjust WGB pressure setpoint in Pressure Mode

5. Adjust WGB high and low LSG header pressure setpoints

6. Adjust GF high and low LSG header pressure setpoints

7. Enter Flare shutdown temperature setpoint

Figure 1 shows the sequence of pressure control and gas wasting of LSG digester gas through the

WGBs and Duty GF.

PCCS Automatic Mode Control Logic:

The following auto mode control logic is to be programmed in the PCCS:

1. DUTY GF FAILOVER:

a. Should the Duty GF fail to start or have a trouble condition while running, after

an operator adjustable time delay, the Standby1 GF will be commanded to turn

on and be assigned the Duty GF. When the new Duty GF is assigned that role,

the failed/faulted GF will be assigned the Standby2 GF role and called to turn

off. The vendor PLC will initiate a shutdown sequence.

2. LSG HEADER PRESSURE CALCULATION:

01/28/19



40 61 96.10 - 24

a. LSG gas pressure measured by PIT8391 LSG-1 header pressure, PIT8392 LSG-

2 header pressure, and PIT870007 WGB LSG header pressure are compared by

signal high selector logic and the WGB and GF PLCs use that calculated high

value as the LSG header pressure. Any transmitter with a Bad value is ignored

by the LSG header pressure selection logic.

3. DUTY GROUND FLARE ON:

a. When calculated LSG header pressure exceeds the operator adjustable pressure

setpoint, initially set to 8.5”WC, the PCCS calls for the Duty GF is commanded

to turn on.

b. The Duty GF PLC starts the warmup cycle by opening the FSG isolation valve

and modulating the GF air intake louvers and FSG throttling valves to bring the

Ground Flare up to temperature as quickly as possible.

4. DUTY GROUND FLARE OFF:

a. When calculated LSG header pressure falls below the operator adjustable

pressure setpoint, initially set to 6.5”WC, Duty GF is commanded to turn off.

b. The Duty GF PLC starts the shutdown cycle by closing the FSG isolation valve

and FSG throttling valves.

c. Hold closed the MSG recycle valve CV87007 for an operator adjustable time

when Duty GF is called to start.

5. Summary table of PCCS LSG header pressure relief control points.

Point LSG Pressure Rising Falling Action

High-High Alarm Set 10.5”WC HMI Alarm On

High-High Alarm Reset 9.5”WC HMI Alarm Off

Command Duty GF On 8.5”WC Duty GF PLC initiates warmup

cycle

WGBs On 8.5”WC WGB Backpressure Valve pops

open and LSG immediately flows

to WGBs

Command Duty GF Off 6.5”WC Duty GF PLC initiates shutdown

cycle

WGBs Off 6.5”WC WGB Backpressure Valve closes

PLC INTERLOCKS

The following interlocks programmed in the PCCS and enforced in the Manual and Auto modes:

1. Only one Ground Flare can be run at a time.

2. If the FSG pressure is greater than 25”H2O, shutdown all Ground Flares.

01/28/19



40 61 96.10 - 25


1. None.

FIELD CONTROLS

1. None.

01/28/19



40 61 96.10 - 26


SCRUBBER PRESSURES AND MSG COMPRESSOR LOW SUCTION

PRESSURE CUTOFF


9/13/2018 A BID DOCUMENTS

01/28/19



40 61 96.10 - 27


TITLE: SCRUBBER PRESSURES AND MSG COMPRESSOR LOW SUCTION

PRESSURE CUTOFF

PCCS: DROP 10/60

PLC: None

INSTRUMENTS

PIT870021

PIT870022

PIT870020A

PIT870020B

PIT8759

LSG-2 Scrubber Inlet Pressure

LSG-1 Scrubber Inlet Pressure

LSG-2 Scrubber Outlet Pressure

LSG-1 Scrubber Outlet Pressure

Compressor Suction Pressure


NONE

DIAGRAMS

66X281

66X282

66X284

66X284A

66X400

Scrubbers 1

Scrubbers 2

Gas Compressors 1

Gas Compressors 2



CS1010

CS1011

SCP202

Flare Flow Control



01/28/19



40 61 96.10 - 28


SCRUBBER PRESSURES AND MSG COMPRESSOR LOW SUCTION

PRESSURE CUTOFF

DESCRIPTION

There are four pressure transmitters measuring the scrubber inlet and outlet pressures. Two

associated with LSG-1 piping and two associated with LSG-2 piping. These pressures shall be

displayed on the applicable process graphics for monitoring purposes. In addition, the differential

pressures across the scrubbers for LSG-1 and LSG-2 shall be calculated and displayed with the

pressure transmitter valves.

An operator adjustable setpoint in PIT8759 is used for a low suction pressure cutoff of the

operating compressor and generation of an alarm. In addition, the pressure shall be monitored on

the applicable compressor process graphic.


PCCS HMI


1. Monitor pressure transmitters and pressure alarms



PCCS:

1. Differential pressure will be calculated for LSG-1 scrubber loss as PIT870022 –

PIT870020B.


PIT870020A.

a.



the PCCS:


PIT870020B.


PIT870020A.

PCCS INTERLOCKS

The following interlocks are programmed in Ovation DCU Drop 10:

01/28/19



40 61 96.10 - 29

1. When PIT8759 operator adjustable low pressure setpoint is reached, the running

compressor will be stopped and an alarm generated.


1. None.

FIELD CONTROL

None.

**END OF SECTION**


01/28/19



40 61 96.20 - 1

SECTION 40 61 96.20

PROGRAMMABLE LOGIC CONTROLLER CONTROL NARRATIVES

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies control narratives for the PLC regulatory control. Control

narratives describe sequential and interlocking control functions, and analog

control functions.

2. PCCS programming will be completed by the District.

3. Contractor shall provide labor and equipment necessary to test the specified control

narratives as specified in the COMMISSIONING Section (01 91 00) and

PROCESS CONTROL SYSTEM TESTING Section (40 61 21).

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of

this specification to the extent referenced. The publications are referred to in the text by

the basic designation only. The latest edition of referenced publications in effect at the

time of the bid shall govern. In case of conflict between the requirements of this section

and the listed references, the requirements of this section shall prevail.

Reference Title

SRCSD PCCS Programming Design Standards

1.03 SUBMITTALS

A. NOT USED


1.05 CONTROL NARRATIVES SCHEDULE

A. CN8001 Waste Gas Burners

B. CN8701 Ground Flares

1.06 GENERAL REQUIREMENTS FOR OPERATION

A. CONTROLS: The operator can adjust most values thru the PCCS Ovation control system

which is the graphical user interface running on either desk mounted workstations or

01/28/19



40 61 96.20 - 2

panel mounted operator interface terminals. The PCCS Ovation control system is

networked with the PLCs as specified in the PROCESS CONTROL SYSTEM

GENERAL PROVISIONS Section (40 61 13) and the PROGRAMMABLE LOGIC

CONTROLLERS Section (40 63 43). PLC modes, statuses and alarms are specified

herein and function in conjunction with the control strategies developed by the District.

PLC adjustable parameters are also identified within the control narratives and typically

initial values are set during startup and commissioning.

1. LOCAL or HAND CONTROLS:

Most equipment is provided with HOA or L/R switches which are at the starter, VFD

or instrument control station located near the equipment. With this switch in HAND

or LOCAL, the equipment runs. With the switch in AUTO, the equipment is

controlled through the PLC and monitored from the PCCS Ovation control system.

If the equipment is run with a variable or adjustable speed drive, then speed control

at the VFD is active when the switch is in HAND.

2. PLC CONTROLS:

START AND STOP: Start and stop control START/STOP allows an operator to start

and stop equipment sequence or equipment directly. The PLC uses a normally open

discrete output to start and stop the equipment or sends data via Ethernet Fieldbus

Network.

SEQUENCE: Sequence control DUTY/STANDBY allows an operator to select

equipment in an order for the PLC to start and stop. The equipment selected in DUTY

runs when a sequence is started from either the PLC or from the PCCS Ovation

control system (supervisory command). The equipment selected in STANDBY runs

when the DUTY cannot run. The PLC only allows one of the sequenced equipment

to run at any time. The current SEQUENCE ORDER resides in the PLC and is

displayed on PCCS Ovation control system.

1. For more than two pieces of equipment, the Sequence control

LEAD/LAG/STANDBY allows an operator to select equipment in an order

for the PLC to start and stop. The equipment selected as LEAD runs first

when a sequence is started from either the PLC or from the PCCS Ovation

control system (supervisory command). The equipment selected as LAG

runs second when a sequence is started from either the PLC or from the

PCCS Ovation control system (supervisory command). The equipment

selected in STANDBY runs when either the LEAD or LAG equipment

cannot run. The current SEQUENCE ORDER resides in the PLC and is

displayed on PCCS Ovation control system

ALTERNATOR: Alternating sequence control ON/OFF ALT allows the PLC to

change a sequence order based on a SCHEDULED TIME interval when set ON.

SCHEDULE TIME is an adjustable value resident in the PLC and entered from PCCS

Ovation control system in days (1 to 30). When the SCHEDULE TIME has elapsed

01/28/19



40 61 96.20 - 3

(PLC counts the elapsed time and the PCCS Ovation control system displays a time

count when set ON), the PLC changes the sequence order and restarts the

SCHEDULE TIME automatically for the next sequence alternation.

FLOW CONTROL: Flow control options with VFDs or VSD is also provided with a

graphic speed adjustment for changing the speed of the equipment thru the PCCS

Ovation control system screen in MANUAL.

FLOW PACING: Flow pacing is used for automatic samplers, chemical feeders, and

other process applications. The PLC provides an analog output signal of 4-20 mA to

the sampler. The sampler’s control narrative lists the process variable that is used for

flow pacing. For the flow pace analog output signal, 4 mA represents zero flow and

20 mA represents that maximum flow for the flow pacing signal. A process variable

with SIGNAL BAD alarm is set to 4 mA until not SIGNAL BAD.

PROPORTIONAL-INTEGRAL-DERIVATIVE (PID): PLC PID logic shall have

PCCS Ovation control system access to set PID parameters and monitor active PID

logic.

EQUIPMENT SOFTWARE INTERLOCKS: All equipment software interlocks

shall reside in the PLCs and not in the Ovation controller.

B. STATUS:

1. Most equipment is monitored by the PCCS Ovation control system for AUTO

mode selection which enables PLC control system automatic control logic to be in

control. In LOCAL or HAND mode, the PLC control system control is not in

AUTO and only local manual control of the equipment is active.

2. All equipment with starters, VFDs or VSDs has TOTALIZED RUN TIMES

calculated in the PLC in 1/10-hour increments and displayed in PCCS graphics.

TOTALIZED RUN TIME RESET shall be initiated from the PCCS graphics to

reset the totalizer run time to zero.

3. Equipment is monitored for RUNNING by the PLC and the running status is

displayed on PCCS operator graphics.

4. All VFDs are monitored for frequency or SPEED by the PLC and is the frequency

or SPEED is displayed on PCCS per the PCCS Programming Design Standards.

5. Any equipment that cycles on and off (i.e., Pumps for level control) shall have the

PLC count starts and display the counts on PCCS operator graphics.

6. Motor Operated Valves/Gates:

MODULATING: Position is monitored by the PLC and displayed on PCCS graphics

as 0 to 100 percent open.

01/28/19



40 61 96.20 - 4

NON-MODULATING: Open, travel position and closed status is monitored by the

PLC and displayed on PCCS graphics. TRAVEL is displayed when there is no motor

operated valve/gate position feedback and the valve/gate is neither open nor closed.

7. RECORDING: PCCS Ovation control system shall generate reports based upon

monitored process variables (pressure, flow, temperature, level and analytical) and

equipment status (speed, and motor current) in real time and from recent historical

data. The exact report requirements shall be determined and shall be configured

during the project construction period.

8. TRENDING: PCCS Ovation control system shall graphically plot trends of process

variables (pressure, flow, temperature, level and analytical) monitored, controller

set points and outputs, and equipment status (speed and motor current) in real-time

and from historical data. The operator shall be able to select the plotting interval,

within the limits of the actual data collection. The exact trending requirements

shall be determined and shall be configured during the project construction period.

In addition to the plotted data, a trend shall include:

a. Time

b. Date

c. Tag number

d. Plotting interval

e. Time at start

f. Time at latest value

9. PLC HARDWARE: All PLC hardware is monitored for health status and displayed

in PCCS Ovation control system in the same layout as the PLC hardware has been

physically installed.

10. NETWORKING: All PLC and PCCS network communication is monitored and is

displayed to view the health and traffic rate of the data links on the PCCS Ovation

control system.

C. ALARMS:

1. General:

For self-resetting alarms, an analog point which is in alarm status will not be changed

to normal status until the point value changes by the predetermined deadband value

for the point, initial setting of 5 percent of full-scale range. PLC alarm setpoints are

provided in the PROGRAMMABLE LOGIC CONTROLLER INPUT/OUTPUT

Section (40 61 93.20).

For manual-resting alarms, an analog point which is in alarm status will not be

changed to normal status until reset by the PCCS Operator and the point value

01/28/19



40 61 96.20 - 5

changes by the predetermined deadband value for the point, initial setting of 5 percent

of full-scale range.

2. Power Failure:

All PLCs and I/O racks are monitored for power fail from the source power input to

the PLC or I/O rack power supply.

All PCCS power supplies are monitored for power fail from the source power input.

3. EQUIPMENT DISCREPANCY ALARM: A discrepancy alarm is generated when

a PCCS Ovation control system or PLC issued command does not match the

feedback. The following are discrepancy alarms:

RUN FAULT: The discrepancy alarm is called RUN FAULT when equipment with

no active alarms that prevent running is called by the PLC to run or to start and there

is no running status feedback within 30 seconds. The RUN FAULT alarm sets the

PLC command to stop and requires reset at PCCS Ovation control system to clear the

alarm.

POSITION FAULT:

1. NON-MODULATING ACTUATOR: The discrepancy alarm is called

POSITION FAULT when a non-modulating valve/gate with no active alarms

that prevent opening or closing is called by the PLC to open or to close and

there is no open or closed status feedback within travel time + 30 seconds.

The POSITION FAULT alarm is set.

2. MODULATING ACTUATOR: The discrepancy alarm is called POSITION

FAULT when a modulating valve/gate with no active alarms that prevent

opening or closing is called by the PLC to a control position and the feedback

position does not match the PCCS Ovation control system output signal by

+/- 2 percent within 30 seconds. The POSITION FAULT alarm is set.

SPEED FAULT: The discrepancy alarm is called SPEED FAULT when equipment

with no active alarms that prevent running is called by the PLC to an output speed to

the VFD and the speed feedback does not match within 30 seconds +/- 5 percent for

more than 30 seconds. The SPEED FAULT alarm is set.

SIGNAL BAD: All analog inputs are monitored by the PLC for the input signal to

be within the 4-20 mA range (current). If the input signal is outside the range by 5

percent for more than 30 seconds, PCCS Ovation control system displays a SIGNAL

BAD alarm.

CONTROL BAD: All PLC PID functions are monitored for deviation between set

point and the process variable feedback. If the deviation is outside of the PID control

dead band for more than 30 seconds then alarm discrepancy as [CONTROL BAD].

01/28/19



40 61 96.20 - 6

Separate deviation, dead band and time delay are provided for each PLC PID

controller.

4. INSTRUMENT ANALOG ALARM: All analog signals shall be able to have the

PLC generate any or all of the following alarms and display in PCCS Ovation

control system: LOW LOW, LOW, HIGH, HIGH HIGH, and HIGH RATE

CHANGE. HIGH RATE CHANGE is an alarm generated when the difference

between two consecutive measurements exceeds a predetermined value and may be

interlocked with other conditions in the PLC logic. Separate trip value and time

delay are provided for each analog alarm. The control narratives specified herein

include lists of required analog alarms, and the control strategies specified in

PLANT COMPUTER CONTROL SYSTEM CONTROL STRATEGIES Section

(40 61 96.10) includes lists of additional required analog alarms.

5. MOTOR HI CURRENT ALARM AND SHUTDOWN

If the current sensed by the current monitor on any motor has a value 110 percent of

the rated running amps for more than 10 seconds then alarm in the PLC and display

on the PCCS.

On motor overload, hardwired interlock shuts down equipment.

6. NETWORK LOSS: If equipment connects to the PLC or PCCS networks and the

communication data signal is lost for greater than a time delay of 60 seconds then

alarm COMM LOSS is set and is display on the PCCS. When communication is

restored then clear the PCCS Ovation control system alarm. Equipment action on

COMM LOSS varies.

If the equipment PLC commands and statuses are via networked data and there is a

COMM LOSS set the equipment in the field to stop and set the PLC to force a STOP

command. The operator restarts equipment at PCCS Ovation control system when

the alarm is cleared and communication is restored. Note: the equipment is also

monitoring communication loss and there is a time delay parameter for

communication loss which should be the same as the PLC or PCCS Ovation control

system time delay value.

If the equipment is networked to the PLC, the equipment is a vendor package control

system that can operate independently and there is a COMM LOSS set the equipment

to the last received data from PCCS Ovation control system until communication is

restored. PCCS Ovation control system stops monitoring, trending and recording

data until communication is restored.

01/28/19



40 61 96.20 - 7

PART 2 -- PRODUCTS

2.01 NOT USED

PART 3 -- EXECUTION

3.01 GENERAL

A. The following PLC control narratives shall be coordinated with the PROCESS

CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13), the PLANT

COMPUTER CONTROL SYSTEM INPUT/OUTPUT Section (40 61 93.10), the

PROGRAMMABLE LOGIC CONTROLLER INPUT/OUTPUT Section (40 61 93.20),

and the PROGRAMMABLE LOGIC CONTROLLER CONTROL NARRATIVES

Section (40 61 96.20).

B. The control strategies and control narratives are meant to be guidelines in the

requirements of the PCCS and PLC programming requirements. Changes in the PLC

and PCCS programming may be required to meet additional requirements of the

dynamics of the processes including how equipment interact during startup, shutdown,

emergency shutdown, blackout and brownout conditions. The control strategies and

control narratives shall be redlined with changes as necessary to document the PLC and

PCCS programming for RECORD.

3.02 CONTROL NARRATIVES

A. The control narratives are attached to this Section.

3.03 TESTING

A. Testing shall conform to COMMISSIONING Section (01 91 00).

3.04 TRAINING

A. Training shall conform to TRAINING Section (40 61 26) and Vendor equipment

specification section.

**END OF SECTION**

01/28/19



40 61 96.20 - 8

CONTROL NARRATIVE CN8001

WASTE GAS BURNERS


11/13/2017 A DS-2

12/4/2017 B Post DS-2

7/22/2018 – 8/21/2018 C DS-3 review comments and Bid

Document review meeting

1/15/2019 D Bid Set

01/28/19



40 61 96.20 - 9


TITLE: Waste Gas Burners

PCCS: DROP 10/60

PLC: PLC 80200

INSTRUMENTS

PIT870009

PIT8391

PIT8392

FE8112

FIT8112

Waste Gas Burners LSG Header Pressure

LSG Header Pressure at Digesters (LSG-1)

LSG Header Pressure at Digesters (LSG-2)

Waste Gas Burner Flow Element

Waste Gas Burner Flow Transmitter

TE80201

TE80202

TE80205

TE80206

TE80207

TE80208

Pilot Temperature Thermocouple for MME80201A







CV870007

SV870007

MME80201A

MME80202A

MME80205A

MME80206A

MME80207A

MME80208A

V80201

V80202

V80205

V80206

V80207

V80208

Waste Gas Burner Backpressure Control Valve

Emergency Exhaust Solenoid Valve

Waste Gas Burner Pilot Unit for WGB MME80201






Isolation valve for WGB MME80201






01/28/19



40 61 96.20 - 10

DIAGRAMS

66X281 Scrubbers 1

66X401 Waste Gas Burner Supply

66X402 Waste Gas Burners


CN8701

CS1010

CS1022

SCP202

Ground Flares

Flare Flow Control

LSG Recycle Valve/ MSG Dump Valve


01/28/19



40 61 96.20 - 11


WASTE GAS BURNERS

DESCRIPTION




pressure relief valves. The WGBs and GF are called to start at the same operator adjustable LSG

pressure. The WGBs can accept and start burning LSG immediately while the GFs have to

warmup before they can meet their air quality permit. The Duty GF burns higher pressure and

scrubbed Flare Supply Gas (FSG) that burns cleaner than unscrubbed LSG and therefore is the

preferred method for relieving high LSG pressure. The WGBs burn LSG and Duty GF burns

FSG until a low LSG pressure setpoint is reached. The WGB control logic is described in this

control narrative and GF control logic is described in CN8701.

With the WGBs, un-scrubbed digester gas is routed to the pneumatically actuated WGB

backpressure valve (CV870007) from the digesters upstream of the gas scrubbers. Gas is then

routed from the WGB backpressure valve to the six Waste Gas Burners (WGBs) through

individual pneumatically actuated isolation valves. Each burner utilizes a continuous natural gas

pilot light that is monitored by a thermocouple to ensure the presence of a pilot flame. There are

two automatic modes of operations for the WGBs, the Pressure Mode and the Flow Mode.

The Pressure Mode uses the LSG pressure as the process variable and controls the WGB

backpressure valve to maintain an operator adjustable setpoint. LSG header pressure provided as

an input to the WGB PLC control logic is calculated by CS1023 in the PCCS.

The Flow Mode uses the Waste Gas Burner Flow (FIT8112) as the process variable and controls

the WGB backpressure valve to maintain an operator adjustable flow setpoint. FIT8112 also

provides total WGB flow to the WGBs. The PCCS reads and provides a reset for the FIT8112

flow totals. Flow totals logged and archived in the PCCS are used for reporting in the flare

compliance program (SCP202) per the air quality permit.

The WGB backpressure valve CV870007 as well as the six individual WGB burner isolation

valves fail in the open position upon a loss of power, loss of PLC communications, or loss of

signal. The WGB backpressure valve and the burner isolation valves are held in the closed

position when the LSG header pressure is low and there is no operator command to operate the

WGFs in the Flow Mode.

01/28/19



40 61 96.20 - 12


PCCS Supervisory Control Logic

None

PCCS HMI


1. WGB backpressure valve CV870007 valve position command, and position

feedback, and local/remote selector position.

2. WGB isolation valves V80201, V80202, V80205, V80206, V80207, V80208

open/close command, position feedback, and local/remote selector position.

3. WGB emergency exhaust solenoid valve SV870007 open/close command.

4. LSG header pressure and high-pressure alarms

5. WGB LSG inlet pressure PIT870009

6. WGB LSG flow FIT8112, flow total, high and low flow alarms, and flow totoal

reset.

7. WGB burner pilot light thermocouple temperatures TE80201, TE80202, TE80205,

TE80206, TE80207, and TE80208 and alarm when no WGBs are available.




1. Reset WGB flow FIT8112 totalizer from PCCS.

2. WGB pilot flame low and high temperature setpoint.

3. WGB LSG flow and pressure setpoints.



Manual mode:

1. Open and close WGB isolation valves.

2. Modulate WGB backpressure valve position.



Automatic mode:

1. Select between Pressure Mode or Flow Mode for automatic control mode.

01/28/19



40 61 96.20 - 13

2. Change WGB pilot light confirmation low temperature setpoint which is initially

set to 300 degF.

3. Change LSG header pressure setpoint between an operator adjustable range of

6.5”H2O and 8.5”H2O. Initially set to 7.5”H2O.

4. Change WGB LSG flow setpoint between an operator adjustable range of 0 and

3000 cfm. Initially set to 1000 cfm.

PLC CONTROL LOGIC

PCCS Manual Mode Control Logic: The PCCS Operator shall be able to remotely open or

close any burner isolation valve, and remotely modulate the WGB backpressure valve,

CV870007. Manual mode is not recommended, since it can interfere with the WGB system

pressure relief capabilities to prevent uncontrolled venting through the digester pressure relief

valves.

The following manual mode control logic is to be programmed in the PLC:

1. Open or close individual WGB isolation valves.

2. Modulate the WGB backpressure valve (CV870007).


The following auto mode control logic is to be programmed in the PLC:

1. WGB Pressure Mode: The default automatic control mode is the Pressure Mode.

In Pressure Mode the WGB PLC (PLC80200) monitors LSG header pressure and

when the LSG header pressure rise above 6.5”H2O, all WGB isolation valves are

commanded to open and the WGB backpressure valve is released from the closed

position and allowed to modulate around the operator entered setpoint.

a. If the LSG header pressure rises above 8.5”H2O, the Emergency Exhaust

solenoid valve SV870007 is de-energized to pop the WGB backpressure valve

CV870007 fully open in less than 1.0 second. The Emergency Exhaust

solenoid valve will automatically re-energize in 2.0 seconds (operator

adjustable) to allow CV870007 to modulate and be controlled by a PID

controller with the LSG header pressure process variable and an operator

adjustable setpoint between 6.5”H2O and 8.5”H2O, initially set at 7.5”H2O.

While modulating, should the LSG header pressure rise above 8.5”H2O,

SV870007 will again be de-energized and pop open CV870007 to lower the

LSG header pressure. Should the LSG header pressure fall below 6.5”H2O,

CV870007 is modulated closed and held in the closed position, and all WGB

isolation valves are closed.

b. A WGB is available when its pilot light temperature is above an operator

adjustable setpoint of 300 degF (confirming the pilot flame is lit) and its

isolation valve is open. If no WGB is available, generate an alarm.

01/28/19



40 61 96.20 - 14

c. If LSG header pressure is less than an operator adjustable setpoint initially set

to 6.5”H2O, then close CV870007 to 0% open and hold valve closed. Upon

confirmation that CV870007 is fully closed, close all WGB isolation valves.

2. Summary table of WGB Pressure Mode control points.

Point

LSG

Pressure Rising Falling Action

Max LSG flow to

WGBs.

8.5”H2O De-energize SV87007 Emergency

Exhaust solenoid valve to pop open

CV870007. SV870007 de-energized

for an operator adjustable time

(initially set to 2 seconds) followed

by CV870007 resuming modulation.

WGBs active with

modulated LSG flow

to WGBs

8.5”H2O CV87007 modulates to maintain the

LSG header pressure to an operator

adjustable setpoint (initially

7.5”H2O).

WGB Off 6.5”H2O Issue a close command to fully close

CV870007 and hold closed. Upon

confirmation of CV870007 fully

closed, close all WGB isolation

valves.

3. WGB Flow Mode: If the LSG header pressure is within the range of 6.5”H2O to

8.5”H2O, the PCCS operator can select Flow Mode instead of the default Pressure

Mode for automatic WGB control. The operator can enter the desired flow setpoint

(0-3000 cfm) and the WGB backpressure valve CV870007 will modulate to

maintain the desired WGB LSG flow (FIT8112). Flow Mode will continue as long

as the LSG header pressure stays within the range of 6.5”H2O to 8.5”H2O. Should

the LSG header pressure rise above 8.5”H2O, SV870007 is de-energized and

CV870007 pops open, the WGB automatic control mode switches from Flow Mode

to Pressure Mode and stays in Pressure Mode until Flow Mode is reselected by an

operator. If the LSG header pressure falls below 6.5”H2O, WGB automatic control

mode switches from Flow Mode to Pressure Mode and CV870007 closes and

remains closed until called to open in the Pressure Mode.

a. If there is a minimum of one WGB available and the LSG header pressure is

within an operator adjustable range, initially set between 6.5”H2O and

8.5”H2O, then the Flow Mode of automatic control can be selected by the

operator.

b. The WGB backpressure valve (CV870007) modulates to maintain the operator

adjustable flow setpoint. The Flow Mode flow setpoint is operator adjustable

between 0-3000 cfm. The WGB LSG flow is measured by FIT8112.

c. If LSG header pressure exceeds 8.5”H2O, de-energize SV870007 to pop open

the WGB backpressure valve (CV870007) to 100%open to reduce the LSG

01/28/19



40 61 96.20 - 15

header pressure. Close SV870007 after an operator adjustable setpoint initially

set to 2 seconds, switch WGB automatic control mode from Flow Mode to

Pressure Mode, and allow CV870007 to resume modulation to maintain the

operator pressure setpoint, initially set to 7.5”H2O.

d. If LSG header pressure falls below 6.5”H2O, close CV870007 to 0% open and

hold value, and switch from Flow Mode to Pressure Mode. Stay in Pressure

Mode until Flow Mode is operator selected.

PLC INTERLOCKS

The following interlocks are programmed in the PLC and are enforced in the Manual and Auto

modes:

4. If FIT8112 has failed do not allow selection of automatic Flow Mode and alarm.

5. If there is a loss of the PCCS LSG header pressure signal, do not allow operation in

the automatic Pressure Mode and alarm.

6. If no WGB is available, close the WGB backpressure valve CV870007, and alarm.

7. If WGB pilot light temperature falls below 300 degF, close its the insolation valve

and alarm.


None

FIELD CONTROL

At the WGB control panel, the operator has ability to put any WGB isolation valve and the WGB

backpressure valve in local (L/R switch) and open or close each individual valve. Each isolation

valve shall have full open and closed pilot lights. The WGB backpressure valve shall have local

actuator controls for position control and a valve position indicator.

01/28/19



40 61 96.20 - 16

CONTROL NARRATIVE CN 8701

GROUND FLARE OPERATION


11/13/2017 A DS-2

12/4/2017 B Post DS-2

7/23/2018 – 8/21/2018 C DS-3 review comments and Bid

Documents review meeting

1/15/19 D Bid Set

01/28/19



40 61 96.20 - 17

CONTROL NARRATIVE CN 8701

TITLE: GROUND FLARES

PCCS: DROP 10/60

PLC: VENDOR PROVIDED PLC873011, PLC873021, PLC873031

INSTRUMENTS

PIT8391

PIT8392

PIT870009

PIT8768A

PIT8768B

FIT8777

FIT8778

FIT8779

CPNL873011

CPNL873021

CPNL873031

LSG-1 Header Pressure (Existing PCCS)

LSG-2 Header Pressure (Existing PCCS)

WGB LSG Header Pressure (WGB Installed)

Flare Supply Gas (FSG) Header 1 Pressure (Existing PCCS)

Flare Supply Gas (FSG) Header 2 Pressure (Existing PCCS)

Flare 1 LSG Flow (Existing PCCS)



PLC Panel for BRN87301




V87318

V87314

V87319

V87315

V87320

V87316

Modulating Valve for BRN87301

On / Off Valve for BRN87301





DIAGRAMS

66X288 Enclosed Flare System BRN87301



01/28/19



40 61 96.20 - 18


CN8001

CS1020

CS1010

CS1011

SCP202

Waste Gas Burners


Flare Flow Control



01/28/19



40 61 96.20 - 19


GROUND FLARES

DESCRIPTION




pressure relief valves and burning excess LSG. The WGBs and GF are called to start at the same

LSG header pressure. The WGBs can accept and start burning LSG immediately while the GFs

have to warmup before they can meet their air quality permit. The Duty GF burns higher

pressure and scrubbed Flare Supply Gas (FSG) that burns cleaner than unscrubbed LSG and

therefore is the preferred method for relieving high LSG pressure. The WGBs burn LSG and

Duty GF burns FSG until a low LSG pressure setpoint is reached. The GF control logic is

described in this control narrative and WGB control logic is described in CN8001.

The control logic included in the control narrative is a high-level description and does not

provide the detail required to optimally warmup, operate, and shutdown a ground flare. The PLC

control logic is provided by the GF system vendor as part of the GF packaged system (see

Section 43 13 43.01). The three individual vendor-provided GF PLC control panels monitor and

control one GF warmup, operations, and shutdown including modulating the FSG feed valve and

opening and closing the GF isolation valve. Operators assign duty/standby1/standby2 roles to the

three GFs remotely through the PCCS. The PCCS monitors all GF process I/O and applicable

calculated values. The PCCS supervisory control program CS1023 provides the GF PLC

programs the calculated LSG header pressure process variable and the GF minimum allowable

temperature setpoint.

Automatic Control: The PCCS calls for the duty GF to turn on. This command is either a

remote manual operator initiated call or a calculated call from CS1023. Upon receipt of a call to

start, the duty GF initiates a warmup cycle. During operation, when the flare throttling valve is

modulating to optimize the burn, the FSG flow rate must be maintained within the limits of the

Ground Flare, 500 to 3000 cfm (operator adjustable). CS1023 also calls for the duty GF to turn

off as a supervisory command or as a remote manual operator initiated command. If the duty GF

temperature falls below the minimum allowable temperature required by the air quality permit,

or the flow drops below the 500 SCFM, the PLC flare control logic will shut down the duty GF

including modulating closed the FSG valve and closing the duty GF isolation valve.

Manual Mode: The PCCS Operator can remotely turn on and turn off the duty Ground Flare

warmup cycle.

01/28/19



40 61 96.20 - 20


Supervisory Control Logic

The PCCS supervisory control logic includes the following:

1. Call for the Duty GF to turn on

2. Call for the Duty GF to turn off

3. Assign Duty, Standby1, and Standby2 roles to each GF

4. Provide minimum allowable GF temperature

5. Provide calculated LSG header pressure

PCCS HMI


1. Monitor all GF vendor provided I/O points.




1. GF vendor recommended commands

2. Select Duty, Standby1, and Standby2 GF

3. Set minimum allowable GF temperature



Manual mode:


2. Open/Close GF FSG feed isolation valves

3. Modulate GF modulating FSG feed valves

4. Turn on Duty GF

5. Turn off Duty GF



Automatic mode:


2. None

01/28/19



40 61 96.20 - 21

CONTROL FROM THE PLC

PCCS Manual Mode Control Logic

The following manual mode control logic is to be programmed in the PLC:

1. Standard ground flare vendor logic for manually interfacing with modulating

valves and louvers, isolation valves, GF warmup and shutdown cycles, and any

additional manual control specified in Section 43 13 43.01.


The following auto mode control logic is to be programmed in the PLC:

1. Standard ground flare vendor logic for automatically modulating valves and

louvers, opening/closing isolation valves, GF warmup and shutdown cycles, and

any additional logic specified in Section 43 13 43.01.

2. DUTY GF ON:

When the PCCS calls for the Duty GF to turn on, the vendor PLC starts the GF warm-

up cycle including opening the FSG isolation valve and modulating the FSG

throttling valve to rapidly bring the Duty GF up to temperature. The vendor PLC

operates the Duty GF to optimize the completeness of the burn and minimize the

byproducts of combustion. The Duty GF runs continuously until commanded to turn

off by the PCCS.

3. DUTY GF OFF:

When the PCCS calls for the Duty GF to turn off, the vendor PLC starts the GF

shutdown cycle including closing the FSG throttling valve and the FSG isolation

valve. The vendor PLC controls the shutdown in an orderly sequence to a safe state.

4. Ground flare control and process alarms are summarized in the following table.

Point

LSG

Pressure Rising Falling Action

Duty GF Commanded

to Turn On

8.5”H2O Duty GF turns on

Duty GF Commanded

to Turn Off

6.5”H2O Duty GF turns off

01/28/19



40 61 96.20 - 22

PLC INTERLOCKS

The following interlocks are programmed in the PLC and enforced in the Manual and Auto

modes:

1. GF vendor recommended PLC interlocks.

2. The GF FSG isolation valve can only be opened if there is confirmation of a pilot

flame and the purge has been completed.

3. Only the Duty GF can run.

Standard John Zink PLC interlocks.


1. GF vendor recommended hardwired interlocks

FIELD CONTROL

1. GF vendor standard field local control panel lights, switches, and pushbuttons.

2. At each GF PLC local control panel, the operator has ability to put the GF FSG

isolation valve and FSG modulating control valve in local and locally operate each

valve from the local control panel.

**END OF SECTION**

01/28/19


40 63 43 - 1

SECTION 40 63 43

PROGRAMMABLE LOGIC CONTROLLERS

PART 1 -- GENERAL


A. SCOPE

1. This section specifies the requirements for programmable logic controllers (PLC)s, associated input/output devices, communication equipment between PLCs and remote I/O devices, PLC programming standards, and interface requirements to the existing plant control system.

2. There are two different PLC models and software that the Contractor is to provide as part of this project. As shown on the Contract Drawings, instrumentation and equipment associated with the existing Allen-Bradley PLC-5 in the MSG Compressor Building electrical room shall be incorporated into the existing PLC using PLC-5 hardware and PLC-5 programming software. As shown on the Contract Drawings, the new Waste Gas Burner and Ground Flare PLCs shall be Allen-Bradley ControlLogix PLCs programmed in Rockwell Studio 5000. The Contractor and Ground Flare vendor shall program the PLC-5 and ControlLogix PLCs to meet the requirements of the PLC CONTROL NARRATIVES Section (40 61 96.20). District programmers will program the Emerson Ovation DCS to include the functionality described in the PCCS CONTROL STRATEGIES Section (40 61 96.10).

3. The Contractor shall provide all hardware, software, and services necessary for complete and operable PLC systems in compliance with hardware and functional requirements specified in the contract documents. An existing PLC-5 program shall be modified by the Contractor programmer to integrate new I/O points and new I/O modules added as part of this contract following District PLC-5 programming standards. New ControlLogix PLCs shall be programmed following Regional San EchoWater PLC programming standards. All work in this section shall be performed in accordance with the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13).

4. Testing is specified in the PROCESS CONTROL SYSTEM TESTING (40 61 21) and COMMISSIONING Section (01 91 00).

5. Training is specified in the PROCESS CONTROL SYSTEM TRAINING Section (40 61 26).

01/28/19


40 63 43 - 2

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed references, the requirements of this section shall govern.

Reference Title

ANSI/ISA S51.1 Process Instrumentation Terminology

ANSI X3.4 American National Standard Code for Information Interchange

EIA/TIA-232 Interface Between Data Terminal Equipment and Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange EIA 232D Interface Between Data Terminal Equipment and Data Communications Equipment Employing Serial Binary Data Interchange

EIA 422 Electrical Characteristics of Balanced Voltage Digital Interface Circuits

EIA 423-A Electrical Characteristics of Unbalanced Voltage Digital Interface Circuits

EIA 485 Electrical Characteristics of Generators and Receivers for Use in Balanced Digital Multipoint Systems

IEEE 472 Guide to Surge Withstand Capability (SWC) Tests

IEEE 802.3 Information Technology, Local and Metropolitan Area Networks

NEMA IA 2.1 Programmable Controllers, General Information

NEMA IA 2.2 Programmable Controllers, Equipment Requirements

NEMA IA 2.3 Programmable Controllers, Programming Languages

1.03 SUBMITTALS

A. The following information shall be submitted for review in accordance with the SUBMITTAL PROCEDURES Section (01 33 00).

1. A copy of this specification section, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviation.

2. Bill of material listing all components, cables, connectors, and modules included in the system.

01/28/19


40 63 43 - 3

3. Catalog cut sheets and production information for all hardware and software components.

4. Detailed system block diagram showing each PLC module, rack, processor, power supply, etc.

5. Shielding and grounding schematic drawing showing ground impedance and location relative to power source ground.

6. Power consumption, power conditioning, heat loading requirements and all environmental requirements.

7. Functional description of system hardware and software.

8. Programming language software.

9. Screen printouts of the manufacturer’s standard operator interface screen displays along with descriptions of operation shall be submitted for use by the District’s programmer in developing screens for the workstation. All of the screens submitted shall be generated by a color printer.

10. Certificate of compliance or product information on each equipment environmental rating.

11. Hardware design document

12. Software design document

13. Maintenance manual

14. Operator's manual

15. Inventory list

16. For each PLC, a hardware layout drawing which shows the location and the physical size of each major component and of each termination panel including the mounting provisions

17. A copy of the contract document, PLC system block diagrams, control diagrams and process and instrumentation diagrams that apply to the equipment in this section marked to show specific changes necessary for the supplied equipment. If no changes are required, the drawings shall be marked "No Changes Required."

18. Network system block diagram showing all network components including medium attachment units (MAUs), attachment unit interfaces (AUIs), workstation network adapter cards, cables, multi-media repeaters (MMRs), PLC processors and remote I/O adapters.

01/28/19


40 63 43 - 4



PART 2 -- PRODUCTS

2.01 ACCEPTABLE PRODUCTS

A. PLC PRODUCTS:

1. The following manufacturer is approved to submit the products specified in this section in order to standardize on equipment and to maintain interchangeability of parts at the Sacramento Regional Wastewater Treatment Plant. The products shall be modified as required to meet all requirements specified. Products from other manufacturers will not be accepted for this project.

Manufacturer Model

Rockwell/Allen-Bradley PLC/5 Series (Existing)

Rockwell/Allen Bradley ControlLogix 1756 L7 series, no others allowed

Rockwell/Allen Bradley Studio 5000 Software for ControlLogix PLC, no others allowed

Rockwell/Allen Bradley Stratix 5700 series Industrial Ethernet switch, model 1783-BMS06SGA or higher number of copper ports as required for panel connections. Provide a minimum of two single mode fiber optic SFP modules per switch.

01/28/19


40 63 43 - 5

2.02 GENERAL PRODUCT REQUIREMENTS

A. MATERIALS:

1. Equipment and/or products shall be new and unused at the time of system assembly.

2. All components of the PLC system shall be standard products of a single manufacturer.

B. Each PLC and remote I/O chassis shall contain a power supply module to provide the necessary operating voltages to each module in that chassis. The power supply shall be sized to power all modules mounted in the chassis plus an average module load for any empty slots plus 25 percent above that total.

C. PLC-5 control logic shall be programmed following Regional San PLC-5 programming standards.

D. Non-redundant ControlLogix PLCs shall be provided with a minimum of three (3) EN2T modules.

E. Redundant ControlLogix PLCs shall be provided with a minimum of one remote I/O chassis, five (5) EN2T modules and three (3) EN2TR modules for communications. Field I/O and OIT communications shall connect with the remote I/O chassis.

F. ControlLogix controller shall be supplied with the required memory and functional capacity to perform control logic specified in Section 40 61 96.20. The minimum memory for program logic shall be 8 MB.

1. Each CPU shall continually monitor its operation and shall shutdown in case of failure that would cause faulty solution of logic. A running CPU shall identify communications failures, I/O assembly errors, I/O module errors via networked communications with the Emerson Ovation DCS.

G. ControlLogix control logic shall be programmed in ladder logic and follow Regional San EchoWater programming standards.

H. Spare I/O points shall be as shown in the PLC I/O Schedule and on the drawings. In addition, empty I/O points shall be provided as required such that, at a minimum, the total number of fully implemented spares and available chassis space for spares is equal to thirty (30) percent of the fully operational points.

I. MAINTENANCE CONTRACT:

1. Provide a 2-year warranty period and maintenance contract, commencing on the date of substantial completion. Maintenance contract shall be renewable at the end of its term and be combined with any existing contract.

01/28/19


40 63 43 - 6

2. Maintenance contract shall cover all parts and labor for onsite preventive maintenance and onsite demand maintenance and shall cover providing replacement components, parts, and replenish onsite spare parts.

a. Demand response time shall be to provide a qualified maintenance technician onsite when requested within 24 hours for demand maintenance calls placed during normal business hours. Normal business hours shall be Monday through Friday 7AM to 3PM Pacific Standard (and Daylight) Time.

b. Preventive maintenance shall cover visits to perform regular maintenance and inspections to keep the system in satisfactory operation.

c. Persons providing service under this contract shall:

1) Be factory trained at an official Allen-Bradley training facility on the hardware and software associated with the requested service.

2) Have a minimum of two (2) years’ experience maintaining Allen-Bradley ControlLogix PLCs.

3) Be certified by Allen-Bradley to perform maintenance tasks on the Allen-Bradley equipment being maintained.

2.03 PLC MATERIALS/EQUIPMENT

A. CONTROLLOGIX PLC:

1. I/O modules shall be plug-in units. Individual modules shall be removable from the I/O assembly during system operation without disconnecting field wiring, disturbing assembly wiring, halting CPU operation, halting program execution, powering down the I/O rack, or causing a fatal logic error.

2. The following I/O shall be used for the ControlLogix PLC as shown on the Contract Drawings:

Allen-Bradley

Number Voltage I/O type Notes

1756-IA16I 120V AC Digital input (DI) 16 individually isolated inputs

1756-IB16I 12/24V DC

Digital input (DI) 16 individually isolated inputs

1756-OA16I 120V AC

Digital output (DO) 16 individually isolated outputs

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Allen-Bradley


1756-OB16I 12/24V DC

Digital output (DO) 16 individually isolated outputs

1756-IF16 4-20 ma DC Analog input (AI) 8 differential inputs

1756-OF8 4-20 ma DC Analog output (AO) 8 voltage or current outputs

3. Allen-Bradley Stratix 5700 layer 2 network switch shall be provided with Cisco technology embedded. Dual power inputs, input and output alarms, console port and fiber SFP ports shall be provided. Provide 25 percent spare copper ports for future use. Switch shall include Rockwell Studio 5000 add-on profiles.

B. PLC-5:

1. The application software used on the existing PLCs is a Microsoft Windows-based ladder logic development and maintenance program specifically designed for Allen-Bradley PLC-5 series processor. The application program provides on-line and off-line programming, I/O configuration and addressing, documentation of the ladder logic program and troubleshooting. The logic development software originally used was Rockwell Software, RSLogix5/#9324-RL5300ENE series. The Contractor shall use the most recent version of Rockwell RSLogix5 for this project.

2. I/O modules shall be plug-in units. Individual modules shall be removable from the I/O assembly during system operation without disconnecting field wiring, disturbing assembly wiring, halting CPU operation, halting program execution, powering down the I/O rack, or causing a fatal logic error.

3. The following I/O shall be used to expand the existing PLC-5 I/O as shown on the Contract Drawings:

Allen-Bradley


1771-ID 120V AC or 125V DC

Digital input (DI) On/off voltage at 24V AC; input filtering; isolated; six inputs per module.

1771-OD 120V AC

Digital output (DO) 2 amps max. per point, 6 amps max. per module; six outputs per module

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Allen-Bradley


1771-OX 120V AC or 125V DC

Relay output (RO) 2 amps at 100V AC inductive; four isolated contacts per module.

1771-IQ16 24V DC Digital input (DI) 10-32V DC; 12 inputs per module.

1771-OQ16 24V DC Digital output (DO) 2 amps isolated; 12 outputs per module.

1771-IL 4-20 ma DC Analog input (AI) Eight fully isolated differential inputs per module.

1771-OFE2 4-20 ma DC Analog output (AO) Four isolated outputs per module.

C. OPERATOR INTERFACE TERMINAL (OIT)

1. Provide C-more touch panel:

a. 15-inch Color TFT 1024 x 758 SVGA Ethernet and USB EA9

b. AC/DC adaptor for C-more touch panels powered from 100-240 VAC and provides 24 VDC at 1.5 Amps.

c. EA9 C-more series programming software.

d. Contractor and Vendor shall provide all OIT programming. OIT programs shall follow District graphical interface standards.

D. COMMUNICATION

1. Ethernet Modules

a. Non-Redundant PLC Network Ethernet Modules: Each non-redundant PLC shall contain a minimum of three (3) Ethernet communications modules for communications with the PLC network subnets for PLC-PLC and PLC-PCCS communications, and for isolated PLC-OIT communications.

b. Redundant PLC Network Ethernet Modules: Each redundant PLC shall contain a minimum of two Ethernet communication modules for communication with PLC network subnets for PLC-PLC and PLC-PCCS communications. Redundant PLCs will always have a Remote I/O rack with a minimum of one Ethernet

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40 63 43 - 9

communications module for communication to the local OIT. The redundant PLC racks shall be identical and shall be connected with Allen-Bradley redundancy modules.

c. ControlLogix PLC (redundant or non-redundant configuration) and Remote I/O Rack Ethernet Modules: Dual port Ethernet cards shall be provided for communications with remote I/O racks in a Device Level Ring (DLR) using EtherNet/IP protocol. The PLCs and Remote I/O racks shall be cabled following Rockwell’s recommended DLR network configuration.

E. ENVIRONMENTAL RATINGS:

1. GENERAL:

a. PLC equipment, except programming unit, shall comply with the environmental requirements of the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13).

2. ELECTRICAL SURGE:

a. The PLC system power supplies, data transmission circuits, discrete input modules, and discrete output modules shall withstand surges as specified by IEEE 472.

F. PLC AND OIT APPLICATION PROGRAM COORDINATION:

1. The Contractor and Vendor shall program the PLC control logic and OIT graphical interface application programs. Contractor and Vendor shall provide the PLC I/O database in the required format for integration with existing PLCs on the PLC networks.

2. PLC Control Narratives:

a. In the PROGRAMMABLE LOGIC CONTROLLER CONTROL NARRATIVES Section (40 61 96.20), there are detail descriptions for the process control logic that will be developed by the District programmers except for PLCs.

b. The Contractor shall coordinate with the District’s Emerson Ovation programmer for configuration of the following screens as a minimum:

1) System Overview screen showing alarms and status

2) Alarm screen(s) showing alarm status of all points with acknowledge and silence function keys.

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40 63 43 - 10

3) Graphic displays showing alarms and status for each major subsystem. Start-up and monitoring screens with start/stop targets, etc. that will assist the operator through the equipment selection process and start-up sequences.

4) Other screens as required for clarity of operation and monitoring.

PART 3 -- EXECUTION

3.01 GENERAL

A. PROGRAMMER COORDINATION WORKSHOP:

1. A minimum of two 3-hour programming coordination workshops shall be held at the Project site to understand the program standards, the control narrative and control strategies, identify the I/O to be communicated across the PLC-PCCS interface, and resolve design and code issues between the Contractor, Vendor, and District programming staff. The following attendees shall be included as a minimum:

a. District Emerson Ovation Programmer

b. Contractor PLC Programmer

c. Vendor PLC Programmer

2. SCHEDULING WORKSHOPS:

a. The first workshop shall be held prior to the first programming submittal to review the control strategies, the District submittal requirements including level of annotation, I/O database and network interfaces.

b. The second workshop shall be held after the programming submittal has been approved and prior to the applicable Factory Acceptance Test. The Contracotr or Vendor shall provide preliminary factory acceptance test procedures to the District programmer for review a minimum of 4 weeks prior to the second workshop.

B. SOFTWARE DESIGN DOCUMENT:

1. The description of all support, interface, diagnostic, and general I/O software programmed by the Contractor shall be contained in the software design document. Standard documentation of all of the standard software modules shall be included plus the configuration data for this application. This document shall follow the PLC Programming Standards.

2. A section shall describe how the programming approach will conform to District programming standards including how programming will be arranged, documented, tested, and coordinated with District-furnished operator interface programming.

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3. A section shall describe each major software program that has been specifically designed and written for this contract or for which no standard documentation is provided. These documents shall be logical extensions of the standard software documentation and shall include the following information.

a. DESCRIPTION: This section shall describe how the program accomplishes its function.

b. INTERFACES: All interfaces shall be described in this section.

1) The communication interface section shall describe all direct interfaces between hardware devices, other communication devices, and direct communicating field devices. Include complete setup and configuration of hardware devices required for proper communication.

2) The plant PCCS interface section shall describe all data interfaces and register locations for all calculated and hardwired I/O that is passed to the plant PCCS system.

c. INITIATION/TERMINATION: This section shall describe how the program is initiated, whether it is periodic or on demand with the reasons for execution if on demand, and all possible types of exit or termination.

d. OPERATING DIRECTIONS: This section shall describe all operating scenarios to be programmed into the PLC. Complete descriptions of all operator interactions shall be given, and operator inputs and program outputs to the operator shall be described.

e. SPECIAL CONSIDERATIONS/ERROR CONDITIONS: Any special considerations that are important for the operation of the program shall be contained in this section. All error conditions, their probable cause, and response shall be described.

f. DATA DEFINITIONS: Information about all data used by the program shall be defined in this section including input data, output data, and internal data. For each data quantity, name, source, destination, number of entries, format, and a description shall be furnished.

g. FLOW DIAGRAMS: Program logic flow charts shall be provided showing overall program functions and design.

h. APPENDICES: Any other information not included above shall be included in additional sections or appendices to the document.

C. MAINTENANCE MANUAL:

1. The supplier shall submit for review and approval a Maintenance Manual for the equipment furnished.

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40 63 43 - 12

2. The Maintenance Manual shall describe the detailed preventive and restorative procedures required to keep the system in good operating condition. A maintenance manual or a set of manuals shall be furnished for all delivered hardware, including OEM peripherals. This manual shall contain the following information.

a. PERFORMANCE INFORMATION: This information shall include a condensed description of how the equipment operates. The operational sequence of major assemblies shall be described and illustrated by functional block diagrams.

b. PREVENTIVE-MAINTENANCE INSTRUCTIONS: These instructions shall include all applicable visual examinations, hardware testing and diagnostic routines, and the adjustments necessary for periodic preventive maintenance of the equipment. Instructions on how to load and use any test and diagnostic programs and any special or standard test equipment shall be an integral part of these procedures.

c. CORRECTIVE-MAINTENANCE INSTRUCTIONS: These instructions shall include guides for locating malfunctions down to the card-replacement level. These guides shall include adequate details for quickly and efficiently locating the cause of an equipment malfunction and shall state the probable source(s) of trouble, the symptoms, probable cause, and instructions for remedying the malfunction. These guides shall explain how to use on-line test and diagnostic programs for all devices and any special test equipment, if applicable.

1) The corrective maintenance instructions shall include explanations for the repair, adjustment, or replacement of all items.

D. OPERATORS MANUAL

1. The supplier shall submit for review and approval the Operators Manual. This manual shall describe the configuration and functions of the PLC system and how the system interfaces with the Plant PCCS system. Functional descriptions shall include algorithms necessary to fully understand the system functions. The manual shall be organized for quick access to each detailed description of each function.

2. The Operators Manual shall serve as a guide for the programming personal in troubleshooting interface and operational problems with the PLC system.

3. Additionally, the following shall be provided:

a. Summary control strategies written from an operator's point of view describing the operation, control, and monitoring for each system control loop for both normal and emergency conditions.

b. Summary description of data provided to the plant PCCS system available to be presented on screen displays and reports.

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c. Description of how the system reacts to various external anomalies such as heavy alarming, loss of communication links, heavy operator interaction, daylight savings time/standard time changeover, loss of power, and return of power.

d. Description of how the system reacts to various internal anomalies such as loss of loss of communication and I/O hardware failure.

e. Description of the general hardware configuration and device switching capabilities, with specific instructions on fail-over procedures.

E. INVENTORY LIST:

1. An inventory list shall be furnished consisting of all Contractor supplied material, spare parts, and test equipment. Hardware inventory shall be itemized on a replaceable module level only. The inventory list shall include the following information:

a. Manufacturer's name and address, part number, and serial number.

b. Quantity of units supplied.

c. Quantity of spare parts supplied.

d. Applicable cabinet or rack number.

3.02 INSTALLATION

A. PLC system shall be installed in accordance with all manufacturers’ recommendations and as specified on the drawings. Power, signal and grounding connections between components shall be provided as necessary to provide the specified functions.

3.03 APPLICATION PROGRAMMING

A. GENERAL:

1. The Contractor shall provide all programming necessary to cause the PLC system to execute the specified functions. Required functions are specified in the Control Narratives, and shown on the P&IDs and Control and Logic Diagrams.

2. The programming approach shall conform to District PLC Programming Standards. Copies can be obtained directly from the District.

B. LOGIC DIAGRAMS:

1. The logic portion of the Control and Logic Diagrams are drawn in a format that depicts the functional requirements of this specification; these diagrams shall be considered only as functional requirements. The Contractor shall provide complete

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40 63 43 - 14

and operable programming that will execute the indicated control functions on the specific PLC system hardware provided.


**END OF SECTION**


40 66 35 - 1

SECTION 40 66 35

FIBER OPTIC COMMUNICATION CABLING, CONNECTORS

AND TERMINATION PANELS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies communications patch cabling, connectors, termination panels, and accessories associated with the following networks:

a. PCCS-A and PCCS-B redundant networks

b. PLC-A and PLC-B redundant networks

c. Maintenance network

d. MIS network

e. CCTV network

f. OpenNet public access Internet network

2. Metallic cables are specified in the ELECTRICAL POWER CONDUCTORS AND CABLES Section (26 05 21).

3. The PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13), and the PROGRAMMABLE LOGIC CONTROLLERS Section (40 63 43) provide detailed information about the applications each network supports and the roles and responsibilities of the application providers relative to testing their equipment over the various networks and overall responsibilities for functionality and performance.

4. The CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00) specifies the network and communications equipment racks and rack accessories not specified herein.

5. Installation services to mount and connect all networking and communications equipment provided as part of this section. The Contractor is responsible for provision of fiber optic patch cords to complete the assigned paths used for


40 66 35 - 2

equipment communication. The District will assign the port locations for these fiber optic patch cords

6. Testing services to validate communications between all networking and communications equipment provided as part of this section.

1.02 REFERENCES


Reference Title

ANSI American National Standards Institute

ASTM American Society for Testing and Materials International

BELLCORE GR-409-CORE

Generic requirements for premises fiber optic cable

EIA Electronics Industries Alliance

IEEE Institute of Electrical and Electronic Engineers

IES Illuminating Engineering Society

IEC International Electrotechnical Commission

ISA International Society of Automation

JIS C 5961 Test methods for connectors for optical fiber cord

JIS C 5962 General rules for connectors for optical fiber cord

JIS C 5970 FO1 type connectors for optical fiber cables

JIS C 6820 General rules of optical fibers

NEC National Electric Code

NFPA National Fire Protection Association

NFPA 70 National Electrical Code

NFPA 72 Fire Alarm Signaling


40 66 35 - 3

Reference Title

NFPA 820 Standard for Fire Protection in Wastewater Treatment and Collection Facilities

NFPA 101 Life Safety Code

TIA Telecommunications Industry Association

TIA/EIA-455- Series

Standard Test Procedures for Optical Fibers, Cables, Connecting and Terminating Devices, and other Fiber Optic Components (FOTPs)

TIA/EIA-455-25 Repeated Impact testing of Fiber Optic Cables and Cable Assemblies

TIA/EIA-455-33 Fiber Optic Cable Tensile Loading and Bending Test

TIA/EIA-455-41 Compressive Loading Resistance of Fiber Optic Cables

TIA/EIA-455-81 Compound Flow (Drip) Test for Filled Fiber Optic Cable

TIA/EIA-455-86 FOTP-86 Fiber Optic Cable Jacket Shrinkage

TIA/EIA-455-104 Fiber Optic Cable Cyclic Flexing Test

TIA/EIA-455-181 Lightning Damage Susceptibility Test for Fiber Optic Cables with Metallic Components

TIA/EIA-492AAAA-A

Detail Specification for 62.5-�m Core Diameter/125-�m Cladding Diameter Class IA Graded-Index Multimode Optical Fibers

TIA/EIA-598-A Optical Fiber Cable Color Coding

TIA/EIA-568-C Optical Fiber Cable Testing Standard

UBC Uniform Building Code

UFC Uniform Fire Code

UL Underwriters Laboratory

UL 1277 Electrical Power and Control Tray Cables with Optional Optical Fiber Members

UL 1666 Test for Flame Propagation Height of Electrical and Optical-Fiber Cables Installed Vertically in Shafts


40 66 35 - 4

Reference Title

UL 1695 Vertical-Tray Fire-Propagation and Smoke-Release Test for Electrical and Optical Fiber Cables

B. DEFINITIONS:

1. MM – Multimode

2. SM – Single mode

1.03 SUBMITTALS



2. Manufacturer's catalog data for all products provided under this section shall be assembled in a folder with each page clearly marked with the item and reference number to the specification.

3. Manufacturer’s installation guidelines.

4. Network installer qualifications.

5. Fiber optic patch cable schedules for each fiber optic patch panel.

6. Optical Time Domain Reflectometer (OTDR) and attenuation readings for complete end device to end device connections for all fiber optic network connections.

7. Fusion splicer manufacturer’s cut sheet.

B. FIBER OPTIC CABLE:

1. Manufacturer's specifications, data sheets, and catalog literature for the indoor/outdoor rated fiber optic cable which clearly and unambiguously show that the cable meets all the requirements specified herein.

2. Cable manufacturer's testing documentation for all cables shipped to the job site. Documentation shall include the reel number and as a minimum for each fiber in each cable the following data:

a. Attenuation at 850 nm, 1300 nm, 1310 nm, and 1550 nm, as applicable to multimode and single mode fibers.


40 66 35 - 5

b. Optical Time Domain Reflectometer (OTDR) traces for each fiber of each reel, measured at 850 nm, 1300 nm, 1310 nm, and 1550 nm, as applicable to multimode and single mode fibers.

3. Manufacturer's catalog literature and catalog data sheets for the following items:

a. Cable pulling grips, swivel and lubricant

b. Innerduct and its accessories

c. Protective tubing for fiber optic patch cords

4. SHOP DRAWINGS:

a. Termination panel fabrications and layout drawings with complete list of materials and nameplate engraving list in each cable per the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13).

5. Cable manufacturer's installation recommendations.

6. A copy of the contract document control system block diagrams and cabinet and panel drawings that apply to the fiber optic cable system. These documents shall be marked to show specific changes necessary or if no changes are required, the drawings shall be marked "No Changes Required." Each document shall include reviewer's name, company and date of review.

7. All fiber optic cable sample test sheets and all test results. Test forms shall clearly label the test type, the test location, test date, wavelength, index of refraction, cable identification, fiber type, fiber number, fiber color, and the result or the value of the tested parameter. Along with the test forms, the following documents shall be submitted:

a. Manufacturer’s data on testing equipment used on this project.

b. Signature from the District’s Representative who witnesses the test

c. Signature from the Contractor’s representative who witnesses the test

d. Details (such as manufacturer, model number, serial number and calibration expiration date) of test equipment being used. Must be current within 6 months of test date.

e. All OTDR traces and end-to-end attenuation testing results shall be supplied on printed hard copy and submitted electronically.

f. A completed MDIS Warranty Registration Form #124 for Cable Manufacturer 25 Year Fiber System Extended Warranty.


40 66 35 - 6

g. A completed MDIS Program 25 Year Warranty Processing Requirements Checklist

8. Recommended spare parts list in accordance with the OPERATIONS AND MAINTENANCE DATA Section (01 78 23).

9. Experience resume for all personnel installing the fiber optic system on this job.


A. Submit operation and maintenance (O&M) instructions in accordance with the OPERATION AND MAINTENANCE DATA Section (01 78 23) by submitting a copy of the OPERATION AND MAINTENANCE DATA Section (01 78 23) with each paragraph check marked to show compliance. O&M instructions shall be submittedafter all submittals specified above have been returned mark “No Exceptions Taken” or “Make Corrections Noted.” O&M instructions shall reflect the approved materials and equipment.

1.05 INSTALLATION QUALIFICATIONS

A. Submit networking and communications equipment installation qualifications in accordance with the following:

1. All installation, termination, and testing of equipment specified herein is to be performed by a qualified, skilled technician who is regularly engaged in such work and is equipment with the necessary tool to perform such work.

2. Provide three references for the installer that demonstrate a minimum of three consecutive years of successful networking and communications equipment installations of similar size and complexity.

3. BICSI ITS Installer 2 - Copper and ITS Installer 2 - Optical Fiber certified or a certified BICSI RCDD.

4. “Certified Installer” with cable manufacturer in order to obtain cable manufacturer’s 25 year warranty.

PART 2 -- PRODUCTS

2.01 RACK MOUNTED FIBER OPTIC PATCH PANELS, PATCH CABLES, AND CABLE MANAGEMENT SYSTEM

A. General:

1. Fiber optic cable connections shall be spliced to cable manufacturer provided pre- terminated pigtails with LC connectors. As an option, the pigtails may be preinstalled


40 66 35 - 7

into the fiber termination panel and ready for splicing and placement into the splice tray.

2. High density termination panels shall be used that provide a minimum of 24 LC connections per 1U of rack space.

3. Splice trays shall be used to protect the splices between the fiber optic pigtails and the fiber optic cable entering the fiber optic termination panel.

B. TERMINATION PANEL:

1. Termination panels shall consist of a system of components for routing, supporting, and terminating the fiber optic cables. The system shall consist of rack modules, mounting hardware, cable clamps and grommets, cable routers, storage decks, connector racks, splice trays, and all other items for a complete system.

2. 19-INCH RACK MOUNTED TERMINATION PANELS: Rack mounted termination panels shall be suitable for installation in a Type F cabinet conforming to the requirements of the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00) and as shown on the drawings.

3. ENCLOSED TERMINATION PANELS: Enclosed termination panels shall be mounted inside a Type B, C, D or E cabinet conforming to the requirements of the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00) and as shown on the drawings.

4. CHASSIS: Modules shall be designed for 19-inch EIA rack mounting.

5. TERMINATION PANEL: The fiber optic cable rack mount termination panels shall be constructed for industrial applications and with designation labels for each LC termination within each panel.

6. SPLICE TRAYS: Splice trays shall be stackable and hold 12 fibers minimum per tray. Splice trays shall accommodate the type of splicing employed, either fusion or mechanical splicing.

7. Provide Optical Cable Corporation, or equal.

C. PRE-TERMINATED PANEL PACKAGE:

1. A single mode LC “pre-terminated panel package” shall consist of the following components:

a. Fiber optic termination panel

b. Blank adaptor plate

c. LC single mode adaptor module


40 66 35 - 8

d. LC single mode pigtail (3-meter long)

e. Splice tray

2. For each of the 48-strand single mode fiber optic spur cable terminated at 4U panel (terminate up to three 48-strand single mode spur cables), provide the following Optical Cable Corporation LC pre-termination panel package, or equal:

A. OCC Part # RTS4U-12APB – Quantity 1

b. OCC Part # 6112SMDLC – Quantity 4

C. OCC Part # P8LCUPC12-3M – Quantity 4

d. OCC Part # R48S – Quantity 1

3. For each of the 48-strand singlemode fiber optic spur cable terminated at 2U panel, provide the following Optical Cable Corporation LC pre-termination panel package, or equal:

a. OCC Part # RTS2U-6APB – Quantity 1

b. OCC Part # 600 – Quantity 2

c. OCC Part # 6112SMDLC – Quantity 4

d. OCC Part # P8LCUPC12-3M – Quantity 4

e. OCC Part # R48S – Quantity 1

D. Patch Cords:

1. Provide Patch Cords for Single-Mode and Multimode fiber optic cables with LC connectors on both ends. Provide Optical Cable Corporation, Leviton, or equal

2. Provide a minimum of one spare two meter long patch cord with LC connectors for every 12 patch cords installed as part of this project.

3. PATCH CORD MARKER:

a. Lettering shall be resistant to smudging, fading, chemical and harsh environment deterioration.

b. The letters and numbers that identify each fiber optic patch cord shall be machine-printed in one line with 1/8-inch high characters (equivalent to BRADY TLS Thermal Labeling Systems 10 point font) on 1.5-inch white/translucent self-laminating vinyl labels with permanent black ink. The patch cord marking system shall be BRADY Self-Laminating Vinyl Wire


40 66 35 - 9

Marking Labels (P/N PTL-32-427) and BRADY TLS2200 Thermal Labeling System (P/N TLS2200), or equal.

E. Cable Management and Accessories:

1. CABLE MANAGEMENT: Provide cable management accessories to route and store fiber optic cables and patch cords as required for a well-organized and easily accessible fiber optic termination panel and enclosure.

2. SPLICE-TRAYS: Provide splice-trays from the same manufacturer as the patch panel assemblies. Include the number and type of splice trays required to support all current and future fiber optic cables and fiber optic patch cords of installed fiber optic termination panel equipment. bracket) for each fiber optic cable entering the fiber optic termination panel. Provide Optical Cable Corporation, P/N TCSRB or equal.

2.02 CONTROL PANEL MOUNTED FIBER OPTIC PATCH PANELS, PATCH CABLES, AND CABLE MANAGEMENT SYSTEM

A. General:

1. Fiber optic cable connections shall be spliced to cable manufacturer provided pre- terminated pigtails with LC connectors. The pigtails shall be preinstalled into the fiber termination panel and ready for splicing and placement into the splice tray.

2. High density termination panels shall be used that provide a minimum of 6 LC connections.

3. Splice tray module shall be used to protect the splices between the fiber optic pigtails and the fiber optic cable entering the fiber optic termination panel.

B. TERMINATION Panel:

1. Termination panels shall consist of a system of components for routing, supporting, and terminating the fiber optic cables. The system shall consist of panel mounting hardware, cable clamps and grommets, cable routers, connector plates, splice trays, and all other items for a complete system.

2. CONTROL PANEL BACK-PANEL MOUNTED TERMINATION PANELS: Control panel mounted termination panels shall be suitable for installation in any control panel NOT containing a 19-inch rack.

3. CHASSIS: Modules shall be designed for mounting inside an industrial control panel.

4. TERMINATION PANEL: The fiber optic cable termination panels shall be constructed for industrial applications and with designation labels for each LC termination within each panel.


40 66 35 - 10

5. SPLICE TRAYS: Splice trays shall hold 12 fibers minimum per tray. Splice trays shall accommodate the type of splicing employed, either fusion or mechanical splicing.

6. Provide Optical Cable Corporation, or equal.

C. PRE-TERMINATED PANEL PACKAGE:

1. A single mode LC “pre-terminated panel package” shall consist of the following components:

a. Fiber optic termination panel

b. Blank adaptor plate

c. LC single mode adaptor module

d. LC single mode pigtail (3-meter long)

e. Splice tray

2. For each 12-strand single mode fiber optic cable terminated, provide the following Optical Cable Corporation LC pre-termination panel package, or equal:

a. OCC Part # ZDMB-SB-6 – Quantity 1

b. OCC Part # 6112SMDLC – Quantity 1

D. Patch Cords:

1. Provide Patch Cords for Single-Mode and Multimode fiber optic cables with LC or SC connectors on both ends as required for connections. Provide Optical Cable Corporation or equal

2. Provide a minimum of one spare two meter long patch cord with LC or SC connectors (match cords provided) for every 12 patch cords installed as part of this project.

3. PATCH CORD MARKER:

a. Lettering shall be resistant to smudging, fading, chemical and harsh environment deterioration.

b. The letters and numbers that identify each fiber optic patch cord shall be machine-printed in one line with 1/8-inch high characters (equivalent to BRADY TLS Thermal Labeling Systems 10 point font) on 1.5-inch white/translucent self-laminating vinyl labels with permanent black ink. The patch cord marking system shall be BRADY Self-Laminating Vinyl Wire


40 66 35 - 11

Marking Labels (P/N PTL-32-427) and BRADY TLS2200 Thermal Labeling System (P/N TLS2200), or equal.

E. Cable Management and Accessories:

1. CABLE MANAGEMENT: Provide cable management accessories to route and store fiber optic cables and patch cords as required for a well-organized and easily accessible fiber optic termination panel and enclosure.

2. SPLICE-TRAYS: Provide splice-trays from the same manufacturer as the patch panel assemblies. Include the number and type of splice trays required to support all current and future fiber optic cables and fiber optic patch cords of installed fiber optic termination panel equipment. bracket) for each fiber optic cable entering the fiber optic termination panel. Provide Optical Cable Corporation, P/N TCSRB or equal.

2.03 FIBER OPTIC CABLE (FOS AND FOM)

A. GENERAL:

1. The fiber optic cables shall be indoor/outdoor plenum rated cables with a 25-year cable manufacturer extended warranty and provided with the same manufacturer components and terminations.

2. The type of fiber optic cable and the number of fiber strands shall be provided as indicated in the CABLE SCHEDULE Section (26 06 20.24).

3. The 6-strand SM indoor/outdoor fiber optic cable shall be Optical Cable Corporation, P/N OC-0005477, or equal. Cables shall be modified as required to meet all requirements specified herein.


5. The 18-strand SM indoor/outdoor fiber optic cable shall be Optical Cable Corporation, P/N OC-0005371 or equal.




40 66 35 - 12


B. CABLE CONSTRUCTION:

1. GENERAL:

a. The 2-strand MM indoor/outdoor fiber optic cable shall be a breakout style cable. The cable shall be an assembly consisting of a central strength member, two (2) single fiber (1-strand) subcables, extruded plastic rod fillers if necessary, and a UL 910 listed OFNP plenum rated ORANGE-colored outer jacket. The overall cable diameter shall not be larger than 6.3 mm (0.26 in). cable. The cable shall be an assembly consisting of a central strength member, six (6) single fiber (1-strand) subcables, extruded plastic rod fillers if necessary, and a UL 910 listed OFNP plenum rated ORANGE-colored outer jacket. The overall cable diameter shall not be larger than 7.4 mm (0.29 in).

b. The 6-strand SM indoor/outdoor fiber optic cable shall be a breakout style cable. The cable shall be an assembly consisting of a central strength member, six (6) single fiber (1-strand) subcables, extruded plastic rod fillers if necessary, and a UL 910 listed OFNP plenum rated YELLOW-colored outer jacket. The overall cable diameter shall not be larger than 7.4 mm (0.29 in).

c. The 12-strand SM indoor/outdoor fiber optic cable shall be a distribution style cable. The cable shall be an assembly consisting of a central strength member, three (2) multifiber (6-strand) subcables, extruded plastic rod fillers if necessary, and a UL 910 listed OFNP plenum rated YELLOW colored outer jacket. The overall cable diameter shall not be larger than 14.1 mm (0.56 in).

d. The 18-strand SM indoor/outdoor fiber optic cable shall be a distribution style cable. The cable shall be an assembly consisting of a central strength member, three (3) multifiber (6-strand) subcables, extruded plastic rod fillers if necessary, and a UL 910 listed OFNP plenum rated YELLOW colored outer jacket. The overall cable diameter shall not be larger than 14.1 mm (0.56 in).

e. The 24-strand SM indoor/outdoor fiber optic cable shall be a distribution style cable. The cable shall be an assembly consisting of a central strength member, four (4) multifiber (6-strand) subcables, extruded plastic rod fillers if necessary, and a UL 910 listed OFNP plenum rated YELLOW-colored outer jacket. The overall cable diameter shall not be larger than 14.1 mm (0.56 in).

f. The 48-strand SM indoor/outdoor fiber optic cable shall be a distribution style cable. The cable shall be an assembly consisting of a central strength member, four (4) multifiber (12-strand) subcables, extruded plastic rod fillers if necessary, and a UL 910 listed OFNP plenum rated YELLOW-colored outer jacket. The overall cable diameter shall not be larger than 15.4 mm (0.61 in).


40 66 35 - 13

g. The 96-strand SM indoor/outdoor fiber optic cable shall be a distribution style cable. The cable shall be an assembly consisting of a central strength member, eight (8) multifiber (12-strand) subcables, extruded plastic rod fillers if necessary, and a UL 910 listed OFNP plenum rated YELLOW-colored outer jacket. The overall cable diameter shall not be larger than 22.5 mm (0.89 in).

2. STRENGTH MEMBER: A central plastic rod filler that consists of a dielectric strength member surrounded by an extruded elastomeric polymer coating.

3. FIBER OPTIC BUFFERED CABLES:

a. All fiber optic buffered cables shall be constructed using high performance optical fibers.

b. All fibers in the cable shall conform to a proof test of 100 kpsi.

c. Each optical fiber shall be tight buffered PVC at a thickness of 900 m diameter ±50 m.

d. The PVC tight buffers shall be color coded in accordance with TIA/EIA 598-A.

e. Each optical fiber shall conform to BELCORE GR-409 strip force testing for both the coated fiber and the 900 m tight buffer.

f. There shall be no gaps between the coating material and the tight buffer material visible under a 50 power microscope.

g. Loose tube buffers or lubricants between the buffer material and the coating are NOT acceptable.

4. SUBCABLE:

a. The single fiber (1-strand) subcables shall consist of an optical fiber surrounded by a synthetic yarn strength member and a color coded soft plenum jacket. The strength member shall be composed of individually and precisely tensioned elements such that tensile loads are equally shared by each element. The subcable outside diameter shall be 2.0mm.

b. The 6-strand multifiber subcables shall consist of tight buffered optical fibers surrounded by a synthetic yarn strength member and color coded (in accordance with TIA/EIA 598-A) soft plenum jacket. The strength member shall be composed of individually and precisely tensioned elements such that tensile loads are equally shared by each element. The subcable outside diameter shall be 4.5mm.

c. The 12-strand multifiber subcables shall consist of tight buffered optical fibers surrounded by a synthetic yarn strength member and color coded (in accordance


40 66 35 - 14

with TIA/EIA 598-A) soft plenum jacket. The strength member shall be composed of individually and precisely tensioned elements such that tensile loads are equally shared by each element. The subcable outside diameter shall be 5.5mm.

5. HELICAL STRANDING AND EXTRUDING:

a. The 6-strand single mode cable shall be assembled by helically stranding six (6) single fiber subcables and, if necessary, rod fillers around a central rod filler;and extruding a protective outer jacket directly over the stranded cable core. Each single mode subcable shall consist of one (1) tight buffered single mode optical fiber.

b. The 12-strand single mode cable shall be assembled by helically stranding two (2) multifiber (6-strand) subcables and, if necessary, extruded plastic rod fillers around a central extruded plastic rod filler; and extruding a protective outer jacket directly over the stranded cable core. Each single mode subcable shall consist of six (6) tight buffered single mode optical fibers.

c. The 18-strand single mode cable shall be assembled by helically stranding three (3) multifiber (6-strand) subcables and, if necessary, extruded plastic rod fillers around a central extruded plastic rod filler; and extruding a protective outer jacket directly over the stranded cable core. Each single mode subcable shall consist of six (6) tight buffered single mode optical fibers.

d. The 24-strand single mode cable shall be assembled by helically stranding four (4) multifiber (6-strand) subcables and, if necessary, extruded plastic rod fillers around a central extruded plastic rod filler; and extruding a protective outer jacket directly over the stranded cable core. Each single mode subcable shall consist of six (6) tight buffered single mode optical fibers.

e. The 48-strand single mode fiber optic cable shall be assembled by helically stranding four (4) multifiber subcables and, if necessary, extruded plastic rod fillers around a central extruded plastic rod filler; and extruding a protective outer jacket directly over the stranded cable core. Each single mode subcable shall consist of twelve (12) tight buffered single mode optical fibers.

f. The 96-strand single mode fiber optic cable shall be assembled by helically stranding eight (8) multifiber subcables and, if necessary, extruded plastic rod fillers around a central extruded plastic rod filler; and extruding a protective outer jacket directly over the stranded cable core. Each single mode subcable shall consist of twelve (12) tight buffered single mode optical fibers.

6. OUTER CABLE JACKET:

a. The outer cable jacket shall meet all requirements of the NEC for use in all indoor/outdoor areas (including plenums) without being enclosed in conduit.


40 66 35 - 15

b. The outer jacket shall be flame retardant OFNP plenum rated fluoropolymer conforming to UL 910.

c. The outer jacket shall be extruded directly over the outer layer of the stranded cable core, with no tape separators allowed.

d. The outer jacket shall be smooth and free from holes, splits, blisters, and other surface flaws.

e. A non-wicking polyester yarn ripcord shall be incorporated under the cable jacket for jacket removal.

f. The color of the outer jacket shall be YELLOW for single mode fiber optic cable.

g. The color of the outer jacket shall be ORANGE for multimode fiber optic cable.

h. The color of the outer jacket shall be ORANGE for hybrid fiber optic cable.

i. Cable jacket shrinkage test shall measure the shrinkage or expansion of a cable jacket exposed to temperature aging. Maximum shrinkage shall be less than 5 percent for each specimen tested per the test procedure described in EIA 455-86.

7. CABLE MARKING: The outer jacket shall be surface printed with the manufacturer’s identification, date of manufacture, manufacturer’s part number, sequential 2-foot marks and required UL marking. The color of the markings on the cable shall be black. The inner fiber optic cable shall be surface printed with the appropriate manufacturer’s identification and required UL marking.

C. SINGLE MODE FIBER CHARACTERISTICS:

1. The single mode fiber shall meet the following requirements: FIBER TYPE: Single mode CORE DIAMETER: 8.3 m CLADDING DIAMETER: 125.0 ± 1.0 m CORE-CLAD CONCENTRICITY:: 0.5 m CLADDING NON-CIRCULARITY: 1.0% COATING DIAMETER: 245 ± 5 m CUTOFF WAVELENGTH: 1260 nm ZERO DISPERSION WAVELENGTH: Between 1302 nm and 1322 nm ZERO DISPERSION SLOPE: 0.092 ps/(nm2km) MAXIMUM ATTENUATION: (DUAL WINDOW)

0.50 dB/km @ 1310 nm 0.50 dB/km @ 1550 nm

MODE-FIELD DIAMETER: (DUAL WINDOW)

9.2 ± 0.4 m @ 1310 nm 10.4 ± 0.8 m @ 1550 nm


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D. ADDITIONAL REQUIREMENTS:

1. All fiber optic cables shall have the following mechanical performance:

a. Impact Resistance = 1,000 Impacts

b. Crush Resistance = 1,485 N/cm or greater

c. Cyclic Flex Resistance = 2,000 Cycles

2. All fiber optic cables shall have the following environmental performance:

a. Operating Temperature = -40ºC to +85ºC

b. Storage Temperature = -40ºC to +85ºC

c. Flame Retardancy = UL Listed Type OFNP

3. The 6-strand single mode fiber optic cable shall have a maximum pulling tension of 2,400 N (540 lbs) during installation (short term), and 600 N (130 lbs) long term installed.

4. The 12-strand single mode fiber optic cable with two (2) 6-strand subcables shall have a maximum pulling tension of 3,800 N (850 lbs) during installation (short term), and 1200 N (270 lbs) long term installed. The 18-strand hybrid OR single mode fiber optic cable with three (3) 6-strand subcables shall have a maximum pulling tension of 4,700 N (1,060 lbs) during installation (short term), and 1,500 N (340 lbs) long term installed.

5. The 24-strand single mode fiber optic cable with four (4) 6-strand subcables shall have a maximum pulling tension of 5,600 N (1,260 lbs) during installation (short term), and 1,800 N (400 lbs) long term installed.

6. The 48-strand single mode fiber optic cable with four (4) 12-strand subcables shall have a maximum pulling tension of 7,200 N (1,620 lbs) during installation (short term), and 2,400 N (540 lbs) long term installed.

7. The 96-strand single mode fiber optic cable with eight (8) 12-strand subcables shall have a maximum pulling tension of 14,900 N (3,350 lbs) during installation (short term), and 4,950 N (1,113 lbs) long term installed.

8. The cable shall be packaged on a reel with inner hub diameter greater than the recommended minimum bending diameter of the cable.

9. Waterproof labels shall be attached to the reel showing the name of the manufacturer, date of manufacture, the cable identification number, UL label, and


40 66 35 - 17

the total length of cable on the reel. The ends of all cable shall be sealed to prevent the entry of moisture during shipping, handling, storage, and installation.

10. For fiber optic cable terminations, refer to the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00).

2.04 INNERDUCT

A. GENERAL:

1. Innerduct shall be pre-lubricated fabric multi-cell type with rigid backbone.

2. Flexible fabric mesh innerducts shall be white colored with color stitching indicating the cell size and color-coded pull tape in each cell. Furnish MaxCell Plenum MaxCell MXP type for indoor areas and MaxCell Riser MaxCell MXC type for outdoor locations.

3. 2-inch conduits shall contain a minimum of three 2-inch white colored cells, MaxCell P/N 2003YL. MXC or MXP type shall be provided as required.

4. 3-inch conduits shall contain a minimum of six 3-inch white colored cells, MaxCell P/N 3456BK and 3456BL. MXC or MXP type shall be provided as required.

5. 4-inch conduits shall contain a minimum of nine 3-inch white colored cells, MaxCell P/N 3456BK, 3456BL, and 3456RD. MXC or MXP type shall be provided as required.

6. Fabric innerduct shall be installed in all filled fiber conduits 2 inches and larger.

7. Innerduct shall be non-corrugated yellow colored rigid PVC, 1 1/4” in diameter and installed in cable tray where indicated in the ELECTRICAL RACEWAY SCHEDULE Section (26 06 20.21), Furnish DURA-LINE type SDR-11 smooth wall with silicone or equal.

B. ACCESSORIES:

1. Watertight termination plugs shall be used for sealing fabric innerducts in handholes and manholes. Provide MaxCell MXCTP series, or equal.

2. A swivel and chain harness to avoid duct spiral shall be used for installing multiple packs of flexible fabric innerduct in a conduit. Provide MaxCell MXCIK11, or equal.

3. Install 1-¼-inch fiber optic simplex plug, DURA–LINE or equal for PVC innerduct entering handholes or manholes.


40 66 35 - 18

2.05 FIBER OPTIC CABLE TAGS

A. The letters and numbers that identify each fiber optic cable shall be machine-printed with ¼-inch high characters on cable tag with permanent black ink. The cable tag shall be PANDUIT Fiber Optic Cable Marker Rigid (Non-Adhesive) Tag, P/N PST-FO, or equal.

PART 3 -- EXECUTION

3.01 GENERAL

A. The installation of the fiber optic cable shall be performed and supervised by workers with a minimum of 3 years’ experience with installing and terminating the type of fiber optic cable systems specified herein. Prior to installation as specified herein, perform delivery testing of all fiber optic cables.

B. Installation shall be in accordance with cable manufacturer's recommendations. At no time shall the cable be placed in a position with a 10-inch or less, 90-degree bend radius. All installation equipment and methods shall be reviewed and approved by the District Representative prior to installation. The District Representative shall witness all cable pulls unless otherwise advised in the field.

C. Woven wire grips shall be used to pull the cable. The grips shall have a minimum length of 18 inches and shall be applied to the cable in conformance to the cable manufacturer's standard recommendations.

D. A nonfreezing type of swivel shall be inserted between the pulling line and cable pulling grip to prevent twisting under strain. The swivel shall be equipped with shear or tension pins with a breaking strength of 600 pounds. No cable shall be pulled without a functional breakaway swivel.

E. The cable shall be installed using a hydraulic capstan or winch, equipped with a recording running line dynamometer to measure the pulling tension. The pulling equipment shall have "slip-load" capability to allow the winch to maintain a constant pulling force without taking up the winch line. The pulling equipment shall also be equipped with a hydraulic bypass which shall be set so that a maximum tension of 600 pounds is not exceeded. If at any time the tension reaches 600 pounds during the pulling operation, the pull shall be stopped and the District Representative shall be notified. The difficulty shall be determined and corrected before pulling is resumed. The dynamometer shall be connected and turned on before any pulling has begun and shall run continuously through the pulling operation.

F. The cable reel shall be positioned at the feed point in alignment with the raceway and in such a position that the cable can be passed from the top of the reel in a long, smooth bend into the raceway system. The use of a cable feeder is required.


40 66 35 - 19

G. Supply all bull wheels, blocks, split wheels, cable feeders, and necessary equipment required to provide a clean and safe operation. The cable shall not be allowed to travel over any wheel or block which has a radius less than the minimum radius allowed by the cable manufacturer.

H. The use of snatch blocks and rollers to guide the cable into the conduit at the feed point shall be minimized. The cable shall be fed slack by hand into the feed point and raceway without the use of rollers wherever possible. The cable reel shall be tended aall times and shall be turned by hand to provide the required cable slack. Under no circumstances shall the cable tension be allowed to turn the cable reel. A rim roller, with a wheel radius greater than the minimum cable bending radius shall be placed at the manhole or vault opening to prevent the cable from dragging on the manhole rim or steps.

I. A thorough visual inspection for flaws, breaks, or abrasions in the cable sheath shall be made as the cable leaves the reel, and the pulling speed shall be slow enough to permit this inspection. Damage to the sheath or finish of the cable shall be sufficient cause for rejecting the cable. Cable damaged in any way during installation shall be replaced. During installation, the cable shall be subject to continual inspection by the District Representative.

J. If the cable becomes damaged during installation, stop operations and notify the District Representative immediately. The District Representative will determine whether to replace the entire reel of cable or to install a termination panel to eliminate the damaged section.

K. All fiber optic cables should be placed inside their appropriate innerducts, as specified.

1. Innerduct installer shall follow manufacturer’s installation recommendations and pulling procedures.

L. Fiber optic duct plugs shall be used at each end of the innerduct run. Cables within innerrducts will be sealed in accordance with RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS Section (26 05 34) to prevent vapor migration.

M. A minimum of 30 feet fiber optic cable service loop shall be used at each end of termination.

N. Cable ends shall be sealed with temporary caps during installation, up to time when they are terminated.

O. Install protective tubing for all fiber optic patch cords that run between the termination panel and the supplied equipment in as specified herein.

P. Conduits for fiber optic cables entering buildings and all other structures from manholes and handholes shall be sealed in accordance with RACEWAYS, BOXES,


40 66 35 - 20

MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS Section (26 05 34) after cable installation.

3.02 INSTALLATION

A. SPLICING

1. Fiber Optic cables shall be spliced at Fiber Termination Panels only, unless approved in advance by the District Representative.

a. Mechanical splicing is not permitted. Only fusion splicing shall be used.

2. Fusion Splicing:

a. Fusion splice shall be installable on single mode buffered fibers using a portable fusion splice system with integrated workstation.

b. The fusion splicer manufacturer shall be ISO 9001 registered.

c. The field fiber shall be positioned for x and y alignment and shall be automatically aligned with the pigtail fiber with the fiber ends between the electrodes and in view of the projection screen.

d. Magnification of the fiber ends shall be approximately 100x using the projection lens.

e. Automatic pre-fusion and fusion shall be controlled by an integrated microprocessor.

f. The mean splice loss shall be less than 0.05 dB in the connector at wavelengths of 1310 and 1550 nm. The value shall be the mean of splice loss joint losses measured bidirectional with an Optical Time Domain Reflector (OTDR).

B. TERMINATION PANEL INSTALLATION:

1. Termination racks, panels, and cabinets shall be installed in accordance with the manufacturer's instructions and the requirements of the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00). The mounting bolt seismic calculations required per The COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00) shall be approved prior to their installation.

2. Designation labels of all termination panels shall clearly show the panel ID, remote panel ID, cable ID and type of cable and fibers (for fiber optic cable). Consult the District Representative for details


40 66 35 - 21

C. PATCH CORDS:

1. Provide all patch cord from the termination panels to the supplied equipment for District installation. The District will assign the port locations for the patch cord connections.

2. For fiber optic patch cords, use LC connectors at each end of the landing location for each Network.

D. CABLE MANAGEMENT: All network cables shall be organized within the network panels using cable management systems that mount on standard TIA/EIA rail and conform to TIA/EIA structured cable installation requirements.

E. TERMINATIONS:

1. Active and spare fiber optic cables shall be provided, installed, terminated, and tested with all required connectors and appurtenances for all data links.

F. INNERDUCT INSTALLATION:

1. Install innerduct per the manufacturer’s recommendations.

2. Installation of flexible fabric innerduct shall include the use of pulling lubricant, swivel and chain harness.

a. The maximum pull tensile strength shall not be less than 2500 lbs force. b. A swivel shall be used during pulling operation to avoid duct spiral.

3. The flexible fabric innerduct is to run from manhole/handhole to manhole/handhole and be slit or cut by the contractor per manufacturer’s representative best practice at each manhole/handhole to allow for six (6) feet of cable slack to be coiled and accessed at each manhole/handhole per the plans and specifications.

4. Where flexible fabric innerduct is used, install watertight termination plugs in conduits inside manholes and handholes. The watertight terminations must provide a watertight seal around the used and unused cells and shall be removable when cables are added in the future.

5. All signal conduits, 2 inch and larger, with cables installed, shall contain flexible fabric innerduct. Signal ductbanks containing fiber conduits should have a minimum of two (2) spare innerduct cells available for future use. If only one (1) spare cell is available or all cells are occupied by cables, one of the spare conduits shall have innerduct installed.

6. Where flexible fabric innerduct is installed, different color coded stitching multipacks shall be used in both 3 inch and 4 inch conduits for cell identification.


40 66 35 - 22

3.03 TESTING

A. GENERAL:

1. Testing shall be coordinated with testing requirements specified in the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00).

2. Test forms shall be used for End-to-End Attenuation Test Data, Splice and Connector Loss Test Data, and OTDR Signal Trace Test Data, as provided in the REFERENCE FORMS Section (01 91 10).

B. FIBER OPTIC TESTING:

1. GENERAL:

a. Perform field tests on each fiber of each cable in accordance with this Section. All fibers shall be tested for breaks, abnormalities, and overall attenuation characteristics to ensure that the cable system meets the attenuation specifications specified herein.

b. The District shall witness all testing and final checkout of the fiber optic system to determine fiber optic cable system acceptability.

2. TEST EQUIPMENT:

a. All test equipment used shall have a calibration sticker indicating the equipment has been calibrated within the preceding 6 months.

b. The following equipment shall be used for testing of the fiber optic cable:

1) Power Meter and Testers. Fluke SimpliFiber ProOptical Power Meter, or equal.

2) Optical Time Domain Reflector (OTDR). Fluke OptiFiber Prop OTDR or equal.

3) Jumpers, connectors, adapters, 1-km backscatter suppression kit, attenuators, and other miscellaneous items.

3. DELIVERY TEST:

a. After delivery to the site, before the cable is installed, each fiber shall be tested. Generate an end-to-end OTDR trace for each single mode (SM) fiber at both 1310 and 1550 nm wavelengths, and each multimode (MM) fiber at 850 and 1300 nm wavelengths, using the proper index of refraction for that fiber. The field reel test shall be performed with a fused patch cord connected to a 1 km- launch cable. These traces shall also identify the total optical length. An optical attenuation measurement (dB/km) shall be made for each fiber at both 1310/ 1550 nm


40 66 35 - 23

wavelengths (SM), and 850/1300 nm wavelengths (MM) with an OTDR. Each measurement shall be captured on a trace.

b. The District shall witness all pre-installation testing. All test documentation shall be turned over to the District within 5 days after the delivery test. If any cable is found to not meet the performance levels of the manufacturer's factory tests, the cable shall be replaced.

C. FIBER OPTIC PREOPERATIONAL TEST:

1. Preoperational testing is to be completed after the pre-installation delivery test of the fiber optic cable specified herein.

2. OTDR TEST:

a. Each optical fiber shall be tested end-to-end for each installed span after cable installation. For each optical fiber, an end-to-end OTDR trace shall be made at both 1310/1550 nm wavelengths (SM), and 850/1310 nm wavelengths. This testing shall be conducted from both ends of the fiber. For OTDR testing, a 1- kilometer backscatter suppression fiber shall be used.

b. For the following equations: L = Optical length of fibers in meters, N = Number of splices in the cable, C = Number of mated-pair connectors.

c. For each installed single-mode (SM) optical fiber, the measured optical power loss in dB shall not exceed the following:

1) For 1550 nm, measured loss less than: 0.5/km + (0.1)N + (0.75)C

2) For 1310 nm, measured loss less than: 0.5/km+ (0.1)N + (0.75)C

d. Any installed fiber optic cables containing one or more fibers not meeting the specified insertion loss above will not be accepted and shall be repaired or replaced at no additional cost to the District.

3. POWER METER TEST:

a. Each optical fiber shall be tested for end-to-end attenuation after the cable is installed. The attenuation test shall utilize a stabilized optical source and power meter. The test shall be conducted per the TIA/EIA568-C standard.

b. Any installed fiber optic cables containing one or more fibers not meeting the specified optical power loss above will not be accepted and shall be repaired or replaced at no additional cost to the District.

D. CABLE TAGS:

1. All fiber optic cables installed shall be identified with cable tags.


40 66 35 - 24

2. Fiber optic cable shall be identified at each end at the fiber optic termination panel with printed cable tag.


**END OF SECTION**


40 67 00 - 1

SECTION 40 67 00

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies requirements for modification of existing and fabrication of new panels, cabinets, termination cabinets, and 19-inch electronic racks which support and/or enclose control, instrumentation, and communication equipment as shown on the drawings.

2. Provide the instrument, control, and monitoring features indicated on the P&ID and electrical drawings.

3. Panels that contain Allen-Bradley programmable logic controllers (PLCs), and remote I/O are shown on the drawings.

a. PLC and PLC remote I/O equipment shall comply with the PROGRAMMABLE LOGIC CONTROLLERS Section (40 63 43).

4. Panels that contain transmitters, analyzers, signal conditioning modules and other equipment or devices are specified in INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 70 00); and the MISCELLANEOUS INSTRUMENTS, CALIBRATION EQUIPMENT, INSTRUMENT VALVES, AND FITTINGS Section (40 79 00).

5. Panels that do not comply with the specified products, specified logic method, hardwired or PLC logic, shall not be accepted. Cost to retrofit the panel as specified shall be borne by the panel supplier. Corrections or modifications to UL 508A Industrial Control Panels shall be transported to the panel supplier’s facility for corrections, testing, relabeling and inspection, or shall require a UL inspector site inspection for approval of panel modifications and to re-label the panel after the field modifications are completed.

B. UNIT RESPONSIBILITY:

1. Provide all conforming electrical and/or pneumatic components and devices, support hardware, fasteners, interconnecting wiring, and/or piping required to make the control panels and/or enclosures complete and operational.


40 67 00 - 2

2. Demonstrate panel conformance, performance, and functionality as specified in the COMMISSIONING Section (01 91 00).

C. PANEL DESIGN:

1. GENERAL: Panel hardware and software is specified herein and in other Division 40 sections.

2. CONTROL POWER DISTRIBUTION: Panel containing 120-volt powered equipment use the din-rail power distribution method with fuses and blown fuse indication. Power is restricted to 120 Vac and 24 Vdc.

3. POWER SUPPLIES: Panel containing direct current powered instruments or serving as the termination point for transmission loop powered field instruments contain direct current power supply system as specified herein.

4. AIR SUPPLIES: Each panel containing pneumatically operated instruments shall be provided with a dual service regulator and distribution manifold, and all other devices necessary to perform the functions specified. Air distribution and control devices shall be provided as specified in the MISCELLANEOUS INSTRUMENTS, CALIBRATION EQUIPMENT, INSTRUMENT VALVES, AND FITTINGS Section (40 79 00).

5. ELECTRICAL CONTROL DEVICES: Comply with requirements of the ELECTRICAL CONTROLS AND RELAYS Section (26 09 16) for pushbuttons, indicating lights, relays, and similar equipment located in panels specified herein and shown on the drawings.

6. UNINTERRUPTIBLE POWER SUPPLIES: UPS power shall typically be distributed from a large UPS located outside of the control panel. However, where a panel mounted UPS is called for, it shall have a 120 Vac input and 120 Vac output as specified herein.

D. SHIPMENT, PROTECTION AND STORAGE:

1. Equipment shipment, protection and storage shall conform to the requirements specified in the PRODUCT DELIVERY REQUIREMENTS Section (01 65 00).

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of a conflict between the requirements of this section and those of the listed references, the requirements of this section shall prevail.


40 67 00 - 3

Reference Title

ANSI/EIA 310 Racks, Panels and Associated Equipment

ASTM A36 Structural Steel

ISA S5.1 Instrumentation Symbols and Identification

NEMA ICS 1 Industrial Control and Systems: General Requirements

NEMA ICS 2 Industrial Control and Systems: Controllers, Contactors and Overload Relays Rated 600 Volts

NEMA ICS 6 Industrial Control and Systems: Enclosures

NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum)

NFPA 70 National Electrical Code (NEC)

NFPA 79 Electrical Standard for Industrial Machinery

UL 20 General-Use Snap Switches

UL 50 Enclosures for Electrical Equipment

UL 83 Thermoplastic-Insulated Wires and Cables

UL 94 Tests for Flammability of Plastic Materials for Parts in Devices and Appliances

UL 508 Industrial Control Equipment

UL 508A Industrial Control Panels

UL 698A Industrial Control Panels Relating to Hazardous (Classified) Locations

UL 1063 Machine-Tool Wires and Cables

UL 1598 Luminaires

B. DEFINITIONS:

1. Definitions shall be as defined in the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13).

1.03 SUBMITTALS

A. Submittals shall be coordinated with submittal requirements of the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13).

B. The following information shall be submitted for review in accordance with SUBMITTAL PROCEDURES Section (01 33 00):


40 67 00 - 4

1. A copy of this specification section with addenda updates, with each paragraph check marked to show compliance or marked to show deviations.

2. A copy of the contract document control diagrams, cabinet and panel drawings, and process and instrumentation diagrams that apply to the submitted panel. These documents shall be marked to show specific changes necessary or if no changes are required, the drawings shall be marked "No Changes Required." Each document shall include reviewer's name, company and date of review.

3. Table of contents and list of explanations, clarifications or exceptions.

4. Elementary diagrams for systems where contract documents are inadequate or do not exist.

5. Dimensioned panel fabrication and layout drawings:

a. Exterior panel layout.

b. Interior panel layout.

c. Door-in-door construction devices, where required.

d. Sections showing clearances between face and rear mounted equipment.

6. Complete bill of materials, nameplate engraving list and product data sheets for each item. Include panel and equipment tag number and description, nameplate size and character size of nameplates. Indicate engraving by line.

7. Connection diagrams.

8. Software and firmware documentation coordinated with requirements of the PROGRAMMABLE LOGIC CONTROLLERS Section (40 63 43).

9. Written sequence of operations coordinated with the requirements of the PROGRAMMABLE LOGIC CONTROLLER CONTROL NARRATIVES Section (40 61 96.20).

10. Electronic assembly diagrams.

11. Seismic calculations for freestanding panels in accordance with the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00).

12. Heat load calculations for each panel based on the highest ambient temperature listed in the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13) for the area in which the subject panel will be located.


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13. UPS calculations for the required kVA rating at 150 percent, schematic diagrams, and wiring connection diagrams.

14. Test results as specified in COMMISSIONING Section (01 91 00).


A. Submit operation and maintenance (O&M) instructions in accordance with the OPERATION AND MAINTENANCE DATA Section (01 78 23) by submitting a copy of the OPERATION AND MAINTENANCE DATA Section (01 78 23) with each paragraph check marked to show compliance. O&M instructions shall be submitted after all submittals specified above have been returned “NO EXCEPTIONS TAKEN” or “MAKE CORRECTIONS AS NOTED.” O&M instructions shall reflect the approved materials and equipment.

1. Manual shall include final reviewed submittal redlined to show as-built conditions, and a separate record of all final configuration, jumper and switch settings.

PART 2 -- PRODUCTS

2.01 GENERAL

A. Control and power panels and cabinets shall be factory assembled and tested. Panels and cabinets shall include all components indicated in the applicable drawings, required by the particular equipment specifications, specified in this section, and all necessary accessories to make a complete and operable system. The catalog numbers listed herein require special modifications and accessories to meet all requirements specified herein and shown on the drawings.

B. Equipment and materials shall be new and free from defects.

1. All material and equipment of the same or similar type shall be of the same manufacturer throughout the work.

2. Standard production materials shall be used wherever possible.

C. All control panels shall include marking to identify the short circuit current rating (SCCR) to which it is designed per the National Electric Code Article 409.

D. Panels located outdoors or located in corrosive areas shall be bottom coated with waterproof coatings.

E. Panels shall be arranged to separate control and instrument devices from power wiring and for dedicated field wiring terminations rated for 600 Vac or less for power, control, and instrument signal wiring.


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F. Panels shall be fabricated by a UL-508A recognized facility and shall bear the appropriate UL 508A Industrial Control Panel label. Panels for Hazardous (Classified) Locations shall bear the appropriate UL 698A label.

2.02 PANEL TYPES

A. The following panel types are applicable to new panels and to the modification of existing panels. Panel type designations shall conform to the requirements of NEMA 250, NEMA ICS 6, UL 50, UL 508 or 508A, and as specified herein.

Type Construction

A Open plate with all devices, interconnections, and accessories surface mounted.

B NEMA 4 enclosed unit with hinged door(s) and front access only. All devices mounted on an interior subpanel or the door.

C NEMA 4X, otherwise the same as Type B.

D NEMA 12 enclosed unit with hinged door(s) and front access only. All devices mounted on an interior subpanel or the door.

E NEMA 1 enclosed unit with hinged door(s) and front access only. All devices mounted on an interior subpanel or the door.

F NEMA 12 freestanding enclosed unit with hinged access door(s). All devices compatible with 19 inch rack mounting hardware.

G NEMA 7 enclosed unit with hinged door(s) and front access only. All devices mounted on an interior subpanel or door.

H Freestanding open frame rack 19 inches with all devices, interconnections and accessories accessible from all sides.

2.03 FABRICATION REQUIREMENTS

A. GENERAL:

1. SEISMIC: Completed and installed panelwork shall safely withstand Seismic Zone 3 loading requirements as defined in the Uniform Building Code and as specified in the COMMON WORK RESULTS FOR ELECTRICAL Section (26 05 00). All enclosures and equipment shall be braced to prevent damage from specified forces. Equipment shall not be required to function properly during periods of seismic disturbance but shall be capable of manual restart following a disturbance.

2. UL LABEL: Enclosures shall be UL labeled. All other devices specified in this section shall be UL listed. This requirement shall be waived only if a UL listing is not available from any manufacturer of a similar product that meets all other specified requirements.


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3. FACE-MOUNTED INSTRUMENT REINFORCEMENT:

a. Face-mounted instruments on panel Types B, C, D, E, and F, as defined herein, that are more than 6 inches deep, weigh more than 10 pounds, or exert more than a 4 ft-lb moment force on the face of the panel shall be rigidly supported at the rear of the instrument.

b. Identify face-mounted devices with nameplates including tag number and equipment description. Mount instruments for access to components and ease of removal. Components for installation on panel exterior locate a minimum of 36 inches above the operating floor level and no greater than 60 inches above the operating floor level. Blank off cutouts for future equipment with suitable covers as required to retain the cabinet's NEMA rating. Identify device tag numbers on the panel rear as well as the panel front.

c. Face-mounted devices shall be the same NEMA rating as the associated panel.

4. FLOOR STANDS AND PEDESTALS: Where specifically shown on the drawings panels shall be provided with floor stands or pedestals. Floor stands shall raise the panel approximately 12 inches above the floor. Pedestals shall raise work station enclosures so the keyboard is approximately 36 inches above the floor.

5. STEEL THICKNESS: For fabrication Types B, C, D, and E, the enclosure and interior panel shall constructed using the sheet steel sizes in the table below. Heavier sheet metal shall be used if required to meet seismic requirements, required to meet design standards in this section, or needed due to Contractor's selection of equipment.

Enclosure Height

(inches) Minimum Enclosure

Steel Thickness Minimum

Panel Thickness

4 - 8 16 14

9 - 56 14 12

57 or more 12 12

6. DISCONNECT SWITCHES: Where shown on the drawings or specified in the particular equipment section, a flanged mounted fused disconnect switch shall be provided which conforms to the requirements of the ELECTRICAL CONTROLS AND RELAYS Section (26 09 16). Disconnect switches shall be mounted between 36 inches and 72 inches above the floor. Flange and disconnect shall have the same NEMA environmental rating as the enclosure.

7. MISCELLANEOUS:


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a. Locate and install all devices and components so that connections can be easily made and ample room is provided for servicing each item. Provide at least 20 percent spare contiguous sub-panel area for future expansion inside the panel

b. Face-mounted equipment shall be flush or semi-flush with flat black escutcheons.

c. Cutouts for future equipment shall be blanked off with suitable covers as required to retain the cabinet's NEMA rating.

d. Panels shall include a drawing pocket and ground studs on the enclosure and doors.

e. Panels with a total finished weight of over 50 pounds shall be furnished with lifting eyes.

f. Provide minimum of 20 percent spare terminal blocks, with a minimum of 10 each of analog, discrete, and power spare terminal blocks.

g. Provide minimum of 12 inches clear space from the bottom of the panel to the bottom of the subpanel.

h. Terminate all wiring to panel connections from field instruments, devices, and other panels at master numbered terminal strips.

i. Provide a minimum of 2½ inches between wire ways and terminals.

j. Panels shall be arranged to separate control and instrument devices from power wiring. AC, DC, and digital circuits shall be arranged to be physically separated inside the panel. Digital circuits shall follow the network installation protocol requirements

k. Wiring channels shall comply with UL94, Type V. Wiring channel fill shall not exceed 40 percent.

l. Wiring duct, spiral wrap, and cable ties shall be used to manage cables within the panel.

m. All equipment mounted on subpanels shall be drilled and tapped, the use of drive screws or nuts and bolts are prohibited for equipment mounting.

B. PANEL FABRICATION REQUIREMENTS:

1. TYPE A: Panels shall be 3/8-inch thick ASTM A36 mild steel plate and mounting channel hot dipped galvanized after fabrication in accordance with the HOT DIP ZINC COATING Section (05 05 14). Plates over 2 feet in any dimension shall be


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braced with 1-1/2-inch angles for rigidity. Mounting hardware shall be Type 304 stainless steel. Wiring shall be carried in raceways and fittings in accordance with the RACEWAY, BOXES, MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS Section (26 05 34). Equipment shall be surface mounted on the panel's front face.

2. TYPE B: Cabinet shall conform to the requirement of NEMA 250 and NEMA ICS 6, Type 4 and shall be provided with a drip shield. Cabinet shall be provided with an interior frame or otherwise formed to provide a rigid structure. Hinges shall be full length piano-type with removable stainless steel hinge pin. Door shall be provided with stainless steel door clamps located around the three, non-hinged sides of the door spaced no more than 12 inches apart. Door latch shall be fitted with hasp and staple to accept a 3/8-inch shackle padlock. No single door shall exceed 36 inches in width. Where shown on the drawings devices shall be mounted on an interior hinged subpanel with quarter turn latches arranged to swing completely out of the enclosure. Type B panels shall be Hoffman Bulletin A-4, or equal; modified as necessary to meet all requirements specified herein.

3. TYPE C: Cabinet shall comply with all requirements of Type B, above, and shall conform to requirements of NEMA 250 and NEMA ICS 6, Type 4X. Type C fiberglass panels shall be Hoffman Bulletin A-17, or equal; Type C stainless steel panels shall be Hoffman Bulletin A4S (type 316L); or equal; modified as necessary to meet all requirements specified herein.

4. TYPE D: Cabinet shall be a NEMA 250 and NEMA ICS 6, Type 12 enclosure fabricated from sheet steel. Face-mounted instruments, if required, shall be mounted in the door. Cabinet shall be provided with an interior frame or otherwise formed so as to provide a rigid structure. Doors shall be hung on full-length piano-type hinges and equipped with vault-type latch capable of accepting a 3/8-inch shackle padlock. Three-point latch hardware shall be provided for doors exceeding 30 inches height. No single door shall exceed 36 inches in width. Type D panels shall be Hoffman Bulletin A-12, A-27, or A-30, or equal; modified as necessary to meet all requirements specified herein.

5. TYPE E: Cabinet shall conform to the requirements of NEMA 250 and NEMA ICS 6, Type 1 enclosure. Cabinet shall be provided with an interior frame or otherwise formed so as to provide a rigid structure. Door(s) shall be hung on removable pin hinges and equipped with vault-type latch capable of accepting a 3/8-inch shackle padlock. Three-point latch hardware shall be provided for doors exceeding 30 inches height. No single door shall exceed 36 inches in width. Type E shall be Hoffman Bulletin A-1 or A-12, or equal; modified as necessary to meet all requirements specified herein.

6. TYPE F: Cabinet shall be a freestanding 19-inch rack type cabinet which conforms to requirements of NEMA 250 and NEMA ICS 6, Type 12. Unless otherwise


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shown on the drawings, cabinet shall have 14-gage steel front fixed panel and rear doors with hinges and flush handle. Unused space on the rack shall be provided with blank filler panels and closure strips to cover mounting hardware. Cabinets shall have 16-gage steel walls with roll formed welded frame construction nominally 78 inches high, 24 inches wide, 32 inches deep with a 3-inch-high pontoon base. Every cabinet in a lineup shall have a duplex receptacle on alternate front and rear facing of the pontoon base. Cabinet ventilation shall consist of door mounted intake fan unit and exhaust louver. Intake unit shall include a 10-inch 560-CFM fan with ball bearings and 120V AC thermally protected split capacitor motor. Fan noise level at 3 feet and 30 degrees off axis shall not exceed 57dBA. Both intake unit and exhaust louvers shall have disposable filters and external grills. Type F panels shall be Rittal Corporation PS4000 series, Hoffman APX series, or equal

7. TYPE G: Cabinet shall conform to the requirements of NEMA 250 and NEMA ICS 6, Type 3/7. Cabinet shall be rated suitable for use in a Class I, Division 1, Group D atmosphere as defined in the NEC. Cabinets shall be surface mounted with hinged front covers. Type G panels shall be Crouse-Hinds EJB Series, or equal; modified as necessary to meet all requirements.

8. TYPE H: Open frame racks shall be 19-inch, free-standing, two-post type that conforms to the requirements of ANSI/EIA 310. Open frame racks shall be constructed of aluminum 6063-T6 alloy extrusion finished with black powder coat paint system. Side rails shall be tapped both sides with 12-24 UNC threads. Load rating of open frame racks shall be 1000 pounds. Open frame racks shall be equipped with full height, 6 inch wide, vertical cable channels with hinged cable keepers and horizontal cable organizers. One-sided shelves shall be constructed of solid steel and shall be load rated for 150 pounds. Double-sided shelves shall be constructed of solid steel and shall be load rated for 300 pounds. Keyboard/Monitor shelf shall be constructed of steel and ergonomically engineered to accommodate a monitor and keyboard, with a load capacity of 200 pounds. Type H open frame racks shall be Hoffman DataCom E-DR19FM series, or equal, modified as necessary to meet all requirements specified herein.

2.04 HEATING AND VENTILATING

A. Forced air ventilation shall be provided for panels where shown on the drawings and for panels where the cabinet’s heat load calculations indicate that the interior temperature of the cabinet will exceed 115 degrees-F, under worst case conditions.

B. PANEL AIR CONDITIONERS: Air conditioners, and heat shields shall be provided where specifically shown on the drawings. Air conditioners shall be sized to keep the interior temperature of cabinets at least 5 degrees C below the maximum operating temperature rating of the enclosed components. Sizing should take into account solar loading and should assume a maximum ambient temperature of 50 degrees C. Air


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conditioners shall be thermostatically controlled thermoelectric type designed for use with sealed NEMA 4X enclosures. Air conditioners shall be ThermoTEC series or equal.

C. PANEL HEATERS: Outdoor cabinets shall also be provided with thermostatically controlled space heaters with an expanded metal guard. Space heater surface temperature that exceeds 120 degrees F requires an expanded metal guard. Thermostats shall be Honeywell T631B1013, Penn Controls A28AA-4, or equal.

2.05 COATING

A. Metal surfaces of panels and cabinets shall be prepared by chemical cleaning and mechanical abrasion in accordance with the panel manufacturer's recommendations. Scratches or blemishes in panel faces shall be putty filled prior to finishing. One coat of zinc phosphate shall be applied at the manufacturer's recommended dry film thickness and allowed to dry prior to applying the finish coat. Finish coat shall be alkyd melamine liquid enamel coating. Total dry film thickness shall be 3 mils. Cabinet interiors shall be panel manufacturer's standard white. Exterior color of cabinets mounted outdoors shall be panel manufacturer's standard white. Exterior color of cabinets mounted indoors shall be panel manufacturer's standard light gray.

2.06 CORROSION-INHIBITORS

A. For panels located outdoors and in non-air conditioned areas, install corrosion-inhibitors inside selected to protect the given enclosure volume. Corrosion-inhibitors shall produce corrosion inhibiting vapors that provide a molecular film on metal surfaces. The film shall not affect electrical or mechanical operations of contacts, relays, or other devices.

B. The corrosion-inhibitors shall provide protection from humidity, salt and other corrosive agents for up to 24 months.

C. The corrosion-inhibitors shall be as manufactured by Cortec Corporation, Hoffman Engineering Co., or equal.

2.07 NAMEPLATES

A. Identify external door-mounted components and the panel description with nameplates. Nameplates shall be machine engraved laminated plastic. Color shall be black with white lettering. Warning nameplates shall be red with white lettering. Nameplate shall be constructed with two mounting screw holes.

B. Nameplate engraving shall include the panel title, panel tag number and power source(s) in 3/32-inch minimum size lettering.


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C. Attach nameplates to the panel with RTV or Epoxy sealant designed for adhering to NEMA-4X stainless steel panels.

D. Machine embossed metallic adhesive labels shall identify tag number of instruments inside panels. Nameplates shall be attached to panel surfaces, not to instruments.

E. The nameplate wording may be changed without additional cost or time prior to commencement of engraving.

2.08 RECEPTACLES AND PLUG STRIPS

A. DUPLEX RECEPTACLES: Duplex receptacles shall be rated 15 amps, 125V AC, NEMA 5-15R two pole, three-wire grounding type. Bodies shall be of ivory colored phenolic compound. Contact arrangement shall be on two sides of the inserted blade. Receptacles shall be side wired with two screws per terminal. Duplex receptacles shall be heavy duty specification grade type Hubbell HBL5262I, or equal.

B. PLUG STRIPS: Plug strips with single grounding type receptacles on 6-inch centers shall be provided for 120 V AC power supply connections for cord cap connected equipment. Plug strips shall be Plugmold 2000 series, or equal. Where necessary equipment shall be provided with an NFPA 70 Type SJ cord with molded-on grounding type plug for 120V AC power connection.

C. GROUND FAULT RECEPTACLES: GFI receptacles shall be duplex 15 amp, NEMA 5-15R two pole, three-wire type. Receptacles shall be ground-fault circuit interrupter, heavy duty hospital grade. Bodies shall be gray colored nylon compound. GFI receptacles shall be Hubbell GF8200GYA or equal.

2.09 WIRING

A. PANEL CONNECTION WIRE: The term "connection wiring" shall refer to all wires that have both ends terminated within the same panel or group of attached enclosures.

1. Power and control wiring shall be single conductor stranded copper with 600V rated insulation conforming to UL 83 type THHN, 14 AWG minimum, except micro and small PLC discrete input/output wiring shall be UL 1063 type MTW, 16 AWG minimum.

2. Instrument wiring for signal types a, b, c, d, e, and h, as defined in the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13), shall be multiple conductor shielded cable 16 X 30, 18 AWG stranded tinned copper twisted pair with 300V rated PVC jacket and polyethylene conductor insulation conforming to UL 83. Conductor color code shall be black and clear. Shield shall provide 100 percent coverage with aluminum polyester foil and #20 AWG stranded tinned copper drain wire. Cable shall be Belden Type 8760, or equal.


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3. Instrument wiring for signal types f and g shall be single conductor 16 x 30, 18 AWG stranded tinned copper with 300V rated PVC insulation conforming UL 83, which can withstand a 600V electronic circuit peak and shall be Belden Type 9918, or equal.

4. Wiring harnesses for PLC systems shall be provided in accordance with the PROGRAMMABLE LOGIC CONTROLLERS Section (40 63 43).

B. CABLE AND WIRE MARKERS: Cable and wire markers for all power, control, and signal wires shall be as specified herein and in Division 26.

C. Conductor insulation Colors

1. POWER & CONTROL INSULATION COLORS: Power and control conductors in panels shall have the following insulation colors per NFPA 70 & NFPA 79:

Conductor Insulation Color

AC Power & Control Black and/or Red

DC Power & Control Dark Blue

DC Power & Control common White w/blue stripe

Intrinsically Safe Light Blue

Neutral White

Ground Green

AC Control External Source Yellow

External Neutral White w/yellow stripe

DC Control External Source Yellow w/blue stripe

2. SIGNAL INSULATION COLORS: Signal conductors in panels shall have the following insulation colors per NFPA 70 & NFPA 79:


DC Power & Control Dark Blue

DC Power & Control common White w/blue stripe

Intrinsically Safe Light Blue

Signal, pair Black, White or Clear

Signal, triad Black, Red, White

Signal Common White


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Equipment Ground Green

2.10 DIN-RAIL TERMINAL BLOCKS

A. TERMINALS BLOCK TYPES: Terminal blocks shall be panhead captive screw strap type rated 600 volts. All metal parts shall be made of 85 percent copper alloy nickel-plated. Insulated housing shall be made of 6.6 polyamide suitable for DIN EN 50034 rail mounting. Terminal block types shall be as specified in the following table, or equal:

Description Type Application

120V AC Power and Control

Fuse terminal block w/blown fuse LED indicator

Phoenix UK6.3- HESILED, or equal

Power supply for field panels

Terminal block Phoenix UK5N, or equal Neutral and control wiring

Grounding terminal block Phoenix USLKG5, or equal Equipment grounding Conductor

Disconnect terminal block, w/ female test socket

Phoenix UK5-MTK-P/P, or equal

Foreign circuit disconnect

Above 120V AC Power

Terminal block Phoenix UK16N, UKH series, or equal

Power wiring

24V DC (and other voltage) Signals

Disconnect terminal block w/ female test socket

Phoenix UK5-MTK-P/P, or equal

4-20 mA current loop (supply side)

Terminal block Phoenix UK5N, or equal 4-20 mA current loop (return side)

Terminal block w/test sockets

Phoenix UK5N w/PSB 3/10/4 Test Plug Socket, or equal

1-5V DC analog signals, RTD wiring

Terminal block Phoenix UK5N, or equal shield drains 24V DC signal & discrete control

Terminal block Phoenix UK5N, or equal Pulse train

Computer Pulse Train Signals


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Description Type Application

Terminal block w/suppressor diode

Phoenix UK5, Termitrab (24VDC, 117VAC), or equal

Pulse train increase, decrease, and common

Terminal Markers

Terminal marking card Phoenix ZB series, or equal All terminal blocks

2.11 FUSES AND BREAKERS

A. CONTROL POWER TRANSFORMER FUSING: Control power transformers shall be protected by 13/32-inch x 1½-inch rejection type primary fuses rated 200,000AIC and ¼-inch x 1¼-inch secondary fuses rated 10,000AIC. Secondary fuses shall be sized at 125 percent of full load. Fuses shall have time delay characteristics to prevent false tripping due to coil in-rush currents. Fuses shall be Bussman FNQ-R, MDQ, and MDA series, or equal. Primary fuse holders shall be rated 600V, 30A, 200,00AIC with DIN-rail adaptors. Secondary fuse holders shall be blown fuse indicating type with clear transparent knob mounted on the panel face. Fuse holders shall be Bussman BC series and HK series, or equal.

B. TERMINAL BLOCK FUSES: Fuses shall be 1/4 x 1-1/4 inches. Fuses on 120VAC circuits shall be ceramic tube type with 25,000 amperes interrupting capacity at 125 volts and neon blown fuse indicator lamps. Fuses for 24V DC circuits shall be fast acting glass tube type rated 1/8 or 1/10 amp for 4-20 mA loops and 3 amps for the power supply to individual instruments. Fuse holders for 120VAC shall be din rail mounted terminal block style or the panel mounted style as specified herein.

C. BREAKERS: Din rail mounted circuit breakers shall be thermal magnetic type rated 240V, 10,000 AIC. Breakers shall be Square D QOU Series 3 or equal.


A. PUSHBUTTONS: Pushbuttons shall be nominal 1-1/2-inch diameter, flush head, heavy-duty, with NEMA rating to match enclosure type as specified herein. The escutcheon legends shall be included when shown on the drawings. Unless otherwise shown on the drawings, pushbuttons shall be momentary contact type. Contact blocks shall be rated NEMA ICS 2 A600. Pushbuttons shall be Allen Bradley, 800T (NEMA 4, 13), 800H (NEMA 4X, 7) series, or equal. Contacts monitored by programmable controllers or other solid-state circuits shall be hermetically sealed, logic-reed type with contacts rated NEMA ICS 2 B600. Pushbuttons shall be Allen Bradley, 800R (NEMA 4) series, or equal.

B. SELECTOR SWITCHES: Selector switches shall be nominal 1-1/2-inch diameter, heavy-duty, with NEMA rating to match enclosure type as specified herein. Selector


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switches shall have spring return or maintained position contacts as shown on the drawings. Switches shall be provided with contact blocks and number of positions as required to perform the operations as shown on the control diagram drawings. Contact blocks shall be rated NEMA ICS 2 A600 except hermetically sealed units shall be rated B600. Selector switches shall be Allen Bradley, 800T (NEMA 4, 13), 800H (NEMA4X, 7) series, or equal.

C. PUSHBUTTON AND SWITCH COLORS: Pushbutton colors shall be red for STOP or OPEN, green for CLOSE, and black for all other functions. Switch color shall be black unless otherwise shown on the drawings.

D. INDICATING LIGHTS: AC indicating lights shall be nominal 1-1/2-inch diameter, push-to-test transformer type, with 6.3 volt lamps. DC indicating lights shall be nominal 1-1/2-inch diameter, push to test, full voltage type. Lamps shall be heavy-duty, with NEMA rating to match enclosure type as specified herein. Indicating lights shall be Allen Bradley, 800T (NEMA 4, 13) 800H (NEMA 4X, 7) series, or equal.

E. INDICATING LIGHTS TYPE AND COLOR: Indicating lights located indoors shall have LED or neon lamps, and lights located outdoors shall have incandescent lamps. For panels with multiple lights; the push to test feature can be deleted, if a common push button is included to test all lamps as a group. Indicating lamp colors shall be in accordance with the following schedule:

Color Function Example

Red Run, valve status Equipment operating, motor running, valve open

Green Normal condition, ready, valve status

Status OK, equipment ready, valve closed

White Control power Control power on

Amber Abnormal condition Failure of equipment or status abnormal, fault condition

F. CONTROL DEVICE NEMA RATING: Control devices shall have an environmental rating to match the NEMA 250 and NEMA ICS-6 enclosure type as follows:


NEMA 1 NEMA 4/13

NEMA 4 NEMA 4/13

NEMA 4X NEMA 4X


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NEMA 7 NEMA 7

NEMA 12 NEMA 4/13

G. LEGEND PLATES: Legend or escutcheon plates shall be provided and inscribed as shown on the drawings and schedules.

2.13 RELAYS

A. CONTROL AND SIGNAL RELAYS: Control and signal relays shall be enclosed plug-in type with heavy-duty, barrier-protected screw terminal sockets and clear polycarbonate dust cover with clip fastener. Relays shall have a minimum of three silver-cadmium oxide SPDT contacts rated 10 amps resistive at 120V AC or 28V DC. Relays shall be mounted on DIN rail socket bases. DC relays shall have diode suppression in parallel to the coil. All relays shall have a lamp indicator wired in parallel with the coil. Control and signal relays shall be Potter Brumfield model KUPXXA35-120, KUPXXDS 35-24 series, or equal.

B. TIMING RELAYS: Timing relays shall be multifunction timers available in standard 8- or 11-pin, and 11-blade terminations. Adjustable time delays between 0.1 second and 600 hours shall be available with each timer relay. Interval, delay on operate, delay on release, single shot and repeat modes shall be available. Timers shall reset within 0.1 seconds and shall have a set point accuracy of plus or minus 2.0 percent with a repeatability of plus or minus 0.2 percent. Relays shall have contacts rated 10 amps resistive at 120V AC or 30V DC. Relays shall be mounted on DIN rail socket bases. All relays shall have an ON and timing OUT LED indicators. Timing relays shall be IDEC RTE Series, model RTE-P2-AF20 (for 120V AC) and RTE-P2-AD24 (for 24V DC), or equal.

C. SINGLE PHASE VOLTAGE MONITOR RELAYS: Single phase voltage monitor relays shall be enclosed plug in type with solder terminals and solid lexan dust cover. Relays shall monitor for both under voltage and over voltage conditions with built in hysteresis providing differential between pick up and drop out trip points. Relay shall operate at nominal 50 msec and release at nominal 0.5 seconds. Relays shall have DPDT silver-cadmium oxide contacts rated 5 amps resistive at 120V VA or 28V DC. Relays shall be mounted on DIN rail socket bases. Voltage monitor relays shall be ATC Diversified Electronics model VBA series, or equal.

2.14 PROGRAMMABLE LOGIC CONTROLLERS

A. PLCs shall conform to the requirements specified in the PROGRAMMABLE LOGIC CONTROLLERS Section (40 63 43).


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2.15 POWER DEVICES

A. THREE PHASE STARTERS: Three phase starters shall be the combination type consisting of a magnetic breaker, contactor, surge suppressor and overload relays conforming to the ELECTRICAL CONTROLS AND RELAYS Section (26 09 16).

B. SINGLE PHASE STARTERS: Single phase starters shall be the combination type consisting of a thermal magnetic breaker, contactor and overload relay conforming to the ELECTRICAL CONTROLS AND RELAYS Section (26 09 16).

C. CONTROL POWER TRANSFORMERS: Control power of 120V AC shall be derived from primary and secondary fused control circuit transformers conforming to the ELECTRICAL CONTROLS AND RELAYS Section (26 09 16).

2.16 DC POWER SUPPLIES

A. Direct current, 24V DC power supplies shall be switching type. Output voltage regulation shall be plus or minus 0.05 percent maximum for line voltage variations from 90 to 132 volts. Undervoltage monitoring and local annunciation shall be provided by an audible whistle. Units shall be redundant and as shown on the drawings with automatic transfer to the backup unit. Each unit shall have two (2) DC voltmeters and two (2) DC ammeters.

B. Each unit shall contain two (2) identical power supplies with their outputs interconnected through a diode switching arrangement that will detect any fault condition, isolate it from the system output, and pass only the output of the other supply with no interruption of output power during the transition. Unit may be operated with only one AC power source. However, two (2) isolated sets of AC input connections shall be provided so that two (2) independent sources of input power may be used to obtain the additional protection of input redundancy.

C. Each unit shall have two (2) voltage monitoring circuits with relays. The contact wiring of the two relays shall be connected in cascade to simulate a single set of Form C contacts which switches if the output voltage of either power supply decreases by more than 2.0 volts (3.0 volts for outputs over 48 volts) from the nominal rating. Each unit shall contain an overvoltage protection circuit to assure that neither power supply output will significantly exceed the nominal output voltage rating under any condition, including incorrect application and adjustment.

D. Power supply shall be sized to meet requirements of each application, not to exceed 60 percent of capacity at 55 degrees C.


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2.17 PANEL GROUNDING

A. Each panel shall be provided with two copper ground bars. One bar shall be bonded to the panel frame or sheet metal and to the facility grounding system. The second (isolated signal) ground bar shall be mounted on insulated stand-offs and shall be bonded to the frame ground bar at one point only. Provide minimum dimensions per grounding bar of 1/4 inch x 1 inch x entire length of panel interior at bottom of panel.

B. Signal circuits, signal cable shields, and low-voltage DC power supply commons shall be bonded to the signal ground bar. The individual cabinet signal ground bar shall be connected to the plantwide grounding grid at one point only.

C. Surge protectors and separately derived AC power supplies shall be bonded to the frame ground bar.

D. Ovation Control System Cabinets: Grounding of the PCCS controller cabinets and extended I/O cabinets shall be in accordance with the manufacturer’s strict published grounding guidelines. The Contractor is required to be familiar with these guidelines prior to installation of the cabinets. Prior to applying power to the cabinets, the Contractor shall arrange for Emerson Process Management approval of the installed cabinet grounding system. This Emerson approval shall be in writing and shall specifically include results from inspection and test measurement of the cabinet grounding system validating compliance with Emerson’s published grounding guidelines.

2.18 UNINTERRUPTIBLE POWER SUPPLY (UPS)

A. NOT USED.

2.19 MISCELLANEOUS

A. WIRING DUCT, SPIRAL WRAP AND CABLE TIES: Flame retardant plastic wiring duct shall be slotted type with dust cover, Panduit Type E/C series, or equal. Cable ties shall be plastic self-locking with integral screw clamp, Thomas & Betts TY series, Panduit PLC series, or equal. Cable tie mounts shall be plastic screw mounted style, Panduit TM series, or equal.

B. DC POWER SUPPLY: 24V DC power supplies shall conform to the MISCELLANEOUS INSTRUMENTS, CALIBRATION EQUIPMENT, INSTRUMENT VALVES, AND FITTINGS Section (40 79 00).

C. FIXTURES AND SNAP SWITCHES: Fixtures shall be listed as conforming to UL 1598. Fixtures shall be a fluorescent strip with trigger start lamp and wire guard, Lithonia S115TS series, or equal. Snap switches shall be UL 20 listed and conform to the requirements of Division 26.


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D. ROTARY SWITCH: Rotary switches for switching signal circuits (less than 80 volts) shall be premium grade, multiple deck rotary switches designed for switching low voltage circuits. Contacts shall be gold plate over nickel plate over silver plate, completely enclosed, break-before-make, with contact resistance of less than 20 milliohms at 2 to 4 volts DC, 100 milliamperes. Contact rating shall be 0.3 amperes at 115 volts AC and 0.5 amperes at 28 volts DC. Switches shall be Electroswitch Series M15, C&K Series A, or equal.

E. PROGRAMMABLE TIMERS: Programmable timers shall be solid state, programmable, 365-day, two-channel type with independent programming for each channel. Power supply shall be 120V AC, 60 hertz, with 100-hour battery backup for program memory. Timer range shall be 1 minute minimum to 365 days maximum. Each channel's output shall be an isolated SPDT contact rated 15 amp resistive at 120V AC. Programmable timers shall be Paragon EC72D series, or equal.

PART 3 -- EXECUTION

3.01 GENERAL

A. Examine all specified panel requirements, design the panel layouts and fabrication details for all new and existing panels within the guidelines specified herein, and submit these layouts to obtain approval prior to fabrication.

B. Floor-mounted panels except in dry control rooms or electrical equipment rooms shall be mounted on 3-1/2-inch minimum height concrete pads or grouted bases as specified, and shimmed for a precise alignment to prevent doors from binding. Coating shall be provided for outdoor panels in contact on concrete.

C. Vacuum clean control panels and cabinets.

D. Spray terminals and terminal blocks after all terminations have been completed with a silicone resin similar to Dow Corning R-4-3117 conformal coating. Spray coating only required for control panels in corrosive or classified installation environments.

E. Provide panels with the as-built schematic, connection, and interconnection diagrams mounted behind Plexiglas holder on the inside of the door. Place documentation in a water proof clear bag in the panel document holder.

1. PANEL LOCATIONS:

a. AREA CONTROL CENTERS (ACCs): Unless otherwise shown on the drawings, the following panel types shall be used in the ACC rooms. Freestanding rear access control panels shall be Type F and shall be designed with fascia to form a complete wall of their associated rooms. The panel face shall completely fill the allotted space. Trim strips shall provide a finished


40 67 00 - 21

appearance at panel edges. Other panels in the ACC besides the freestanding rear access control cabinet shall be Type D.

b. CONTROL SYSTEM ROOMS: Unless otherwise shown on the drawings, the following panel types shall be used in the Control System Rooms. Freestanding open rack control panels shall be Type H and shall be designed with cable guides and overhead trays to form a complete system. Other panel types in the Control System Rooms shall be Type D.

c. OUTDOOR AREAS: Fabricate the custom aluminum panel shade cover and mount the panels facing away from the prevailing sun or wind. Provide Sun/Rain covers per Electrical Detail for outdoor vendor, manufacture, and custom panels. Fabricate based upon known panel dimensions or accepted submittal drawing dimensions.

d. OTHER AREAS: Panels located outdoors, in tunnels, galleries, motor equipment rooms, or any area subject to hosedown, shall be Types B and I. Panels in rooms containing chlorine, sulfur dioxide, or other corrosive chemicals shall be Types C and I. Panels in HVAC, switchgear, MCCs and other electrical rooms shall be Type D. Panels in architecturally finished or other rooms not subject to hosedown, shall be Type E. Panels in hazardous classified areas shall be Type G.

3.02 INSTALLATION

A. FREESTANDING PANELS: Type F panels shall be mounted on embedded steel sills as shown on the drawings. Other freestanding panels shall be anchor bolted to the floor. The seismic calculations shall be approved prior to installation of freestanding panels. Sills shall be leveled so panel structures will not be distorted. Panels shall be shimmed to precise alignment so doors operate without binding.

B. SURFACE MOUNTED PANELS: Surface panels shall be mounted on walls or support racks as shown on the drawings. All wall-mounted panels shall be bolted to framing channels to space them approximately 1-inch off the wall surface.

C. HOUSEKEEPING: Prior to final acceptance, clean-up and remove all metal filings and debris.

D. PANEL POWER SUPPLY:

1. Mount and connect power supply and conditioning equipment in compliance with the manufacturer's instructions.

2. Provide line side disconnect switches for power supply and conditioning equipment. Provide line and load side over current protection for power supply and conditioning equipment in compliance with NFPA 70. Comply with the


40 67 00 - 22

ELECTRICAL CONTROLS AND RELAYS Section (26 09 16) for disconnect switches.

3. Mount small power supply and conditioning equipment in the panel served. Mount large power supply and conditioning equipment adjacent to the panel served. Enclose unconditioned power conductors in metallic raceways within the panel.

4. Provide sound isolators for power supply and conditioning equipment larger than 5-kVA load capacity supported from surfaces other than concrete.

5. Provide flexible conduit in compliance with the RACEWAYS, BOXES, MANHOLES, AND HANDHOLES FOR ELECTRICAL SYSTEMS Section (26 05 34) for final raceway.

E. WIRING:

1. GENERAL: Power conductor sizing shall comply with the minimum requirements specified herein and of NEMA ICS 1, NFPA 70 and NFPA 79. Wiring shall be supported independently of terminations. Conductors shall be trained onto terminals and laced into fixed bundles at nominal 6-inch centers and routed into wire duct. For floor mounted panels the bottom of the wiring duct shall be a minimum of 12 inches above the floor. Conductors crossing hinged doors shall be slack looped to accommodate the door fully opened. Slack conductors shall be contained in spiral wrap secured on both sides. Wire duct fill shall not exceed 40 percent of cross section area.

2. CIRCUIT SEPARATION: In any panel containing signal conductors and power or control conductors, proper circuit isolation shall be maintained. Locate terminals and devices to separate power and control circuits from signal circuits. One of the following methods shall be used.

a. METALLIC RACEWAY FOR POWER AND CONTROL: Run all power and control circuits in covered, fully enclosed metallic channels or Wiremold surface raceway.

b. METALLIC RACEWAY FOR SIGNALS: Run all signal circuits in fully enclosed metallic channels or Wiremold surface raceway. Use multiple raceways if required to maintain the signal circuit separation requirements.

c. MINIMUM PHYSICAL SEPARATION: Install wiring so that power & control conductors are spaced 4” apart from signal conductors.


40 67 00 - 23

3. FIELD WIRING PROVISIONS:

a. For field wiring terminal blocks located in interior spaces, provide dedicated wire duct with sufficient capacity for all field wiring and space for the wire tags between the wire duct and the terminal blocks.

b. Provide terminal blocks for field wiring such that connecting wires terminate on one side and all field wiring is terminated on the opposite side of the terminal block.

c. Field wiring terminal blocks located along the outside edges shall be located so that sufficient space is provided for wire bending radius and wire tags.

4. TYPE F FREESTANDING PANELS:

a. BUS BARS: Two 1/4-inch by 1-inch copper buses shall be provided over the length of ACC control panels: one for 24V DC signal common, and one for equipment and cabinet grounding. The 24V DC common bus shall be mounted on insulated stand-offs, and the entire signal ground system bonded to the cabinet ground system at a single point.

b. PANEL CONNECTION WIRING: Raceways used to interconnect the control panels do not have to comply with cable fill requirements specified in the Division 26 schedules. For the purposes of cable fill requirements, the control panels, computer interface terminal cabinets, computer I/O cabinets, and PLC panels, shall be considered a single panel. Therefore, conductors that provide interconnection between these panels, although carried in raceway between individual panels, are not contained in the ELECTRICAL CABLE SCHEDULE Section (26 06 20.25). These raceways shall be filled as determined by the Contractor's detail design. The cost of determining the required conductors and the cost for their provision and installation shall be included in the Contractor's bid price.

c. CONNECTION WIRING ROUTING: Wiring between control cabinets shall not be routed through the cabinet sides from rack to rack. Wiring between cabinets shall be routed through the cabinet's top or bottom into tray or wireway as shown on the drawings.

d. EXISTING ANNUNCIATORS: Due to ongoing plant operations, the Contractor will not be allowed to leave any alarm circuit without its alarm window engraving or disrupt the alarm circuit for more than 5 minutes.

F. MODIFICATIONS TO EXISTING PANELS:

1. GENERAL: Panel modifications shall conform to all requirements specified in this section


40 67 00 - 24

2. CUTOUTS: Cutouts shall be drilled or punched such that all debris is drawn out the front with continuously running vacuum devices. Torch cutting of any panel front, side, back, top, bottom, or of any structural member is prohibited. Cutouts shall be deburred and free of tool marks.

3. NAMEPLATES: Engraving shall be as shown on the drawings or as required to describe all added components.

4. PAINTING: Interior and exterior panel surfaces which were damaged or marred during modifications or other work shall have the scratches or blemishes filled, sanded, and painted with two coats of paint matching the existing color(s) and texture.

5. EQUIPMENT AND PANEL PROTECTION: Protect equipment mounted in or on the panel and the panel surfaces by covering with heavy-duty, industrial grade plastic sheets when making cutouts, deburring, sanding, or painting. All equipment mounted on subpanels shall be drilled and tapped, the use of drive screws or nuts and bolts are prohibited for equipment mounting.

G. CABLE AND WIRE MARKERS:

1. GENERAL: All conductors and cables shall be identified with markers. Each wire shall be numbered in accordance with approved connection drawing. Signal cable markers shall not be heat shrunk until the outer jacket and foil shield is cut back so that the marker shall also serve to insulate the end of the foil shield from ground. Installed markers shall be positioned to be read without twisting the conductor. Installed conductor markers that can be smudged or erased after installation shall be sprayed with a clear acrylic fixative. No two markers shall have the same number unless they are electrically identical. Conductors shall have the same marker number on both ends. The marking scheme shall conform to the existing scheme as defined below and shown on the contract drawings "Example Wiring Diagrams". Wiring numbers shall follow requirements specified in the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13).

2. ACC TYPE F PANEL POWER & CONTROL CIRCUITS: Marker numbers for connection wires within any immediately adjacent lineup of Type F panels in ACCs shall consist of the associated equipment number, a dash, followed by a unique wire number.

3. ALL OTHER CONTROL PANEL POWER & CONTROL CIRCUITS: All control panels (other than ACC Type F) markers shall consist of a unique wire number system. Wire numbers of wires that are connected to field termination blocks shall match the field terminal numbers. Wire numbers in panels used on identical equipment shall be the same for identical wire paths.


40 67 00 - 25

4. ANALOG & DISCRETE LOOPS: Wire numbers shall consist of four parts: prefix, body, code and unique sequential number. The prefix shall be ISAS5.1, Table 1, first letter identification. The body of the wire number shall be the instrument loop number. If an instrument loop number is not available, the mechanical equipment number shall be used. Code letters are either S for analog signal or C for discrete signal. The fourth part shall be a dash followed by a unique wire number.

5. ANALOG & DISCRETE LOOP EXAMPLE: The following table illustrates an example of the loop numbering system.

Wire number = L8133S-25

Where: L = "Level" from ISA S5.1-Table 1, 1st letter 8133 = loop number S = code letter (S = signal, C = discrete event) -25 = dash & unique sequential number

H. TERMINAL BLOCKS:

1. TERMINALS: Each field connection shall be made to an individual terminal block, except for low level (less than 80 volts AC or DC) signals where no more than two conductors shall be inserted into a terminal. Terminal blocks for field terminations shall be separated from terminal blocks for other purposes and shall be located close to where the field cables enter the panel. Panelwork shall contain no exposed power or control (80 volts or greater) connections, and adjustments to equipment shall be made without exposing these terminals. Terminal blocks shall be numbered with permanent type- written characters with minimum 1/8 inch text height. Provide 15 percent spare terminals on each block.

2. TERMINAL TAGS, COVERS AND MARKERS: Each terminal strip shall have a unique identifying alphanumeric code at one end and a plastic marking strip running the entire length with a unique number for each terminal. Numbers shall be machine printed and l/8 inch high. All terminal blocks carrying power circuits over 120V AC shall be guarded with a transparent removable cover for personnel protection.

3.03 TESTING

A. All panels shown on the drawings shall be tested in accordance with the COMMISSIONING Section (01 91 00).

3.04 TRAINING

A. Training shall be as specified in the PROCESS CONTROL SYSTEM TRAINING Section (40 61 26) and conform to the TRAINING Section (01 79 10). The number of


40 67 00 - 26

training session and hours for each craft shall conform to the requirements of TRAINING Section (01 79 10).

**END OF SECTION**


40 70 00 - 1

SECTION 40 70 00

INSTRUMENTATION OF PROCESS SYSTEMS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies requirements for process instruments. Specific application dependent requirements are delineated in the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70) and on the drawings.

1.02 REFERENCES

A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of referenced publications in effect at the time of the bid shall govern. In case of a conflict between the requirements of this section and those of the listed standards, the requirements of this section shall prevail.

Reference Title

ISA S51.1 Process Instrumentation Terminology

ANSI B16.5 Steel Pipe Flanges and Flanges Fittings

ANSI B40.1 Gauges-Pressure Indicating Dial Type-Elastic Segment: Special Notice

IEEE C62.41.1 Guide on the Surge Environment in Low-Voltage (1000 V and less) AC Power Circuits

ANSI C96.1 Temperature Measurement Thermocouples

API 670 Machine Protection Systems

Noncontacting Vibration and Axial Position Monitoring System

API 678 Accelerometer - Based Vibration Monitoring System

ASTM A105 Specifications for Carbon Steel Forging for Piping Components

ASTM E230 Temperature Electromotive Force (EMF) Tables for Standardized Thermocouples

ASTM A269 Seamless and Welded Austinitic Stainless Steel Tubing for General Service

ASTM B68 Seamless Copper Tube, Bright Annealed


40 70 00 - 2

Reference Title

ASTM D883 Standard Terminology Relating to Plastics

IPTS-68 International Practical Temperature Scale of 1968

JIC P-1 Pneumatic Standards for Industrial Equipment

NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 6 Industrial Control and Systems: Enclosures

UL 1002 Electrically Operated Valves for use in Hazardous (Classified) Locations

UL 1012 Power Units Other Than Class 2

UL 1449 Transient Voltage Surge Suppressors

UL 1778 Uninterruptible Power Supply Equipment

MIL STD 461-A Electromagnetic Interference Characteristics Requirements for Equipment

SAMA RC 17-10 Bushings and Wells for Temperature Sensing


1.03 SUBMITTALS

A. The following information shall be submitted for review in accordance with the SUBMITTAL PROCEDURES Section (01 33 00) and the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13):

1. A copy of this specification section, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviation.

2. Manufacturer's specifications, installation recommendations, and catalog literature for each type of instrument specified herein Part 2 which clearly and unambiguously shows that the instrument meets all the requirements specified herein.

3. Instrument data sheet for each instrument or a group of instruments with similar loop application.

4. Instrument manufacturer’s factory calibration certification for vibration sensors and switches, pitot and magnetic flow tubes, rotameters, orifice plates and mass flowmeters.

5. Panel fabrications and layout drawings with complete list of materials and nameplate engraving list.


40 70 00 - 3

6. Contractor’s instrument installation details including all required mounting stanchions or racks.

7. A copy of the contract document process and instrumentation diagrams, instrument installation details, and miscellaneous hardware detail drawings that apply to the instruments specified herein. These documents shall be marked to show specific changes necessary or if no changes are required, the drawings shall be marked “No Changes Required.” Each document shall include reviewer’s name, company, and date of review.

8. Instrument or panel seismic mounting calculations in accordance with the METAL FASTENINGS Specification Section.

9. Contractor’s instrument calibration test results in accordance with the COMMISSIONING Section (01 91 00) and the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13).

10. Analog control station programming configuration and display format.

11. Recommended spare parts in accordance with the SPARE PARTS Section (01 78 43).


A. Submit operation and maintenance (O&M) instructions in accordance with the OPERATION AND MAINTENANCE DATA Section (01 78 23) by submitting a copy of the OPERATION AND MAINTENANCE DATA Section (01 78 23) with each paragraph check marked to show compliance. O&M instructions shall be submitted after all the submittals specified above have been returned mark “No Exceptions Taken” or “Make Corrections Noted.” O&M instructions shall reflect the approved materials and equipment.

PART 2 -- PRODUCTS


A. Unless otherwise specified herein or shown on the drawings, measuring elements, transmitters, and switches shall have the following general characteristics. Output indicators shall be provided with any transmitter that does not include an integral indicator. Indicators shall be calibrated in percent of span unless engineering units are specified as listed in the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70). Transmitters shall be two wire type with operating power derived from the 24V DC loop power, unless otherwise specifically identified in this Section. Transmitter output shall be 4 to 20 mA, current regulated and shall drive any load between 0 and 600 ohms with the power supply at 24 volts DC. Transmitter shall meet specified performance requirements with load variations within the range of


40 70 00 - 4

0- 600 ohms with power supply at 24 volts DC. Transmitter output shall be electrically isolated from ground and from all other internal circuits that are not isolated from ground. Output isolation shall be provided by the transmitter or by a signal isolator located adjacent to the transmitter of the type specified herein. Time constant of transmitters used for flow or pressure measurement including level transmitters used for flow measurement shall be minimally adjustable from 0.5 to 5.0 seconds.

B. Contact outputs shall be double pole double throw (DPDT) and they shall be automatic or manual reset as specified in the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70) or as shown on the Control and Logic Diagrams. Contacts for alarm shall be normally open, held closed for normal conditions, and shall open on alarm condition. The term "normally open" when applied to a magnetically operated switching device contact signifies the position taken when the operating magnet is de energized. The term when applied to a process sensing device signifies the contact state that exists in the "shelf" condition, at ambient temperature (23 degrees C) and pressure. Contacts used to start equipment shall close to start the equipment. Contacts used to stop equipment shall open to stop the equipment. Contact outputs for 24V DC circuits shall be suitable for switching logic level (5 volts DC) circuits and shall be rated not less than 100 milliamps at 120 volts AC and 75 volts DC.

C. Instrument enclosures shall be rated NEMA 4 in conformance with NEMA ICS 6 and NEMA 250, unless otherwise specified herein, or otherwise specified in the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70), or shown otherwise on the drawings. All required accessories shall be provided with each instrument including mounting hardware and instrument manufacturer's interconnection cable required to connect elements and remote mounted transmitters. The catalog numbers listed in this section require special modifications and accessories to meet all requirements specified herein, specified in the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70), and shown on the drawings.

2.02 PRESSURE COMPONENTS

A. PRESSURE TRANSMITTERS:


a. Emerson Rosemount 3051.

b. No others allowed.

2. MATERIALS/EQUIPMENT:

a. Pressure transmitters shall be the capacitance type. Static pressure rating shall be 500 psig or greater. Over range capacity without affecting calibration shall not be less than 150 percent of maximum range. Span shall be adjustable over


40 70 00 - 5

a 10:1 or greater range. Zero elevation, adjustable damping, and suppression capability shall be provided. External pushbuttons for local zero and span adjustment shall be provided for site re-ranging. Volumetric displacement at maximum span shall not exceed 0.01 cubic inch.

b. The remote transmitter shall contain the electronics required for processing the signal from the flow element into a linear 4 20 mA DC pressure signal capable of driving a 600 ohm load. The transmitter shall be provided with a 2-line LCD scaled in the pressure units specified in the Instrument Schedule.

c. Accuracy shall be ± 0.1 percent of span. Meters shall have 2-inch scale and 4-digit LCD display with linear scale of 0 to 100 percent. Pressure transmitters shall be provided with Hart protocol Smart electronics capable of digital calibration, configuration, diagnostics and communications.

d. Wetted parts shall be type 316 stainless steel and wetted O-rings shall be Viton. Sensor fill liquid shall be silicone oil except for use on sulfur dioxide or chlorine the sensor fill shall be halocarbon or other inert fill. Pressure transmitters used for oxygen service shall be provided with factory options for oxygen service cleaning. Process flanges, adaptors, isolating diaphragms, drain and vent valves shall be cast 316 stainless steel. Electronics housing shall be cast aluminum with epoxy paint finish. Electronic enclosure shall be rated watertight in accordance with NEMA ICS 6 type 4.

e. Gage pressure transmitters with an upper range of less than 20 psig shall be the differential pressure type. The low pressure connection shall be provided with a weatherproof, bugproof, atmospheric vent assembly. Differential pressure transmitters shall be provided with two 1/2 inch process connections on 2.125-inch centers for direct mounting of 3-valve manifold specified in the MISCELLANEOUS INSTRUMENTS, CALIBRATION EQUIPMENT, INSTRUMENTATION VALVES, AND FITTINGS Section (40 79 00).

B. PRESSURE GAGES:


a. HIGH RANGE GAGES: Ashcroft Duragauge Figure 1279, Ametek 1981L, or equal.

b. LOW RANGE GAGE: Ashcroft type 1188, or equal.

c. DIFFERENTIAL PRESSURE GAGE: Ashcroft type 1127, or equal.


a. HIGH RANGE PRESSURE GAGES (> 10 PSI):


40 70 00 - 6

1) Pressure gage scales shall be selected so that the normal operating pressure falls between 25 and 75 percent of full scale. All gages shall be 4-1/2 inches, dampened movement, and suitable for bottom stem mounting unless otherwise shown on the drawings. Accuracy shall be plus or minus 0.5 percent of span. Gages shall have a phenolic case, high temperature acrylic window, thermoset or thermoplastic case, NEMA 3 enclosure, and a 1/2-inch NPT bottom connection. Pressure gages shall be premium grade, heavy-duty, 316 stainless steel bourdon tube units (bellows type for low pressure of vacuum) with 316 stainless steel movement.

2) Gages on liquid service shall be as noted above except they shall be provided with an internal pulsation dampening system consisting of a silicone or halocarbon fluid fill. Gages used for oxygen service shall be provided with factory options for oxygen service cleaning. Snubbers or orifices shall not be utilized. Chemical seals shall be provided as noted in the MISCELLANEOUS INSTRUMENTS, CALIBRATION EQUIPMENT, INSTRUMENTATION VALVES, AND FITTINGS Section (40 79 00). Sanitary/chemical seals shall be one piece construction with diaphragms fastened directly to the instrument top flange. Seals shall be 2 inches with ¼-inch NPT instrument connection and a bleed screw. Seals shall be provided with quick disconnect clamp with wing nut. Diaphragm and clamp shall be designed to mate with a sanitary seal male adapter. Seal body and clamp shall be 316 stainless steel. Diaphragm material shall be 316L stainless steel, except for chlorine service where the material shall be Hastelloy-C. Diaphragm fill fluid shall be silicone, except for oxygen and chlorine service where the fluid shall be halocarbon. Seals and gauges shall be factory filled and assembled. Seals shall be Ametrek CST series, with #24-90001 clamp, or equal.

b. LOW RANGE PRESSURE GAGES (< 10 PSI):

1) Gage shall be 4-1/2-inch phenolic turret case construction with acrylic window, 270 degree movement, 1/2-inch NPT process connection. Unless otherwise specified, element shall be a 316 stainless steel bellows. Gage shall be provided with a throttle screw as standard. Accuracy shall be Grade A, in conformance with ANSI B40.1. Unit shall be designed for outdoor installation in sunlight and rain.

c. DIFFERENTIAL PRESSURE GAGE:

1) Gage shall be 4-1/2-inch all black epoxy coated aluminum case construction with acrylic window, bronze bellows element, 270-degree movement, 316 stainless steel wetted parts, ¼-inch NPT process connections. Accuracy shall be Grade A, in conformance with ANSI B40.1. Unit shall be designed for outdoor installation in sunlight and rain.


40 70 00 - 7

C. DIAPHRAGM SEALS


a. Quick disconnect seals shall be Ametek CST series, with #24-90001 clamp, or equal.

b. Diaphragm seal shall be Ashcroft Type 101 for NPT connection or Type 103 for flange connection, ITT Conoflow Model 100AC for NPT connection or Model 100B for flange connection, or equal.

c. In line isolation type shall be Ametek or Red Valve, or equal.


a. QUICK DISCONNECT:

1) Sanitary/chemical seals shall be one piece construction with diaphragms fastened directly to the instrument top flange. Seals shall be 2 inches with ¼-inch NPT instrument connection and a bleed screw. Seals shall be provided with quick disconnect clamp with wing nut. Diaphragm and clamp shall be designed to mate with a sanitary seal male adapter. Seal body and clamp shall be 316 stainless steel. Diaphragm material shall be 316L stainless steel, except for chlorine service where the material shall be Hastalloy-C. Diaphragm fill fluid shall be silicone, except for oxygen and chlorine service where the fluid shall be Fluourolube FS-5.

b. DIAPHRAGM TYPE:

1) Seal shall be diaphragm type with a 1/4-inch flushing connection, type 316 stainless steel body, type 316 stainless steel diaphragm and a 1-inch NPT sludge process connection for gages and a 3-inch flanged sludge process connection for transmitters and switches. All other process connections shall be ½-inch NPT unless otherwise specified or required by the application. Fill fluid shall be Silicone DC200, except that Fluorolube FS-5 shall be used for oxygen or chlorine service.

c. IN LINE ISOLATION TYPE:

1) Body and flanges shall be 316 stainless steel except for chlorine service where it shall be Hastelloy-C. The liner shall be Buna-N. Provide full 360-degree annular pressure sensor with flexible in-line sleeve. Sensor shall not restrict the process flow (non-intrusive). Seal shall have ANSI Class 150 flanges or wafer as defined in the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70). Instrument connection shall be ¼-inch female NPT. Diaphragm fill fluid


40 70 00 - 8

shall be silicone, except for oxygen and chlorine service where the fluid shall be Fluourolube FS-5.

2.03 FLOW COMPONENTS

A. THERMAL DISPERSION MASS FLOWMETER:


a. Fluid Components Inc. ST100 with FCI/VORTAB Flow Conditioner.

b. No others allowed.

2. MATERIAL/EQUIPMENT:

a. The flowmeter shall utilize thermal sensing techniques for direct measurement of the mass flow rate of a gas. The flowmeter shall consist of an invasive flow element assembly and integral or remote mounted electronics with interconnection cable, as required.

b. The flow element assembly shall consist of a temperature sensor and a separate heated sensor, each mass temperature equalized and contained within 316 stainless steel. The flowmeter shall measure the mass flow by measuring the cooling effect of the fluid as it passes the heated sensor.

c. The flow element shall be provided with 1-inch MNPT threads for insertion into the process piping. The flow element and interconnection to transmitter shall be Class I, Division I rated.

d. The flow element shall be capable of measuring flows at standard conditions from .25 to 200 feet per second. The actual mass flow rate range shall be specified for each application in the SCHEDULES OF INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 06 70).

e. Flow element shall be mounted to pipe with 316 stainless steel ball valve and packing gland assembly which will allow removing the probe without taking the line out of service. A mechanical stop at the sensing element shall be provided to prevent accidental removal.

f. All "wetted" materials shall be appropriate for the fluid being measured. Provide Hastelloy C-276 flow element for digester gas application.

g. The integral transmitter shall contain the electronics required for processing the signal from the flow element into a linear 4 20 mA DC mass flow rate signal capable of driving a 600 ohm load. The transmitter shall be provided with a 4-line by 20-character LCD scaled in the mass flow rate units specified in the Instrument Schedule. A 20-key, built-in keypad shall allow programming to


40 70 00 - 9

change zero, span, switch points, engineering units, and other critical instrument functions.

h. The flowmeter accuracy shall be plus or minus 1 percent of full scale or 3 percent of reading for turn downs of 10:1 or less; repeatability shall be plus or minus 0.5 percent of reading, respectively, or better.

1) Flowmeter shall be provided with FCI VeriCal dynamic in-situ calibration.

i. Spool piece flow conditioners shall be provided for each flowmeter to condition the flow profiles reducing the effects of minimum upstream runs and irregular flow profiles. Flow conditioner shall be the meter run type and shall provide mounting tap for flowmeter.

j. Factory calibrate flowmeters used for digester gas with 60 percent methane/40 percent carbon dioxide test gas mixture. Factory calibrate flowmeters used for natural gas with natural gas.

k. FM approved for Class I, Division 1 Group D locations.

l. Provide manufacturer’s standard “rain shield” accessory for sensor tip to protect against in-pipe condensation.

2.04 TEMPERATURE COMPONENTS

A. THERMOCOUPLE FOR PILOT FLAME DETECTION:


a. Honeywell Q340;

b. Or equal.


a. THERMOCOUPLES:

1) Temperature Rating – Hot Junction: 1400°F

2) Temperature Rating – Cold Junction: 780°F

3) Voltage: 30mV

4) Insertion Length: 18”

B. BUSHINGS AND THERMOWELLS:



40 70 00 - 10

a. Bushings or thermowells shall be provided at temperature measurement locations and shall comply with SAMA RC17-10. Temperature taps shall be 3/4-inch NPT, and lagging type units shall be provided on insulated vessels or pipes. Thermowells and bushings shall be 316 stainless steel unless otherwise specified.

C. TEMPERATURE INDICATORS:


a. Ashcroft EL "Every-Angle",

b. Weksler Type AF,

c. Or equal.


a. Temperature indicators shall be industrial quality bi-metal thermometers. Accuracy shall be 1 percent of range. Dial size shall be 5 inches, and head shall swivel to facilitate viewing. External adjustment shall be provided for calibration.


A. (NOT USED)

B. PNEUMATIC CONTROL DEVICES:

1. CURRENT TO PNEUMATIC CONVERTER:


1) Brandt (Cashco or Thermo) STD 5131;

2) Fairchild T5200;

3) Or equal.

b. MATERIALS/EQUIPMENT:

Field mounted converter shall accept a 4-20 mA input signal and produce a proportional 3-15 psig output. Housing shall be weatherproof and dustproof. Converter accuracy shall be plus or minus 0.5 percent of output span. Output capacity shall not be less than 4.5 SCFM of midrange.


40 70 00 - 11

2. SOLENOID VALVES (PNEUMATIC SIGNAL CONTROL):


1) ASCO 8317;

2) Skinner C Series;

3) Or equal.

b. MATERIALS/EQUIPMENT:

1) The contract documents show process solenoid valves which are specified in the SOLENOID VALVES FOR PROCESS SERVICE Section (40 05 82). In addition to process solenoid valves, there are solenoid valves used for pneumatic signal control which are specified in the next paragraph.

2) Solenoid valves shall be 3 way, piped exhaust, soft seat, 1/4 inch bronze bodied NPT units with zero leakage. Valves shall be suitable for non-lubricated air service from 0 to 150 psig. Cv shall be 0.17 minimum. Coil shall be Class H molded type rated 24 volts DC, 0.35 amperes maximum. Panel mounted valves shall have spade terminal open yoke construction. Field mounted valves in nonhazardous areas shall comply with JIC P 1 1975. Valves in hazardous areas shall comply with ANSI C33.30 1973 and shall be UL listed as Class I, Division 1, Group D.

C. (NOT USED)

D. (NOT USED)

PART 3 -- EXECUTION

3.01 GENERAL

A. Submit and obtain approval of instrument data sheets, instrument installation details and instrument calibration sheets prior to installing any instrument.

B. Instrument tests, inspections, and preventative maintenance shall comply with the PROCESS CONTROL SYSTEM TESTING Section (40 61 25). Panel and field mounted instrument supports, nameplates, tags, process connections and wiring shall comply with the requirements of the INSTRUMENTATION FOR PROCESS SYSTEMS Section (40 70 00) and the CONTROL SYSTEM EQUIPMENT PANELS AND RACKS Section (40 67 00).


40 70 00 - 12

3.02 INSTALLATION

A. Instruments shall be installed in accordance with the instrument installation detail drawings, manufacturer’s installation requirements, and as specified herein. Installation of process taps are specified in Division 40.

B. The mechanical drawings shall be coordinated with process drawings. The locations of the process taps need to be shown on the mechanical drawings. Process taps shall be specified in the COMMON WORK RESULTS FOR PROCESS PIPING Section (40 05 03).

C. Pressure Transmitters and Switches shall be installed as follows:

1. Root valves shall be provided at all process pressure taps except taps made for safety service. Gage isolation valves shall be provided at the instrument where the instrument is not within sight of the root valve or where two or more instruments are connected to a single tap. Safety instruments shall not be connected to the same process tap as instruments used for control, indication, or recording. Pressure instruments shall be located as close as practical to the process tap but shall be positioned to permit observation and maintenance. Pressure gages may be supported from the process tap if this location permits observation and maintenance from the floor or a permanent work platform.

2. Provide 3-valve manifolds on all differential pressure transmitters and switches.

3. Provide condensate chambers on all pressure taps for pressure instruments connected to steam piping. Provide shutoff valves at both the condensate chamber and at the instrument for each pressure sensing line.

D. (NOT USED)

3.03 TESTING

A. All instruments shall be job site calibrated prior to installation, except for instruments where factory calibration is specified herein.

B. The instrument pre-operational testing shall be performed as specified in the PROCESS CONTROL SYSTEM TESTING Section (40 61 21). Operational testing shall be in accordance with the COMMISSIONING Section (01 91 00).

C. Test results shall be documented on test forms from the PROCESS CONTROL SYSTEM TESTING Section (40 61 21) and the REFERENCE FORMS Section (01 91 10).

D. Control and logic and loop testing shall be performed on all instruments in accordance with the COMMISSIONING Section (01 91 00) and the PROCESS CONTROL SYSTEM TESTING Section (40 61 21).


40 70 00 - 13

3.04 TRAINING

A. Training shall conform to the PROCESS CONTROL SYSTEM TRAINING Section (40 61 26). The number of training session and hours for each craft shall conform to the requirements of TRAINING Section (01 79 10).

**END OF SECTION**


40 70 00 - 14


01/28/19


40 79 00 - 1

SECTION 40 79 00

MISCELLANEOUS INSTRUMENTS, CALIBRATION EQUIPMENT, INSTRUMENT VALVES AND FITTINGS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies accessories that shall be provided by the Contractor for process control equipment that is specified in other sections of Division 40. All work in this section shall be performed in accordance with the provisions of PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13).

1.02 REFERENCES


Reference Title

IEEE 62.41.1 Surge Voltages in Low Voltage AC Power Circuits

ASTM A269 Seamless and Welded Austinitic Stainless Steel Tubing for General Service

ASTM B68 Seamless Copper Tube, Bright Annealed

ASTM D833 Standard Terminology Relating to Plastics

MIL STD 461-A Electromagnetic Interference Characteristics Requirements for Equipment

UL 1012 Power Units Other Than Class 2

UL 1449 Transient Voltage Surge Suppressors

UL 1778 Uninterruptible Power Supply Equipment


01/28/19


40 79 00 - 2

1.03 SUBMITTALS

A. The following information shall be submitted for review in accordance with the SUBMITTAL PROCEDURES Section (01 33 00) and the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13):


2. A copy of the contract document control diagrams and process and instrumentation diagrams that apply to the equipment in this section marked to show specific changes necessary for the supplied equipment. If no changes are required, the drawings shall be marked "No Changes Required."

3. Manufacturer's data in sufficient detail to verify compliance with these specifications for:

a. Air purge assembly

b. Water purge assembly

c. Air sets

d. Manual pressure regulators

e. Three-valve manifolds

f. Hand valves and fittings

g. Process connections and tubing

h. Direct-current power supplies

i. Noise-suppression isolation transformers

j. Transient voltage surge suppressor

k. Signaling devices

l. Uninterruptible power supply equipment


A. Submit operation and maintenance (O&M) instructions in accordance with the OPERATION AND MAINTENANCE DATA Section (01 78 23) by submitting a copy of the OPERATION AND MAINTENANCE DATA Section (01 78 23) with each paragraph check marked to show compliance. O&M instructions shall be submitted after all submittals specified above have been returned mark “No Exceptions Taken” or

01/28/19


40 79 00 - 3

“Make Corrections Noted.” O&M instructions shall reflect the approved materials and equipment.

PART 2 -- PRODUCTS

2.01 AIR PURGE ASSEMBLY

A. ACCEPTABLE PRODUCTS

1. Siemens (Moore Products Co.) Model 62VA

2. ABB 10A6100

3. Conoflow GDH21-12

B. MATERIALS/EQUIPMENT

1. Air purge assembly shall consist of a constant-differential pressure regulator, needle valve, check valve and 0.2 - 2.0 standard cubic feet per hour (scfh) rotameter.

2.02 WATER PURGE ASSEMBLY


1. Siemens (Moore Products Co.) Model 63BD4A

2. ABB 10A6100

3. Conoflow GDH21-1


1. Water purge assembly shall consist of a strainer, constant-differential regulator, needle valve, check valve and 20-200 cubic centimeters per minute (cc/min) rotameter.

2.03 AIR SETS


1. ITT Conoflow GFH-75;

2. Fairchild Industrial Products Company Model 63 OR 65A; or equal.

01/28/19


40 79 00 - 4


1. Air sets shall consist of service regulator with nominal 1/2 to 30 psig range and 10 micron filter of capacity to serve the connected instrument load plus 100 percent spare capacity.

2. Air sets for individual field mounted instruments shall be nonadjustable or otherwise sealed to prevent tampering, shall be provided with 2-inch gage or Schrader air connection.

3. Air sets for panels shall be adjustable with 3-1/2-inch or larger gage.

2.04 MANUAL REGULATORS


1. Siemens (Moore Products Co.);

2. Fairchild Industrial Products Company; or equal.


1. Manual pressure regulators shall be capable of supply or exhaust of not less than 9 scfm and shall be selected to provide the required final operator range with a supply pressure of 60 to 125 pounds per square inch gage (psig).

2.05 THREE-VALVE MANIFOLDS


1. Manifolds shall be Anderson Greenwood M4T, or equal.


1. Three-valve manifolds shall be provided for differential pressure measurements. Manifold shall have a one-piece body of extruded 316 stainless steel bar stock. Valves shall be globe configuration with 316 stainless steel ball seats and Teflon stem packing. Manifolds shall be designed for direct mounting to force-balance differential pressure transmitters in place of the flanges normally furnished. Fabricated manifolds or manifolds employing needle or soft seat valves are not acceptable. Purge taps, 1/4-inch NPT, shall be furnished on manifolds where water purge is indicated.

2.06 SOLENOID VALVES


1. ASCO 8317;

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40 79 00 - 5

2. Skinner C Series; or equal.


1. The contract documents show process solenoid valves which are scheduled and specified in SOLENOID VALVES FOR PROCESS SERVICE Section (40 05 88). In addition to process solenoid valves, there are solenoid valves used for pneumatic signal control which are specified in the next paragraph.

2. Solenoid valves shall be 3-way, piped exhaust, soft seat, ¼-inch bronze bodied NPT units with zero leakage. Valves shall be suitable for non-lubricated air service from 0 to 150 psig. Cv shall be 0.17 minimum. Coil shall be Class H molded type rated 24 volts DC, 0.35 amperes maximum. Panel mounted valves shall have spade terminal open yoke construction. Field-mounted valves in nonhazardous areas shall comply with JIC P 1 1975. Valves in hazardous areas shall comply with ANSI C33.30 1973 and shall be UL listed as Class I, Division 1, Group D.

2.07 HAND VALVES AND FITTINGS


1. Valves shall be Parker B Series with CPI fittings, Swagelok 40 Series, or equal.

2. Thermoplastic fittings shall be Parker Fast & Tite, or equal.

3. Fittings shall be Crawford "Swagelok", Parker CPI, or equal.


1. Valves shall be full port ball valves with 316 stainless steel trim and body and with Teflon seats and packing. Three-way switching valves shall be as specified.

2. Thermoplastic fittings shall be nylon with nitride "0" ring and stainless steel grab ring fitting.

3. Metal fittings shall be type 316 stainless steel. Fittings shall be of the swage ferrule design.

2.08 PNEUMATIC TUBING


1. Polyethylene tubing shall be Dekoron Type P, Imperial Eastman Poly-Flo, or equal.

2. Fittings shall be compression-type brass as manufactured by Imperial Eastman Poly-Flo, Dekoron E-Z fittings, or equal.

01/28/19


40 79 00 - 6


1. Stainless steel pneumatic tubing shall be ¼-inch seamless, annealed, ASTM A269, type 316 stainless steel unless otherwise identified on the drawings. Fittings shall be compression type fitting of the same material.

2. Copper pneumatic tubing shall be ¼-inch seamless ASTM B68 soft annealed copper. Fittings shall be compression type fitting of the same material.

3. All other pneumatic tubing shall be black polyethylene capable of withstanding 190 psig at 175 degrees F. Fittings shall be compression-type brass.

2.09 PROCESS CONNECTIONS AND TUBING


1. Thermoplastic tubing: Parker Parflex Series N nylon, or equal.


1. Process connections for instruments shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03).

2. Instrument tubing between the process connection and instruments shall be ½-inch by 0.035-inch seamless, annealed, ASTM A269, type 316 stainless steel unless otherwise identified on the drawings.

2.10 DIRECT CURRENT POWER SUPPLIES


1. Acopian, R24xx, or equal.


1. Direct current, 24V DC power supplies shall be switching type. Output voltage regulation shall be plus or minus 0.05 percent maximum for line voltage variations from 90 to 132 volts. Undervoltage monitoring and local annunciation shall be provided. Units shall be redundant and as shown on the drawings with automatic transfer to the backup unit. Each unit shall have two DC voltmeters and two DC ammeters.

2. Each unit shall contain two identical power supplies with their outputs interconnected through a diode switching arrangement that will detect any fault condition, isolate it from the system output, and pass only the output of the other supply with no interruption of output power during the transition. Unit may be operated with only one AC power source. However, two isolated sets of AC input

01/28/19


40 79 00 - 7

connections shall be provided so that two independent sources of input power may be used to obtain the additional protection of input redundancy.

3. Each unit shall have two voltage monitoring circuits with relays. The contact wiring of the two relays shall be connected in cascade to simulate a single set of Form C contacts which switches if the output voltage of either power supply decreases by more than 2.0 volts (3.0 volts for outputs over 48 volts) from the nominal rating. Each unit shall contain an overvoltage protection circuit to assure that neither power supply output will significantly exceed the nominal output voltage rating under any condition, including incorrect application and adjustment.

4. Power supply shall be sized to meet requirements of each application, not to exceed 60 percent of capacity at 55 degrees C.

2.11 NOISE-SUPPRESSION ISOLATION TRANSFORMERS


1. MGE UPS System Topaz "Ultra-Isolator", or equal.


1. Isolation transformers shall be of the triple box shield type. Each coil shall be completely enclosed in a grounded conductive faraday shield, and the overall transformer enclosed in a faraday shield. Common mode noise attenuation between primary and secondary shall exceed 140 db at 100 kHz. Normal-node noise attenuation shall be 60db at 100kHz. Isolation transformer dielectric strength shall be 2500 volts minimum. Isolation transformers shall have a load capacity not less than 125 percent of the connected load. Power loss in the isolation transformer shall not exceed 5 percent of the maximum load rating. Harmonic distortion introduced by the isolation transformer shall not exceed 0.1 percent. Isolation transformers shall comply with UL 1012 and 1449 and shall be approved by UL, CSA, or FM for the application.

2.12 TRANSIENT VOLTAGE SURGE SUPPRESSOR


1. Leviton, Model 51020-0WM, or equal.


1. The transient voltage surge suppressor (TVSS) shall be a suitable surge protection device for a 120V AC, 60 Hz, 20 ampere branch circuits. The unit shall be enclosed in a metal enclosure. Terminal shall be provided for the connection of the line, load and grounding wiring. An acoustical alert shall activate when surge protection is lost.

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40 79 00 - 8

2. The TVSS device shall conform to UL Standard 1449. The device shall be tested in accordance with ANSI/IEEE 62.41, Category B3 (8/20 S) peak clamping voltage.

3. The peak clamping voltage using Category B3 shall be L-N:300V, L-G:350V. The UL 1449 rating shall be L-N:330V, L-G:400V, N-G:400V. The single-pulse transient energy (10X1000 Joules) shall be L-N:300J, L-G:320J. The maximum single-pulse transient current (8X20 S ampere peak) shall be L-N:26KA, L-G:26KA. The noise rejection at 50 ohms (5K to 100 MHz) shall be -40 to -50 db, both normal and common mode. The fault current rating of the device shall be 5000 amperes.

2.13 SIGNALING DEVICES


1. Horns for non-hazardous locations: Edwards 5520-N5 or equal.

2. Horns for Class 1, Division 1, Groups C and D hazardous locations: Edwards 5522-Y6 or equal.

3. Beacon lights: Edwards 105EXBRINR-N5, Appleton Code-Master, or equal.


1. Signaling devices shall be suitable for outdoor (weatherproof), upright wall mounting. Signal devices shall operate on 120 VAC power and shall be suitable for hazardous area operation. For non-hazardous locations, horns shall be capable of 114dB at 10 feet. For Class 1, Division 1, Groups C and D hazardous locations, horns shall be factory sealed and capable of 109dB at 10 feet.

2. Beacon lights shall be the rotating type with a 40-watt halogen bulb, high impact glass dome, guard, and silicon gaskets and shall include a wall mounting bracket. Lights shall be UL-listed for Class 1, Division 1, Groups C and D hazardous locations and for marine installations. Beacon light colors shall be blue for LEL and H2S, white for UV/IR, amber for CL2 (internal or indoors sensor), and red for CL2 (external or outdoor sensor). Lights shall be factory sealed.

PART 3 -- EXECUTION

3.01 GENERAL – NOT USED

3.02 INSTALLATION

A. GENERAL:

1. Install to requirements specified herein and manufacturer's instructions.

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40 79 00 - 9

B. AIR SUPPLIES:

1. For instruments or assemblies requiring instrument air the service air header, piping, and isolation valves are specified in the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13) and the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03) and as shown on the drawings.

2. Piping and pneumatic system components downstream of the isolation valve shall be as specified herein.

C. TUBING:

1. Tubing shall be provided on supports spaced not more than 3 feet apart and shall be run parallel or perpendicular to walls, structural members, or intersections of vertical planes and the ceiling. Unless otherwise specified, tubing shall follow building surfaces closely or shall be carried in trays or conduit. Tubing shall not be supported from piping or equipment except at process taps or final operators. Tubes supported directly from concrete shall be spaced at least 1/8-inch from concrete. Tubing support shall be one-hole malleable iron clamps with clamp backs as required.

2. Bends shall be formed to uniform radii without flattening. Ends of tubing shall be square-cut and cleaned before being inserted in fittings. Compression fittings shall be used for splices, turns, and connections near instruments; bulkhead assemblies shall be provided in panels. Instrument lines shall be cleaned with dry, oil-free air before final connection to instruments.

3. Pneumatic tubing in chlorine and sulfur dioxide corrosive areas shall be stainless steel tubing as described herein. Use polyethylene tubing for connections between the bubbler panel and tube when pulled through conduit. Use copper in all other locations.

4. Tubing cleaning shall be as specified in the COMMON WORK RESULTS FOR PIPING SYSTEMS Section (40 05 03), Type 3.

5. All tubing shall be blown clean of all interior moisture and debris prior to closing system.

3.03 TESTING

A. Pre-operational testing shall be in accordance with the PROCESS CONTROL SYSTEM GENERAL PROVISIONS Section (40 61 13). Operational testing shall be in accordance with the COMMISSIONING Section (01 91 00).

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40 79 00 - 10


**END OF SECTION**

DIVISION 43 – PROCESS GAS AND LIQUID HANDLING PURIFICATION, AND STORAGE EQUIPMENT 43 05 10 COMMON WORK RESULTSFOR GAS HANDLING EQUIPMENT43 13 43 WASTE GAS BURNER SYSTEM43 13 43.01 GROUND FLARE REFURBISHMENT43 41 23.01 50” WC WATER SEAL CONDENSATE TANK43 41 23.03 FSG CONDENSATE TANK



43 05 10 - 1

SECTION 43 05 10

COMMON WORK RESULTS FOR GAS HANDLING EQUIPMENT

PART 1 - GENERAL


A. Scope:

1. This section specifies general requirements which are applicable to all mechanical equipment. The Contractor is responsible for ensuring that all mechanical equipment meets the requirements of this section in addition to the specific requirements of each individual equipment specification section.

B. Equipment Lists:

1. Equipment lists, presented in these specifications and as specified on the drawings, are included for the convenience of the Construction Manager and Contractor and are not complete listings of all equipment, devices and material required to be provided under this contract. The Contractor shall prepare his own material and equipment takeoff lists as necessary to meet the requirements of this project manual.

C. QUALITY ASSURANCE

1. The arrangement of equipment shown on the drawings is based upon information available to the Owner at the time of design and is not intended to show exact dimensions conforming to a specific manufacturer. The drawings are, in part, diagrammatic, and some features of the illustrated equipment installation may require revision to meet actual submitted equipment installation requirements; these may vary significantly from manufacturer to manufacturer. The contractor shall, in determining the cost of installation, include these differences as part of his bid proposal. Structural supports, foundations, connected piping, valves, and electrical conduit specified may have to be altered to accommodate the equipment actually provided. No additional payment shall be made for such revisions and alterations.

1.02 REFERENCES



43 05 10 - 2

Reference Title

ABMA Std 9 Load Ratings and Fatigue Life for Ball Bearings

ABMA Std 11 Load Ratings and Fatigue Life for Roller Bearings

ANSI B1.1 Unified Inch Screw Threads (UN and UNR Thread Form)

ANSI B1.20.1 Pipe Threads, General Purpose (Inch)

ANSI B16.1 Gray Iron Pipe Flanges and Flanged Fittings, (Classes 25, 125, and 250)

ANSI B18.2.1 Square and Hex Bolts and Screws (Inch Series)

ANSI B18.2.2 Square and Hex Nuts (Inch Series)

ANSI S2.19 Mechanical Vibration – Balance Quality Requirements of Rigid Rotors, Part 1: Determination of Permissible Unbalance, Including Marine Applications

1.03 SUBMITTALS

A. List of Lubricants. See Section 43 05 10. 2.09 for requirements.


1.05 UNIT RESPONSIBILITY

A. The Contractor shall cause equipment assemblies made up of two or more components to be provided as a working unit by the unit responsibility manufacturer, where specified. The unit responsibility manufacturer shall coordinate selection, coordinate design, and shall provide all mechanical equipment assembly components such that all equipment components furnished under the specification for the equipment assembly, and all equipment components specified elsewhere but referenced in the equipment assembly specification, is compatible and operates reliably and properly to achieve the specified performance requirements. Unless otherwise specified, the unit responsibility manufacturer shall be the manufacturer of the driven component equipment in the equipment assembly. The unit responsibility manufacturer is designated in the individual equipment specifications found elsewhere in this project manual. Agents, representatives or other entities that are not a direct division of the driven equipment manufacturing corporation shall not be accepted as a substitute for the driven equipment manufacturer in meeting this requirement. The requirement for unit responsibility shall in no way relieve the Contractor of his responsibility to the Owner for performance of all systems as provided in the General Conditions of the Contract Documents.

B. The Contractor shall ensure that all equipment assemblies provided for the project are products for which unit responsibility has been accepted by the unit responsibility


43 05 10 - 3

manufacturer(s), where specified. Unit responsibility for related components in a mechanical equipment assembly does not require or obligate the unit responsibility manufacturer to warranty the workmanship or quality of component products not manufactured by them. Where an individual specification requires the Contractor to furnish a certificate from a unit responsibility manufacturer, such certificate shall conform to the content, form and style of Form 43 05 10-C specified in REFERENCE FORMS Section 01 91 10, shall be signed by an officer of the unit responsibility manufacturer's corporation and shall be notarized. No other submittal material will be processed until a Certificate of Unit Responsibility has been received and has been found to be satisfactory. Failure to provide acceptable proof that the unit responsibility requirement has been satisfied will result in withholding approval of progress payments for the subject equipment even though the equipment may have been installed in the work.

C. Balance:

1. Unless specified otherwise, for all machines 10 HP and greater, all rotating elements in motors, pumps, blowers and centrifugal compressors shall be fully assembled, including coupling hubs, before being statically and dynamically balanced. All rotating elements shall be balanced to the following criteria:

a. N

GWU per

015.6

b. Where:

1) Uper = permissible imbalance, ounce-inches, maximum

2) G = Balance quality grade, millimeters per second

3) W = Weight of the balanced assembly, pounds mass

4) N = Maximum operational speed, rpm

2. Where specified, balancing reports, demonstrating compliance with this requirement, shall be submitted as product data. Equipment balance quality grade shall be G 2.5 (G = 2.5 mm/sec) or better in accordance with ANSI S2.19.

PART 2 - PRODUCTS

2.01 FLANGES AND PIPE THREADS

A. Flanges on equipment and appurtenances provided under this section shall conform in dimensions and drilling to ANSI B16.1, Class 125. Pipe threads shall conform in dimension and limits of size to ANSI B1.1, coarse thread series, Class 2 fit.

B. Threaded flanges shall have a standard taper pipe thread conforming to ANSI B1.20.1. Unless otherwise specified, flanges shall be flat faced.

C. Flange assembly bolts shall be heavy pattern, hexagonal head, carbon steel machine bolts with heavy pattern, hot pressed, hexagonal nuts conforming to ANSI B18.2.1


43 05 10 - 4

and B18.2.2. Threads shall be Unified Screw Threads, Standard Coarse Thread Series, Class 2A and 2B, ANSI B1.1.

2.02 (NOT USED)

2.03 (NOT USED)

2.04 (NOT USED)

2.05 GUARDS

A. Exposed moving parts shall be provided with guards which meet all applicable OSHA requirements. Guards shall be fabricated of 14-gage steel, 1/2-13-15 expanded metal screen to provide visual inspection of moving parts without removal of the guard. Guards shall be galvanized after fabrication and shall be designed to be readily removable to facilitate maintenance of moving parts. Reinforced holes shall be provided. Lube fittings shall be extended through guards.

2.06 CAUTION SIGNS

A. Equipment with guarded moving parts which operates automatically or by remote control shall be identified by signs reading "Caution - Automatic Equipment May Start At Any Time". Signs shall be constructed of fiberglass material, minimum 1/8 inch thick, rigid, suitable for post mounting. Letters shall be white on a red background. The sign size and pattern shall be as shown on the drawings. Signs shall be installed near guarded moving parts.

2.07 GAGE TAPS, TEST PLUGS AND GAGES

A. Gage taps shall be provided on the suction and discharge sides of pumps, blowers and compressors. Pressure and vacuum gages shall be provided where specified. Gage taps, test plugs, and gages shall be as specified in Section 40 70 00.

2.08 FSG DRIP LEG LEVEL INDICATORS

A. Acceptable Products:

1. Dwyer Insruments series VR-S SS2 BM-B-1.0-150-200-036 A N; or equal.

B. General Description:

1. Drip leg level indicators shall be a Type 316 stainless steel housing with magnetic float and external indicating flags.

C. Housing:

1. Tube housing shall be Type 316L stainless steel, 2½” diameter.

D. Configuration:

1. Upper and lower side connections.


43 05 10 - 5

2. Connections shall be 1” NPT.

3. Float access shall be from the bottom.

4. Float shall be designed for specific gravity = 1.0.

E. Maximum Operating Conditions:

1. 150 psig @ 200°F.

F. Indicator:

1. Indicating length shall be 36”.

2. Indicating flags shall be aluminum, silver and black.

3. No scale.

G. Isolation Valves:

1. Level indicator isolation valves shall be Type SS-3P ball valves, per Ball Valve Specification Section (40 05 63).

2.09 NAMEPLATES

A. Nameplates shall be provided on each item of equipment. Equipment nameplates shall be 16-gauge stainless steel bearing the equipment name and equipment number legibly engraved in ¾-inch high letters. Nameplates shall be attached to the equipment in an accessible location with stainless steel screws.

2.10 LUBRICANTS

A. The Contractor shall provide for each item of mechanical equipment a supply of the required lubricant adequate to last through the specified commissioning period. Lubricants shall be of the type recommended by the equipment manufacturer and shall be products of the Owner's current lubricant supplier. The Contractor shall limit the various types of lubricants by consolidating them, with the equipment manufacturer's approval, into the least number of different types. Not less than 90 days before the date shown in his construction schedule for starting, testing and adjusting equipment (Section 01 91 00), the Contractor shall provide the Owner with three copies of a list showing the required lubricants, after consolidation, for each item of mechanical equipment. The list shall show estimated quantity of lubricant needed for a full year's operation, assuming the equipment will be operating continuously.

2.11 ANCHOR BOLTS

A. Anchor bolts shall be designed for lateral forces for both pullout and shear in accordance with the provisions of the ANCHOR BOLTS Section (05 05 20). Unless otherwise stated in the individual equipment specifications, anchor bolt materials shall conform to the provisions of the ANCHOR BOLTS Section (05 05 20).


43 05 10 - 6

2.12 SPARE PARTS

A. The manufacturer’s recommended spare parts and special tools lists shall be in accordance with the OPERATION AND MAINTENANCE DATA Section (01 78 23).

PART 3 EXECUTION

3.01 GENERAL

A. Installation of equipment accessories included in this section shall be as recommended by the equipment manufacturer unless otherwise specified in the individual equipment specification section.

3.02 (NOT USED)

3.03 (NOT USED)

3.04 (NOT USED)

**END OF SECTION**


43 13 43 - 1

SECTION 43 13 43

WASTE GAS BURNER SYSTEM

PART 1--GENERAL


A. SCOPE:

1. This section specifies the waste gas burners for consuming excess combustible digester gas. The waste gas burners shall be of the open candlestick type with automatic ignitors including an additional thermocouple to verify pilot operation.

B. EQUIPMENT LIST:

Description Equipment Number Waste Gas Burner 1 MME80201Pilot Ignition System MME80201AFlame Arrester ARST80201Thermal Shut Off Valve ARST80201 Waste Gas Burner 2 MME80202Pilot Ignition System MME80202AFlame Arrester ARST80202Thermal Shut Off Valve ARST80202 Waste Gas Burner 5 MME80205Pilot Ignition System MME80205AFlame Arrester ARST80205Thermal Shut Off Valve ARST80205 Waste Gas Burner 6 MME80206Pilot Ignition System MME80206AFlame Arrester ARST80206Thermal Shut Off Valve ARST80206 Waste Gas Burner 7 MME80207Pilot Ignition System MME80207AFlame Arrester ARST80207Thermal Shut Off Valve ARST80207 Waste Gas Burner 8 MME80208


43 13 43 - 2

Description Equipment Number Pilot Ignition System MME80208AFlame Arrester ARST80208Thermal Shut Off Valve ARST80208

1.02 REFERENCES


Reference TitleASME B1.1 Unified Inch Screw Threads ASME B1.20.1 Pipe Threads, General PurposeASME B16.3 Malleable Iron Threaded FittingsASME B16.5 Pipe Flanges and Flanged FittingsASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings ASME B16.11 Forged Fittings, Socket-Welding and Threaded ASME B16.39 Malleable Iron Threaded Pipe Unions Classes 150, 250 and 300ASME B31.1 Power PipingASME B31.3 Chemical Plant and Petroleum Refinery Piping ASME Section IX

Certification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators


ASTM A105 Forgings, Carbon Steel, for Piping Components ASTM A193 Alloy-Steel and Stainless Steel Bolting Materials for High-

Temperature ServiceASTM A197 Cupola Malleable IronASTM A234 Pipe Fittings of Wrought Carbon Steel and Alloy Steel for

Moderate and Elevated TemperaturesSAE J429 Mechanical and Material Requirements for Externally Threaded

Fasteners, StandardSSPC-SP 10 Near-White Blast Cleaning

1.03 DIGESTER GAS COMPOSITION:

A. Approximately 60% methane, 35% carbon dioxide, balance of nitrogen, up to 300 ppm hydrogen sulfide, trace gases. The gas will have approximately 550 to 600 BTU value. The gas will contain particulate materials and greasy oils.


43 13 43 - 3

1.04 WARRANTY

A. A one year 100% parts and labor warranty against manufacturing defects or failure of the equipment specified in this section caused by normal wear and tear shall be provided. The warranty period shall start from the date of final acceptance of the equipment specified in this section.

1.05 SUBMITTALS

B. The following information shall be provided in accordance with SUBMITTAL PROCEDURES Section (01 33 00).

1. A copy of this specification section, with addenda updates, with each paragraph check-marked to show specification compliance or marked to show deviations.

2. Manufacturer’s information and catalog data showing compliance with this specification and a full description of the product.

3. A copy of the contract document control diagrams and process and instrumentation diagrams that apply to the equipment in this section marked to show specific changes necessary for the supplied equipment. If no changes are required, the drawing or drawings shall be marked "No changes required".

4. Equipment control panel wiring diagram identifying internal and face mounted components and connections to remote equipment.

5. Shop drawings indicating construction and installation details, a complete detailing of the materials construction and equipment weights.

6. Dimensioned drawings of all equipment and accessories as a complete system including cross-section views.

7. Warranty information.

PART 2--PRODUCTS

2.01 WASTE GAS BURNERS


1. Varec Biogas model 239A, no equal.

B. OPERATING REQUIREMENTS:

1. Nominal WGB size: 6”.


43 13 43 - 4

2. Nominal gas flow range, per WGB: 0 to 358+ scfm (depends on biogas Btu content).

3. Normal operating gas inlet pressure at backpressure valve inlet flange: 0 to 10” WC.

4. Maximum allowable gas inlet pressure: 20” WC.

5. Minimum natural gas supply pressure for pilot: 6” WC.

6. Wind speed: 100 mph.

7. Seismic Zone classification: 3.

C. BURNER STACK:

1. The burner stack shall be constructed of carbon steel. The stack shall be bolted to a pedestal of carbon steel. All welds on the stack shall be continuous and solid type.

2. The burner stack shall include two observation & ignition ports.

3. Provide combustion air dampers at the base of the stack.

4. The stack shall be designed in accordance with AISC standards.

D. PEDESTAL:

1. The pedestal shall be insulated, and shall contain the main gas line and two pilot gas lines. The pedestal shall contain braces for bolting the burner stack to it, and a base flange for attachment to the mounting base.

2. Main gas line shall be ASTM A53 Schedule 40 steel pipe, or equal.

3. Pilot gas lines shall be ASTM A53 Schedule 40 steel pipe, or equal.

E. MOUNTING BASE:

1. The mounting base shall be bolted to a structural steel frame.

2. The base shall be designed in accordance with AISC standards, and UBC Seismic Zone 3 requirements.

F. PILOT FLAME RING:

1. The pilot flame ring shall provide a “curtain of flame” that the waste biogas must pass through.


43 13 43 - 5

2. The pilot flame ring shall be supplied by two natural gas pilot lines with two Type 304 stainless steel pilot orifices.

3. The pilot flame ring shall be constructed from heat resistant cast iron.

G. SECONDARY STACK:

1. Secondary stack shall provide additional wind protection. Secondary stack shall be independently supported by a structural steel frame designed in accordance with AISC standards and UBC Seismic Zone 3 requirements.

2.02 PILOT IGNITION SYSTEMS


1. Varec Biogas model 240 H-O-A, no equal.

B. IGNITION ELECTRODE:

1. Ignition electrode shall provide a high voltage spark across an air gap to the pilot ring.

2. Ignition electrode housing shall be fabricated from steel, with an aluminum cover.

C. CONTROL PANEL:

1. Each WGB shall be provided with its own pilot ignition system.

2. Control panel shall be Type 316 stainless steel construction, and shall be rated NEMA 4X.

3. Control panel shall include a hand-off-auto switch, and a factory nameplate on the cover.

4. Control panel shall include a spark generator, timing relay, terminal block, and fuse.

5. Timing relay shall provide separate adjustments for spark duration and spark interval.

6. Power supply input shall be 120 VAC-1Ø-60Hz.

7. Panel shall include a heater and thermostat.

8. An additional thermocouple will be added to each pilot burner assembly to verify that the pilot is operating. This work may be performed by a third party vendor.


43 13 43 - 6

2.03 FLAME ARRESTERS


1. Varec Biogas model 5010, no equal. When the flame arrester is provided along with the thermal shut off valve, the Varec biogas model number is 450.


1. Nominal size: 8”.

2. Mounting orientation: Horizontal.

3. Nominal gas flow range: 0 to 358+ scfm (depends on biogas Btu content).

4. Pressure drop @ 358 scfm: < 0.7” WC.

5. Maximum pressure rating: 10 psig.

C. MATERIAL:

1. Housing & removable cover plates: ASTM B26 ANSI Alloy 356 T6.

2. Bank assembly frame: Type 316 stainless steel.

3. Bank sheets: Type 316 stainless steel.

4. Hardware: Type 316 stainless steel.

D. EQUIPMENT:

1. Inlet & outlet flange connections: ANSI Class 125/150 pattern.

2. Bank assembly shall be accessed through removable cover plates, without requiring jacking apart end housings.

2.04 THERMAL SHUT OFF VALVES


1. Varec Biogas model 430; Shand & Jurs model 97130; or equal. When the thermal shut off valve is provided along with the flame arrester, the Varec Biogas model number is 450.


1. Nominal size: 8”.

2. Mounting orientation: Horizontal.


43 13 43 - 7

3. Nominal gas flow range: 0 to 321+ scfm (depends on biogas Btu content).

4. Pressure drop @ 358 scfm: 0.9” WC.

5. Thermal fuse performance: 22 to 45 seconds @ 260°F.

6. Maximum pressure rating: 5 psig.

C. MATERIALS:

1. Valve body & cover: ASTM B26 ANSI Alloy 356 T6 cast aluminum.

2. Pallet: Low copper aluminum.

3. Compression spring: Type 304 stainless steel.

4. Sight glass indicator: Acrylic or Pyrex glass, with Buna-N gaskets.

D. EQUIPMENT:

1. Inlet & outlet flange connections: ANSI Class 125/150 pattern.

PART 3--EXECUTION

3.01 GENERAL

A. Equipment shall be shipped and stored in accordance with PRODUCT DELIVERY REQUIREMENTS Section (01 65 00).

3.02 INSTALLATION

A. Installation shall be in accordance with Common Work Results for Gas Handling Equipment Section (43 05 10). The installation and initial operation of all components shall be certified on Form 01 91 00 C2 as specified in REFERENCE FORMS Section (01 91 10).

3.03 COATINGS

A. The bare carbon steel main gas line from the connection to the pedestal shall be coated with high temperature zinc primer, per Sections (09 06 90) and (09 90 00).

B. The bare carbon steel pilot gas line from the connection to the pedestal shall be coated with high temperature zinc primer, per Sections (09 06 90) and (09 90 00).

C. The bare carbon steel mounting base and pedestal up to within 4 ft from the burner head shall be coated with high temperature zinc primer, per Sections (09 06 90) and (09 90 00).


43 13 43 - 8

3.04 TESTING

A. The equipment manufacturer shall provide a factory-trained representative for one working day (8 hours). The factory representative shall inspect the installation, provide start up services, and train plant personnel on operating and maintenance requirements. See REFERENCE FORMS Section (01 91 00).

3.05 TRAINING

A. Training shall conform to the TRAINING Section (01 79 10). The number of training sessions and hours for each craft shall conform to the requirements of the TRAINING Section (01 79 10).

B. Training shall be certified on Form 01 79 10 E specified in TRAINING Section

(01 91 10).

**END OF SECTION**


43 13 43.01 - 1

SECTION 43 13 43.01

GROUND FLARE REFURBISHMENT

PART 1 GENERAL

1.01 DESCRIPTION

A. SCOPE:

1. This section specifies existing ground flare system work and refurbishment for consumption of excess combustable digester gas. The ground flare system will be specifically designed for burning flare pressure sludge gas (FSG).

2. The manufacturer shall review the mechanical layout drawings to familiarize themselves with the location and the set-up of the equipment specified and shall assure themselves that the equipment specified is appropriate for and coordinated with what is shown on the contract drawings.

3. The manufacturer shall also review the relevant electrical plan and one-line diagram and the relevant process and instrumentation diagram drawing to ensure that the contract drawings are appropriate and coordinated with the equipment and controls specified.

B. EQUIPMENT LIST:

Item Equipment No.

Enclosed Ground Flare 1 BRN87301



C. RELATED SECTIONS AND PARAGRAPHS:

1. The equipment specified in this section shall be provided in accordance with the following additional sections and paragraphs. This is not a comprehensive list of related and referenced sections and paragraphs and additional related and referenced sections and paragraphs requiring compliance may be specified throughout this section and within other sections. This list is provided as a convenience for the CONTRACTOR.


43 13 43.01 - 2

Related and referenced sections shall be reviewed and submittal information provided as required in paragraph 1.03 of this section.

Section 01 33 00 – Submittal Procedures

Section 01 45 00 – Quality Control

Section 01 99 00 – Reference Forms

Section 26 05 21 – Common Work Results for Electrical

Section 40 63 43 – Programable Logic Controls

Section 43 05 10 – Common Work results for Gas Handling Equipment

1.02 QUALITY ASSURANCE

A. GENERAL:

1. The enclosed flare modifications shall be approved by Sacramento Regional County Sanitation District (District) and Brown and Caldwell. In addition, environmental provisions of Article C500 in the National Electrical Code shall apply to this specification. Design shall meet IBC seismic requirements for Seismic Zone 2.

2. The new systems shall exhibit industrial quality and shall be completely manufactured by the flare supplier.

3. The supplier shall have a minimum 10 years of experience in the design and manufacture of flare equipment and shall have a minimum of 20 low emission flares operating successfully in the United States.

4. The flare system supplied shall be complete and operable as specified within.

B. UNIT RESPONSIBILITY:

1. The CONTRACTOR shall assign Unit Responsibility to the flare manufacturer in conformance with the requirements of this section.

2. The equipment provided shall be manufactured by the ground flare supplier at the supplier's own fabrication facility. All components directly supporting combustion, such as burners and pilots, must be manufactured by the flare supplier. Only ancillary equipment, such as gas blowers, flame arrestors, and instrumentation shall be manufactured by others.

C. REFERENCES:

1. This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict


43 13 43.01 - 3

between the requirements of this section and those of the listed documents, the requirements of this section shall prevail.

2. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced.

D. PRODUCT STORAGE AND HANDLING REQUIREMENTS:

1. The equipment shall be protected during shipment and storage as specified in Section 01 65 00.

E. WARRANTY AND PERFORMANCE AFFIDAVIT:

1. A one year 100% parts and labor warranty against manufacturing defects or failure of the equipment specified in this section caused by normal wear and tear shall be provided. The warranty period shall start from the date of final acceptance of the equipment specified in this section.

2. No performance affidavit above and beyond the inclusion of the checkmarked section(s) as specified in the Submittals paragraph of this section is specified.

1.03 SUBMITTALS

A. The following information shall be provided in accordance with the SUBMITTAL PROCEDURES Section (01 33 00):

1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks (�) shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The District shall be the final authority for determining acceptability of requested deviations. The remaining portions of the


43 13 43.01 - 4

paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.

2. A copy of the contract document control diagrams and process and instrumentation diagrams relating to the submitted equipment, with addendum updates that apply to the equipment in this section, marked to show specific changes necessary for the equipment proposed in the submittal. If no changes are required, the drawing or drawings shall be marked “no changes required.” Failure to include copies of the relevant drawings with the submittal shall be cause for rejection of the entire submittal with no further review.

3. Certificate of Unit Responsibility attesting that the Contractor has assigned unit responsibility in accordance with the requirements of this section and the COMMON WORK RESULTS FOR GAS HANDLING EQUIPMENT Section (43 05 10). No other submittal material will be reviewed until the certificate has been received and found to be in conformance with these requirements.

4. Bracing and anchoring design calculations per the requirements of the DESIGN REQUIREMENTS FOR NON-STRUCTURAL COMPONENTS AND NON-BUILDING STRUCTURES Section (01 73 24).

5. Control Panels:

a) Dimensioned drawings:

(1) Exterior panel and layout

(2) Interior devices and layout

(3) Door-in-door construction devices, where required

(4) Bill of Materials cross-referenced to layout drawings.

(5) Nameplate engraving schedule:

(a) Indicate engraving by line

(b) Character size

(c) Nameplate size

(d) Panel and equipment tag number and description

b. Wiring Diagrams:


43 13 43.01 - 5

a) PLC Input/Output (I/O) loop diagram drawings.

b) Internal power distribution schematic diagram drawings.

c. PLC power supply loading calculations.

d. PLC register/tag map:

1) Identifying information available via the Ethernet IP network communications port. All control, status and alarm points used in the PLC program shall be listed.

e. List of spare parts to be provided.

f. Test Reports:

1) Certified calibration reports for new instruments.

2) Certified loop checks of each new and existing input and output point conneted to the PLC.

3) Certified functional test reports confiring the overall system functions as specified.

1.04 BRACING AND ANCHORING

1. Mechanical, instrumentation and control, electrical, nonstructural systems, components, and elements permanently attached to the structure shall be anchored and braced to resist seismic forces. Contractor shall design the structural components, seismic attachment, braces, and anchors to the structure for all parts or elements of the mechanical and electrical systems in accordance with DESIGN REQUIREMENTS FOR NON-STRUCTURAL COMPONENTS AND NON-BUILDING STRUCTURES Section (01 73 24).

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. John Zink, to match existing equipment.

2.02 MATERIALS

A. Materials of construction shall be as recommended by the manufacturer, and acceptable to the Engineer.

B. Materials specified are considered the minimum acceptable for the purposes of durability, strength, and resistance to erosion and corrosion. The Contractor may


43 13 43.01 - 6

propose alternative materials for the purpose of providing greater strength or to meet required stress limitations. However, alternative materials must provide at least the same qualities as those specified for the purpose.

2.03 ENCLOSED FLARE

A. NATURAL GAS PILOT:

1. Provide a natural gas pilot for each open flare. Install pilot assemblies with beveled tips to prevent rain from impacting pilot performance.

2. All electrical appurtenances shall be Class 1 Division 1, explosion proof.

B. CONTROL PANELS:

1. Provide the following upgrades to each control panel:

a. Replace existing Allen-Bradley SLC series PLC with Allen-Bradley CompactLogix PLC with L33ER series processor and Ethernet IP communications port.

b. Provide human machine interface (HMI) mounted in exterior door of panel. HMI shall be Automation Direct C-More series with 10” color touch-screen interface.

c. Replace existing paper chart recorder with a Yokogawa FX series digital data recorder.

d. All improvements required to implement the functionality described in this Section and in Section 40 61 96.10 – PCCS Control Strategies.

C. PILOT GAS SOLENOID VALVES

1. Replace existing pilot gas solenoid valves in kind.

2. All electrical appurtenances shall be Class 1 Division 1, explosion proof.

D. MECHANICAL COUPLINGS

1. Replace existing flexible mechanical jaw couplings (Lovejoy) in kind.

2.04 (NOT USED)

2.05 SPARE PARTS

A. Spare parts shall be provided as recommended by the flare manufacturer and as acceptable by the Engineer.


43 13 43.01 - 7

PART 3 EXECUTION

3.01 INSTALLATION

A. Perform all work in accordance wih the following Sections:

1. 40 05 03 – Common Work Results for Piping Systems

2. 40 61 13 – Process Control System General Provisions

3. 43 05 10 – Common Work Results for Gas Handling Equipment

B. The installation and initial operation of all components shall be certified on Form

01 91 00 C2 as specified in REFERENCE FORMS Section (01 91 10).

3.02 SYSTEM CONFIGURATION

A. Configure ground flare PLC and HMI as follows:

1. General:

a. Provide controls to optimize system warm-up and operation and ensure compliance with Sacramento Air Quality Management District (AQMD) and Environmental Protection Agency (EPA) requirements.

2. Local Mode:

a. Flare can be started/stopped manually from the local HMI.

3. Remote Mode:

a. General:

1) Flare accepts commands from the plant PCCS via the Ethernet IP network connection to operate as commanded by the PCCS, as specified in Section 40 61 93.20 -

b. Remote – PCCS Manual Mode:

1) The flare can be manually started/stopped remotely from the PCCS.

c. Remote – PCCS Automatic - Pressure Mode:

1) The flare can be automatically started/stopped remotely from the PCCS.

d. Remote – PCCS Automatic - Flow Mode:

1) The flare can be automatically started/stopped remotely from the PCCS.

2) The flare control system will automatically operate the flow control valve to maintain a MSG flow setpoint though the flare. The setpoint shall be read from the PCCS system via the Ethernet IP network connection.

3.03 FIELD INSPECTION AND TESTING

A. Testing of equipment and systems shall be conducted in accordance with the requirements of the COMMISSIONING Section (01 91 00).

B. The supplier of the ground flare control shall provide a qualified service representative to perform the following:


43 13 43.01 - 8

1. Inspect the PLC installation including I/O and network systems, hardware configuration switch and jumper settings.

2. Monitor all PLC system diagnostic indicators, both hardware and software, and certify that the PLC system performance meets or exceeds the Manufacturer’s published specifications.

3. Assist in functional testing, including communication with the plant PCCS system.

4. Certify in writing to the Construction Manager that the PLC system has been installed and configured in accordance with the Manufacturer’s published guidelines.

3.04 TRAINING

A. A minimum of 8 hours of training as specified in the TRAINING Section (01 79 10) shall be provided. Training shall be certified on Form 01 79 10 E specified in the REFERENCE FORMS Section (01 91 10).

**END OF SECTION**


43 41 23.01 - 1

SECTION 43 41 23.01

50” WC WATER SEAL CONDENSATE TANKS

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies digester gas atmospheric condensate tank, with a 50” WC water seal.

B. EQUIPMENT LIST:

Item Equipment No.

Compressor Building Pit Condensate Tank T87305

Ground Flare Pit Condensate Tank T87067

1.02 REFERENCES


Standard Title

ANSI B16.5 Pipe Flanges and Flanged Fittings

API 653 Tank Inspection, Repair, Alteration, and Reconstruction

ASME B31.3 Process Piping

ASME BPVC Section IX Welding, Brazing, and Fusing Qualifications


43 41 23.01 - 2

Standard Title

ASTM A182 Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A193 Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

ASTM A240 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A312 Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A403 Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings


1.03 DESIGN REQUIREMENTS

A. Condensate tanks shall meet or exceed the following design requirements:

Design Requirements

Condensate Scrubbed LSG

condensateNominal capacity 300 gallons Maximum tank pressure Atmospheric Maximum operating condensate inlet dip tube pressure 25” WC Condensate inlet flow connections 2” & 4” Condensate discharge flow connection 2” NPT Tank drain connection 2” NPT Tank vent connection 2” NPT Water seal height from bottom of inlet dip tube to water feeder float level

≥ 50” WC

Nominal tank wall thickness 0.250” Nominal tank bottom thickness 0.375” Nominal tank cover thickness 0.375” Cover mounting flange thickness ½”


43 41 23.01 - 3

Design Requirements

Condensate Scrubbed LSG

condensateMakeup water feeder connections ¾” NPT Minimum tank temperature rating range 0 to 180°F Minimum level indicator pressure rating range 0 to 150 psig Minimum level indicator temperature rating range 0 to 180°F Level indicator center-to-center distance 30”

1.04 SUBMITTALS

A. The following information shall be submitted for review:

1. Manufacturer’s information and catalog data showing compliance with this specification and a full description of the product.

2. A copy of this specification section, and all referenced sections, with each paragraph check marked to show specification compliance or marked to show deviation.

3. A copy of the ASME Certification of Welders and current work history, per ASME BPVC Section IX – Welding, Brazing, and Fusing Qualifications.

4. Certified shop drawings.

5. Tank anchor bolt calculations for Seismic Zone 3.

6. Factory pressure test results.

7. Installation, operation and maintenance (IOM) instructions.

PART 2 -- PRODUCTS

2.01 CONDENSATE TANKS

A. GENERAL REQUIREMENTS:

1. Tank shall be atmospherically vented. Digester gas condensate shall enter through a dip tube creating a water seal. Nozzles shall be provided as shown on the drawings for condensate inlets, makeup water feeder connections, tank drain, condensate discharge, overflow/vent, sight glass level indicator, inspection.


43 41 23.01 - 4

B. TANK WALL:

1. Tank wall shall be fabricated from ASTM A240 Type 316L stainless steel. Tank wall seam shall be full penetration TIG welded in accordance with ASME B31.3.

2. Tank wall shall include a flange, matching the bolt pattern of the cover. The flange shall be TIG welded to the tank wall in accordance with ASME B31.3.

3. Nozzles shall be located in the tank wall in accordance with the drawings.

4. Drain, discharge, and overflow/vent connections shall be 2” NPT, ASTM A182 Type 316L 3000# half couplings.

5. Makeup water feeder connections size shall be ¾” NPT, ASTM A182 Type 316L 3000# half couplings.

6. Level indicator connections shall be ¾” NPT, ASTM A182 Type 316L 3000# half couplings. Makeup water feeder connections shall be interchangeable with level indicator connections.

7. Condensate inlet dip tubes entering through the tank wall shall be TIG welded, inside and outside, to the tank wall as shown on the drawings, in accordance with ASME B31.3. The dip tube shall be constructed from ASTM A312 or ASTM A778 Schedule 10 Type 316L stainless steel.

C. TANK BOTTOM:

1. Tank bottom shall be fabricated from ASTM A240 Type 316L stainless steel. Tank bottom shall be one-piece, and shall be fully TIG welded inside and outside to the tank wall in accordance with ASME B31.3.

2. Tank bottom shall include a flange with bolt holes for mounting to a concrete pad.

D. TANK COVER:

1. Tank cover shall be fabricated from ASTM A240 Type 316L stainless steel. Tank cover shall be one-piece.

2. Condensate inlet dip tube entering through the tank cover shall be TIG welded, inside and outside, to the cover as shown on the drawings, in accordance with ASME B31.3. The dip tube shall be constructed from ASTM A312 or ASTM A778 Schedule 40 Type 316L stainless steel.

3. Tank cover shall include a 3” NPT nozzle and plug for inspections without removing the cover.


43 41 23.01 - 5

4. Tank cover shall include three lifting eyes, fabricated from 3/8” thick ASTM A240 Type 316L stainless steel plate, with 2” diameter holes, and shall be welded to the cover.

5. Tank cover shall be bolted to the cover mounting flange. The tank cover bolt pattern shall match the cover mounting flange bolt pattern.

6. Tank cover gasket shall be premium grade neoprene cloth insert, 1/8” thick, with a bolt pattern matching the cover bolt pattern. Garlock 3205; American Biltrite AB-3205; Warco Biltrite Cloth-Inserted Neoprene – Regular Polyester Ply; or equal.

7. Tank cover bolts shall be ¾”-10 ASTM A193 Grade B8 Class 1 Type 304 stainless steel, with matching nuts and washers.

8. Stainless steel tanks shall have the heat tint removed from welds. Stainless steel tanks do not require additional coatings. Remove weld splatter and sharp edges.

E. ACCEPTABLE PRODUCTS;

1. Varec Biogas; Shand & Jurs: shop fabricated; or equal, modified as required to meet the specifications.

2.02 TANK LEVEL INDICATOR

A. GENERAL DESCRIPTION:

1. Tank level indicator shall be a tubular sight glass style gauge with isolation valves.

B. ISOLATION VALVES:

1. Gauge isolation valves shall be Type 316 stainless steel, automatic style (horizontal check valves), ¾” NPT, with PTFE or graphite composite stem packing, and aluminum or stainless steel hand wheels.

C. SIGHT GLASS:

1. Tubular sight glass shall be redline glass, ¾” outside diameter, ≥ 3/32” wall thickness, with neoprene, Viton, Teflon, or graphite sight glass packing material.

2. Sight glass protectors shall be 4 stainless steel guard rods.

D. ACCEPTABLE PRODUCTS:

1. John Ernst model 416-05; McMaster-Carr model 3700K14 (valves), McMaster-Carr model 3730K29 (sight glass), McMaster-Carr model


43 41 23.01 - 6

3713K144 (guard rods); or equal, modified as required to meet the specifications.

PART 3 -- EXECUTION

3.01 FABRICATION

A. Welders shall be ASME-certified in accordance with ASME BPVC Section IX.

B. Stainless steel tanks shall have the heat tint removed from welds. Stainless steel tanks do not require additional coatings. Remove weld splatter.

3.02 FACTORY TESTING

A. Atmospheric tanks shall be pressure tested at the fabrication shop to 10’ WC above the tank cover for 4 hours with no leakage.

3.03 INSTALLATION

A. Condensate tanks shall be installed in accordance with the drawings and the manufacturer’s installation instructions.

B. Provide ASTM A182 Type 316L stainless steel ANSI Class 150 blind flange, ASTM A193 Grade B8 Class 1 Type 304 stainless steel nuts and bolts, with PTFE/EPDM Asahi style AV flange gasket for unused flanged inlet ports.

C. Provide ASTM A182 Type 316 stainless steel 3000# pipe plugs for unused ¾” nozzle ports.

**END OF SECTION**


43 41 23.03 - 1

SECTION 43 41 23.03

FSG CONDENSATE TANK

PART 1 -- GENERAL


A. SCOPE:

1. This section specifies a pressurized storage tank for ground flare supply gas (FSG) condensate, and tank appurtenances.

B. TYPE:

1. Tanks shall be of the welded stainless steel vertical type, cylindrical in shape, with semi-elliptical heads, and constructed in accordance with the ASME Pressure Vessel Code and California Division of Industrial Safety Requirements.

C. EQUIPMENT LIST:

Item Equipment No.

200 gallon FSG Condensate Tank T870023

D. OPERATING REQUIREMENTS:

1. The tanks shall meet the following operating requirements:

Minimum volume 200 gallons

Diameter 36 inches

Tank height, end of head to end of head, not including legs

54± inches

Tank orientation Vertical

Normal Operating Pressure & Temperature 20” WC & 100°F

Maximum Operating Pressure & Temperature 25” WC & 125°F

Maximum Allowable Working Pressure 50 psig

Maximum Allowable Working Temperature 200°F


43 41 23.03 - 2

Tank, nozzles, man way, supports, lifting eyes, etc.

Type 316L stainless steel

Minimum Corrosion Allowance

20% of shell & head thickness

ASME man way gasket material Viton

USGS Site Coordinates Longitude: 38.45172° Latitude: -121.46091°

IBC 2012: Site Soil Classification D

IBC 2012: I 1.25

IBC 2012: SS 70.5%

IBC 2012: S1 29.9%

1.02 REFERENCES

A. The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of the referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed references, the requirements of this section shall govern.

Reference Title

ASME Section VIII

Boiler and Pressure Vessel Code, Pressure Vessels

ASTM A193 Alloy-Steel and Stainless Steel Bolting Material for High-Temperature Service

ASTM A194 Carbon and Alloy Steel Nuts for bolts for High Pressure of High Temperature Service, or Both

ASTM A351 Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

IBC 2012 International Building Code

1.03 SUBMITTALS


1. Manufacturer's information and catalog data showing compliance with this specification and a full description of the product.


43 41 23.03 - 3

2. A copy of this specification section, with addenda updates, and all referenced sections, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviation.

3. Manufacturer's shop drawings including tank capacity, dimensions, weight, materials of construction, rated working pressure, anchor design, etc.

4. Seismic calculations and anchor design by a registered civil or structural engineer, licensed in the state of California.

5. Completed factory pressure test form.

6. National Board certificate for each pressure vessel.



PART 2 -- PRODUCTS

2.01 TANK

A. Tank shall be constructed to ASME Section VIII, Division I, and shall bear a “U” stamp.

B. Tank shall be configured as shown on the drawings. Heads shall be ASME F&D.

C. External welds shall be polished to remove heat tint.

2.02 TANK LEVEL INDICATOR

A. Acceptable Products:

1. Dwyer Instruments series VR-S SS 2-BM-B-1.0-150-200-042 A N.

B. General Description:

1. Tank level indicator shall be a Type 316 stainless steel housing with magnetic float and external level-indicating flags.


43 41 23.03 - 4

C. Housing:

1. Tube housing shall be Type 316L stainless steel, 2½” diameter.

D. Configuration:

1. Upper and lower side connections.

2. Connections shall be 1” NPT.

3. Float access shall be from the bottom.

4. Float shall be designed for specific gravity = 1.0.

E. Maximum operating conditions:

1. 150 psig @ 200°F.

F. Indicator:

1. Indicating length shall be 42”.

2. Indicating flags shall be aluminum, silver and black.

3. No scale.

G. Isolation Valves:

1. Level indicator isolation valves shall be Type SS-3P ball valves, per Ball Valve Specification Section (40 05 63).

2.03 SAFETY RELIEF VALVE

A. GENERAL:

1. Safety relief valve shall be ASME Section VIII Air/Gas/Liquid “UV” National Board certified safety relief valve, direct acting style, all stainless steel construction with resilient seat and seals, suitable for FSG condensate.

B. BODY:

1. Body shall be cast from ASTM A351 CF8M stainless steel. Body shall be rated for ≥ 150 psig. Inlets and outlets shall be male NPT.

2. Inlet shall be 1.5”.

3. Outlet shall be 2.5”.


43 41 23.03 - 5

C. SEAT:

1. Seat shall be Viton.

D. PERFORMANCE:

1. Capacity shall be sized at 10% accumulation overpressure.

2. Flowrate shall be 164 gpm or 893 scfm.

3. Set pressure = 45 psig.

4. Downstream pressure shall be 0 psig.

E. ACCEPTABLE PRODUCTS:

1. Kunkle model 917JHGV06AJE0045; or equal, modified as required to meet the specifications.

PART 3 -- EXECUTION

3.01 INSTALLATION

A. Provide seismic calculations for anchor bolt sizing using Hilti RE500 epoxy adhesive and ASTM A193 Grade B8 Class 2 all thread, ASTM A194 Grade 8 Type 304 stainless steel washers and ASTM A194 Grade 8 strain hardened nuts. Calculations shall be stamped by a civil or structural engineer licensed in the State of California. The existing 4000 psi reinforced concrete floor is 14” thick.

B. Tanks will be installed level, with a minimum of 1” thick non-shrink grout under the mounting pads.

3.02 CLEANING & FLUSHING

A. Tank shall be cleaned of debris and flushed with clean water before installation.

3.03 TESTING

A. Tank shall be pressure tested with water at the factory. Leakage shall be zero throughout the test duration. Record test results on manufacturer’s test form.

**END OF SECTION**


43 41 23.03 - 6


APPENDIX A

EQUIPMENT DATA FORMS


PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: ActuatorASSET CLASS: ACTUATOR

GENERAL ASSET METADATAEQ. TAG #s EQ. TAG #s EQ. TAG #s EQ. TAG #s EQ. TAG #s

VENDOR:MANUFACTURER:MODEL #:SUBMITTAL #:PURCHASE PRICE:ASSET DESCRIPTION(s):

SPECIFIC ASSET METADATA

Actuator/Valve Size, INActuator TypeActuator Diaphragm Material Accept Value Stem Diameter, IN:Weight, LBS:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: BatteryASSET CLASS: BATTERY




AMP Hour Rating, AMP:Battery Type:Cell Voltage, VOLT:Total Voltage, VOLT:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: BusASSET CLASS: BUS




Bus Type:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: Control TransfomrerASSET CLASS: CONTROL_TRANSFORMER




Bucket:Input Voltage:Output Voltage:Volt-ampre Rating:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: FilterASSET CLASS: FILTER




Filter Air Flow Rating, CFM:Filter Liquid Flow rating, GPM:Filter Media Type:Filter Service (GAS, WATER, AIR or OIL):Filter Size:Maximum Filtration, MICRON:Number of Elements:Pressure Drop, PSI:Pressure Rating, PSI:Filter Type (COALESCING, SIMPLEX, or DUPLEX):

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: GatesASSET CLASS: GATES




Gate Size, IN:Gate Storage Location:Weir Elevation, FT:Weight, LBS:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: LoopASSET CLASS: LOOP




Loop Type:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: Flowmeter InstrumentASSET CLASS: LOOP_FLOWMETER




Flow Range of Meter Settings:Flow Meter Type (SEE BELOW):Meter Output (SEE BELOW):Pipe Diameter, IN:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: Level InstrumentASSET CLASS: LOOP_LEVEL




Loop Type (SEE BELOW):Meter Output (SEE BELOW):Range of Device:GIS Facility:Level Device Type (SEE BELOW):

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: Pressure InstrumentASSET CLASS: LOOP_PRESSURE




Range of Device:Output Type (SEE BELOW):Pressure Device Type:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: Tempature InstrumentsASSET CLASS: LOOP_TEMPERATURE




Range of Device:Output Type (SEE BELOW):Temperature Device Type:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: MiscellaneousASSET CLASS: MISC




OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: PanelASSET CLASS: PANEL




Panel Type:NEMA Design:Phase:Amperage:Voltage:Covered Process (SEE BELOW):Wire:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: Programmable Logic ControllerASSET CLASS: PLC




PLC Firmware:PLC Location:SCADA Address:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: Power SwitchASSET CLASS: PWR_SWITCH




Power Switch Type (DISCONNECT or LOAD_INTERRUPT):Covered Process (CL2, SO2, CH4, or NONE):NEMA Design:Phase:Voltage:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: TankASSET CLASS: TANK




Diameter, IN:Height, FT:Length, FT:Tank Material:Pressure Rating, PSI:Remaining Useful Life, YEARS:Tank Capacity, GAL:Service (SEE BELOW):Tank Type (SEE BELOW):Weight, LBS:Width Feet, FT:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: TransmitterASSET CLASS: TRANSMITTER




Fill Fluid (SEE BELOW):Diaphragm Material (SEE BELOW):Transmitter Service (LIQUID, GAS or VAPOR):Transmitter Type (SEE BELOW):Lower Range Limit:Upper Range Limit:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: Uninterruptable Power SupplyASSET CLASS: UPS




Battery Type:Number of Batteries:Part Number:Power Rating:Tag Number:

OTHER DATA

PROJECT: CONTRACT #:ENTERED BY:DATE:ASSET NAME: ValveASSET CLASS: VALVE




End Connection (SEE BELOW):Valve Material (SEE BELOW):Pressure Rating, PSI:Valve Application/Service (SEE BELOW):Valve Size, IN:Valve Type (SEE BELOW):Weight, LBS:

OTHER DATA

This page intentionally left blank.

APPENDIX B

SIT,SAT, COMMISSIONING PLAN, REFERENCE FORMS


Digester Gas Management System Project Commissioning Plan

Sacramento Regional County Sanitation District

Draft

August 2018

GMS Commissioning Plan

Sacramento Regional County Sanitation District 1 Digester Gas Management System Project September 11, 2018

Contents 1.0 Introduction ........................................................................................................................................... 2

2.0 Project Overview ................................................................................................................................... 2

3.0 Safety ...................................................................................................................................................... 2

4.0 Training ................................................................................................................................................. 2

5.0 Commissioning Team ........................................................................................................................... 2

6.0 Testing .................................................................................................................................................... 4 6.1 Pre-commissioning Tests .................................................................................................................................... 4 6.2 Site Acceptance Test Plans (SAT) ...................................................................................................................... 4 6.3 Site Integration Test Plans (SIT) ......................................................................................................................... 5 6.4 Start-Up (RAT) ................................................................................................................................................... 5

7.0 Schedules ................................................................................................................................................ 5

Tables Table 1. Commissioning Roles and Responsibilities ..................................................................................................... 3

Attachments Attachment A. Equipment Test Plans/Reference Forms Attachment B. Site Acceptance Test Plans Attachment C. Site Integration Test Plans



1.0 Introduction The objective of commissioning is to validate the installation, functionality, performance, and reliability of the equipment, systems, and processes in accordance with the design intent and the required service levels of the Sacramento Regional County Sanitation District (Regional San). This example Commissioning Plan, included as an appendix to the COMMISSIONING Section (01 91 00), is provided to plan, organize, schedule, execute, and document the associated commissioning tests, activities, and deliverables associated with the Digester Gas Management System (GMS) project.

2.0 Project Overview The purpose of the GMS at the Sacramento Regional Wastewater Treatment Plant (SRWTP) is to collect, clean, pressurize, and convey digester gas to the Carson Cogeneration Facility (Cogen) and on-site boilers. The gas pressures within the system must be carefully managed to prevent venting of unburned gas through the digester pressure relief valves. This is accomplished primarily through the use of Ground Flares or Waste Gas Burners (WGBs), which burn off the digester gas when excess gas is produced or Cogen is not available. The GMS Improvements and Rehabilitation Project was initiated to optimize the system to help prevent periodic uncontrolled venting of digester gas and to bring the GMS into compliance.

3.0 Safety The GMS is considered a “covered” process, meaning that its operation and maintenance is subject to the Risk Management Program/Process Safety Management and air quality regulations. At all times, the Contractor shall comply with all health and safety requirements specified in the HEALTH AND SAFETY REQUIREMENTS Section (00 73 19). Additionally, Contractor shall not initiate commissioning activities until notified by Regional San staff.

4.0 Training Training conveys the knowledge required by Regional San staff to safely operate and maintain the equipment furnished as part of the project. The Contractor training requirements are identified in the TRAINING Section (01 79 10) and in individual equipment specifications. The manufacturers’ field service representatives are provided by the Contractor to instruct Regional San’s staff in the operation, disassembly and assembly, startup, shutdown, safety concerns, troubleshooting, installation, alignment, and recommended corrective and preventive maintenance procedures for equipment and systems furnished as part of the contract documents.

5.0 Commissioning Team The preliminary commissioning team roles and responsibilities for the Contractor, Construction Manager (CM), Designer, and Regional San are identified in Table 1. Appropriate and timely communication is essential; thus, the table shall the key individuals, with contact information,



to perform activities such as coordination, troubleshooting, repairs, adjustments, maintenance, and operations.

Table 1. Commissioning Roles and Responsibilities

Party Roles and Responsibilities Representatives

Contractor • Complete the prerequisites • Organize, schedule, and coordinate

commissioning activities • Provide appropriate field personnel for

tasks such as operating equipment, energizing and de-energizing equipment, operating electrical breakers and disconnect switches, PLC programming, simulating process variables, and confirming equipment responses

• Provide support for troubleshooting, repairing, or replacing contract equipment and connections (electrical and control)

Commissioning coordinator name, TBD Senior project scheduler, TBD Mechanical lead, TBD Electrical lead, TBD System integrator lead, TBD

CM • Witness and provide final acceptance of the test

• Provide mediation between Regional San and the Contractor

Resident engineer, TBD Commissioning lead, TBD QA inspector, TBD

Regional San • Provide personnel to operate existing equipment as needed and maintain existing operations

• Manage and document MOC processes • Program Ovation control strategies • Provide personnel for controlling and

confirming equipment responses at the PCCS

O&M representative, TBD PCCS programmer, TBD

Designer • Available on an as-needed basis Designer representative, TBD



6.0 Testing In accordance with the COMMISSIONING Section (01 91 00), the required testing documents include the following at a minimum:

• Pre-commissioning test forms related to electrical equipment, mechanical equipment, instrumentation, and controls

• SAT plans conducted during Pre-Commissioning

• SIT plans conducted during Commissioning

• RAT plan conducted during Start-Up

• All test results and supporting documentation

Each stage of commissioning must be successfully completed and accepted by Regional San before advancing to a subsequent stage. Because the GMS needs to remain in operation, the Project will be staged into different phases of construction that will have critical durations. Commissioning of the various systems will need to be carefully planned to meet these durations and safely startup the system. District management of change (MOC) processes must be complete before a system or subsystem can be returned to operation.

6.1 Pre-commissioning Tests

Pre-commissioning testing includes structural testing, pipe pressure testing and cleaning, electrical testing, mechanical equipment testing, and instrumentation and controls testing (e.g., I/O Tests, Instrument Configuration/Calibration). Equipment test forms are listed in the REFERENCE FORMS Section (01 91 10) and provided in Attachment A. These forms are included as examples for conducting and documenting the specified tests, inspections, or certifications. In accordance with the requirements of the COMMISSIONING Section (01 91 00), the Contractor submits the proposed test forms for Regional San review and acceptance.

6.2 Site Acceptance Test Plans (SAT)

The SATs are conducted under dry conditions and demonstrate the controls and logic of individual assets in local and remote-manual control modes. Example SAT plans, listed below, are included with the Commissioning Plan

• SAT-1: Modulating Actuator

• SAT-2: Non-Modulating Actuator

The test procedures will be conducted to demonstrate the proper function and alarm indication of the equipment, communications, and programming under local and/or remote control (i.e., from the plant computer control system, PCCS). Each asset’s SAT is considered complete after the test procedures are successfully demonstrated, witnessed, documented, and all testing deficiencies are resolved and accepted by Regional San.



6.3 Site Integration Test Plans (SIT)

The SITs demonstrate the functionality of individual systems (e.g., Waste Gas Burner System, Ground Flare System) in the remote-auto control mode. Example SIT plans for individual systems are included with the Commissioning Plan to provide the necessary information for demonstrating the system controls (i.e., PLC control narratives and PCCS control strategies). The example SIT plans provided are:

• SIT-1: GMS Fire Valves

• SIT-2: LSG Recycle Valve/MSG Dump Valve

• SIT-3: Waste Gas Burners

• SIT-4: Ground Flare Gas Supply

• SIT 5: Ground Flares

In accordance with the requirements of the COMMISSIONING Section (01 91 00), each SIT shall have a duration of 10 days. The SIT test may need to be conducted under a combination of dry (i.e., no gas) and process conditions. For example, the automatic operation of the system could be first tested under dry conditions to demonstrate and test the programming logic and equipment operation. Because no gas is present in the system, certain variables (e.g., pressure) would need to be simulated. After successful demonstration of system operation, the system could then be brought online to demonstrate operation under process conditions with gas. Additional loop tuning will likely need to occur under these process conditions. If the SIT is halted due to a significant interruption, the cause of the failure is identified and rectified by the Contractor. The Contractor records the failures and the corrective action(s) required to restore the equipment or system to proper operation in the issues log.

6.4 Start-Up (RAT)

The RAT demonstrates the normal operation of the entire system for an uninterrupted period of time without equipment failing. Unless otherwise specified or directed, the equipment shall operate continuously without failures for 10 consecutive days. If the RAT is halted due to a significant interruption, the cause of the failure shall be identified and rectified by the Contractor. The test is then repeated in its entirety until the specified period of operation is completed without significant interruption. The Contractor records the failures and the corrective action(s) required to restore the equipment or system to proper operation in the issues log.

7.0 Schedules In accordance with the COMMISSIONING Section (01 91 00), the Contractor shall prepare a detailed commissioning testing schedule setting forth a sequence for performing the contract work.



Attachment A

Equipment Test Plans/Reference Forms

Contract #: 01 79 10 E – Instruction Certification


01 79 10 E Page 1 of 2

Equipment Description:

Equipment Submittal #: Specification Section:

Manufacturer:

Prerequisite Items Manufacturer Rep’s Initials

District’s Initials

Outline & resume accepted on:

Submittal #:

O & M manuals accepted on:

Submittal #:

Operations Checklist

1. Start-up procedure

2. Shutdown procedure

3. Normal operation procedure

Maintenance Checklist

1. Greasing frequency

2. Normal oil change

3. Special tools required

4. Normal items to be reviewed for wear

5. Preventative maintenance instructions

Attachments

1. List of persons trained attached

2. One set of training materials provided attached

The undersigned manufacturer certifies that a service engineer has instructed the wastewater treatment plant operations and maintenance personnel in the proper operation and maintenance of the equipment designated herein.

Contract #: 01 79 10 E – Instruction Certification


01 79 10 E Page 2 of 2

Comments:

Witness Block

District’s Representative: Date:

Contractor’s Representative: Date:

Manufacturer’s Representative: Date:

Contract #: 01 91 00 A – Factory Acceptance Test


01 91 00 A Page 1 of 1



Manufacturer: Model #:

Factory Test Plan and Procedures Submittal #:

Factory Test Plan and Procedures Accepted On:

Factory Test Description Test Date Results Contractor’s

Initials District’s Initials

1.

2.

3.

4.

5.

6.

Attachments:

1. All data measured must be recorded and attached to this form, with all analysis to determine results.

2. Number of additional sheets attached?

Comments:

Witness Block

Date of Test:

Test Site:

Manufacturer’s Representative Performing Test: Date:



Contract #: 01 91 00 B1 – Delivery Acceptance Inspection (Equipment)


01 91 00 B1 Page 1 of 1



Manufacturer: Date Received:

Factory Markings / Nameplate Information

Model #: Serial #:

HP: Volts: FLA:

Range: Units: Size:

Quantity received in shipment:

Quantity rejected and removed from site:

Net quantity on site for use in contract:

Other factory markings:

Conformance with submittal checked: (circle one) YES NO

Attachments

1. Manufacturer’s storage recommendations: (circle one) YES NO

2. Manufacturer’s preventive maintenance recommendations: (circle one) YES NO

Comments:

Witness Block



Contract #: 01 91 00 B2 – Delivery Acceptance Inspection (Piping)


01 91 00 B2 Page 1 of 1

Piping System Description:

Submittal #: Specification Section:

Manufacturer: Date Received:

Piping Information

Schedule:

Lining:

Material:

Other Information:

Quantity received in shipment:

Quantity rejected and removed from site:

Net quantity on site for use in contract:

Other factory markings:

Conformance with submittal checked: (circle one) YES NO

Attachments

1. Manufacturer’s storage recommendations: (circle one) YES NO

2. Manufacturer’s preventive maintenance recommendations: (circle one) YES NO

Comments:

Witness Block



Contract #: 01 91 00 C1 – Mechanical Equipment Pre-Operational Test


01 91 00 C1 Page 1 of 2



Location ID #: Serial #(s):

Manufacturer: Model:

Checklist Items Contractor’s


Rotational Equipment Pre-Operational Checklist

1. Verify unit is mounted level with proper shaft and driver alignment per manufacturer’s recommendations. Belts are clean, dry and properly tensioned, sheaves are aligned.

2. Rotate shaft manually to ensure that there is no binding.

3. Verify alignment of coupling and installation of coupling guard and all other safety devices to the equipment base.

4. Verify driver rotates in the proper direction as indicated on equipment housing.

Mechanical Seal Pre-Operational Checklist

1. Verify installation of seal flush water tubing to the flush port on the mechanical seal(s).

2. Verify level in oil reservoir for tandem mechanical seals.

3. Verify that the mechanical seal is oriented so that the drain connection is located on the bottom.

4. Verify mechanical seal water is flowing at correct rate and seal housing is vented prior to starting.

Miscellaneous Installation Pre-Operational Checklist

1. Verify all piping and instrumentation indicated in the drawings and specifications is installed and functional.

2. Verify all seismic anchors and braces are installed.

3. Verify all oil and grease reservoirs are at proper level.

4. Verify that all protective devices have been calibrated and adjusted to correct set points.

Contract #: 01 91 00 C1 – Mechanical Equipment Pre-Operational Test


01 91 00 C1 Page 2 of 2

5. Verify that motor junction box is closed and electrical safe guards in place.

6. Verify suction and discharge gages are installed.

7. Verify installation of temporary screens on suction line.

8. Verify pump prime.

Comments:

Witness Block



Contract #: 01 91 00 C2 – Manufacturer’s Installation Certification


01 91 00 C2 Page 1 of 2



Manufacturer:

The undersigned manufacturer of the equipment items described above hereby certifies that they have checked the installation of the equipment and that the specified equipment has been provided and installed in accordance with the manufacturer's recommendations and that the trial operation of the equipment has been satisfactory.

The undersigned manufacturer also certifies that the submitted operation and maintenance manuals shall be updated to reflect the actual field conditions of the equipment after completion of the installation and performance tests for the equipment.

Comments:

Witness Block



Manufacturer’s Representative: Date:

Contract #: 01 91 00 C2 – Manufacturer’s Installation Certification


01 91 00 C2 Page 2 of 2

Location ID # Serial #

Contract #: 40 05 03 C3 – Pipe Pressure & Leakage Test (Gas, Air, & Vapor)


40 05 03 C3 Page 1 of 3

Piping Description:


Pipe Material: Pipe Liner:

Test Requirements:

1. The contractor shall test steam lines hydrostatically in accordance with ASME procedure for testing pressure piping.

2. Medium:

3. Pressure:

4. Duration:

5. Allowable pressure drop (for air tests only), calculated at required test pressure: psi

6. Allowable pressure drop (for air tests only), calculated at recorded test pressure: psi

7. The allowable leakage rate for hazardous gas systems insulated systems and systems tested with water shall be zero at the specified test pressure throughout the specified test period. Hazardous gas systems shall include sludge gas and natural gas.

8. The allowable leakage rate for other systems tested with air shall be based on a maximum pressure drop of 5% of the specified test pressure for the duration of the period. Prior to starting a test interval using air, the air shall be at ambient temperature and specified test pressure.

9. Attach drawing with line marking tested piping and equipment. List any equipment not shown on the drawing. Show temporary connections.

10. Unless otherwise specified, the testing medium for gas, air and vapor systems shall be as follows:

Pipeline size Spec’d Test procedure Testing Medium

2 inch & smaller 75 psi or less Air or water

2 inch & smaller Grater than 75 psi Water

Greater than 2 inch 3 psi or less Air or water

Greater than 2 inch Greater than 3 psi Water



40 05 03 C3 Page 2 of 3

Test Equipment Required:

1. Pressure gauge, & equipment to measure makeup medium flow rate.

2. Equipment to provide medium at required pressure in the pipe.

3. All appropriate temporary fittings.

Test Equipment Calibration Information

Equipment Type Serial # Calibration Expiration Date

Test Procedures:

1. Test any buried valves before backfilling.

2. Remove all installed equipment which may be damaged by the specified high pressure test conditions.

3. Ensure that all pipeline to be tested is clean.

4. Isolate section to be tested by closing all appropriate valves.

5. Perform 24-hour visible leak test under a pressure of 5 psi.

6. Add air to the specified pressure and record total leakage for the specified period of time.

7. Check for zero leakage for the same specified time period through all valves 8 inches in diameter or larger in the closed position beginning with the valve farthest from the pressure gauge and working backward, one by one, except pressure modifying valves. Test with each valve closed for the same specified time period as the leakage test.

8. Repeat test a maximum of two more times if leakage exceeds allowable level.

9. Visually check piping for any alignment, grade, or other defects.

Test Measurements

Trial # Measured Pressure,

psig

Measured Pressure Drop (Air Test

Only), psi

Measured Leakage Leakage = 0 _p _

Allowable

Total, gal

Rate, gal/hr

Contractor’s Initials

District’s Initials

1

2

3



40 05 03 C3 Page 3 of 3

Zero Leakage Check through All Closed Valves

Valve # Valve Description Contractor’s


Other Checks Contractor’s


Seismic bracing installed.

Pipe free of alignment, grade, or any other defects.

Comments:

Witness Block



Contract #: 40 05 03 C4 – Pipe Cleaning & Flushing Test (Gas, Air, & Vapor)


40 05 03 C4 Page 1 of 1

Piping Description:



Test Requirements:

1. Piping systems shall be cleaned prior to pressure and leakage testing and prior to connection to operating, control, regulating, or instrumentation equipment.

2. Attach drawing with line marking cleaned piping sections.

3. Indicate on the attached drawing the locations of the installed temporary screens. Number of temporary screens installed in this section:

Test Procedures:

1. For:

a. Piping 6 inches in diameter and smaller: blown out using: (air or testing medium specified).

b. Piping larger than 6 inches in diameter: swab or “pig” drawn through reaches of pipe indicated on attached drawing.

c. Piping larger than 6 inches in diameter: blown out after connection to the equipment.

2. Piping drained.

3. Piping dried with an airstream.

Comments:

Witness Block



Contract #: 40 05 03 C5 – Pipe Pressure & Leakage Test (Drain & Vent)


40 05 03 C5 Page 1 of 2

Piping Description:



Test Requirements:

1. Medium:

2. Pressure:

3. Duration:

4. Attach drawing with line marking tested piping and equipment. List any equipment not shown on the drawing. Show temporary connections.

5. Enter specific test requirements for this piping in accordance with Section 318 of the Uniform Plumbing Code.

Test Equipment Required:

As required by UPC:

Test Equipment Calibration Information

Equipment Type Serial # Calibration Expiration Date

Test Procedures:

1. xx

Test Measurements

Trial # Contractor’s


1

2

3

Other Checks

Contractor’s


Contract #: 40 05 03 C5 – Pipe Pressure & Leakage Test (Drain & Vent)


40 05 03 C5 Page 2 of 2

Seismic bracing installed.

Pipe free of alignment, grade, or any other defects.

Comments:

Witness Block



Contract #: 40 05 57 C – Valve Operator Pre-Operational Test


40 05 57 C Page 1 of 3





Electric Motor Operator

Power = Voltage =

Phase = Hertz =

Cycle the operator through at least five full cycles (open-close-open) and record the following data:

Close Stroke 1 2 3 4 5

Stroke time

Seating (dynamic) torque

Seating (dynamic) amps

Open Stroke 1 2 3 4 5

Stroke time

Seating (dynamic) torque

Seating (dynamic) amps



40 05 57 C Page 2 of 3

Pneumatic or Hydraulic Cylinder Operator

Cycle the operator through at least five full cycles (open-close-open) and record the following data:

1 2 3 4 5

Maximum pressure to cycle the actuator, psi

Note: Not more than 7 psi for water-hydraulic or pneumatic cylinders or 15 psi for oil hydraulic cylinders per AWWA C540-87.

Oil-Hydraulic Cylinders Contractor’s


1. Test the assembly at the rated oil pressure, pressurizing each port in turn for at least one minute.

2. Visual examination shows no leakage at the head, cap ends, or seals.

3. There is no evidence of detrimental or permanent deformation of any part.

Water-Hydraulic and Pneumatic Cylinders

1. Test each cylinder for function at 150 psi for at least 1 minute. Apply pressure individually to the head port and cap port.

2. Visual examination shows no external leakage or leakage across the piston.

3. There is no evidence of detrimental or permanent deformation of any part.

Fail Position Check Contractor’s


Fail position checked twice: functions as intended.



40 05 57 C Page 3 of 3

Comments:

Witness Block



Contract #: 40 61 21 C1 – Wiring Continuity & Insulation Resistance Test


40 61 21 C1 Page 1 of 3

Loop Description:


Test Procedures:

1. List all wiring associated with a loop in the table below. Make applicable measurements as indicated after disconnecting wiring.

2. Continuity Test: Connect ohmmeter leads between wires A and B and jumper opposite ends together. Record resistance in table. Repeat procedure between A and C, A and D, A and shield, etc. Any deviation of ± 2 ohms between any reading and the average of a particular cable indicates a poor conductor, and corrective action shall be taken before continuing with the loop test.

3. Insulation Test: Test insulation resistance for each conductor and shield to ground. Except for conduct being tested, connect all wires and shields to ground. Record insulation resistance between conductor and ground. Repeat for each other conductor and shield.

Wire # Continuity Resistance Insulation Resistance

Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd

C (triad only) A/C C/Gnd

Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd


Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd




40 61 21 C1 Page 2 of 3

Wire # Continuity Resistance Insulation Resistance

Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd


Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd


Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd


Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd


Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd


Shield A/SH SH/Gnd

A -- A/Gnd

B A/B B/Gnd




40 61 21 C1 Page 3 of 3

Comments:

Witness Block



Contract #: 40 61 21 C3 – Field Switch Calibration Test


40 61 21 C3 Page 1 of 2





Data

Input: Range:

Setpoint(s): Adjustable Deadband (Yes/No):

Test Procedures:

1. Simulate process variable (flow, pressure, temperature, etc.) and set desired setpoint(s).

2. Run through entire range of switch and calculate deadband.

Calibration (Adjustable Switch)

Setpoint Incr. Input Trip Point

Decr. Input Trip Point Calculated Deadband Required Deadband

Non Adjustable Switch - Operation Check

Simulate process interface and verify switch operation:

Field Switch Trips: Setpoint:

Field Switch Resets:

Test Equipment Used

Equipment description Manufacturer Model Serial # Calibration Expiration Date

Contract #: 40 61 21 C3 – Field Switch Calibration Test


40 61 21 C3 Page 2 of 2

Comments:

Witness Block



Contract #: 40 61 21 C4 – Transmitter Calibration Test


40 61 21 C4 Page 1 of 2





Data

Input: Range:

Output: Scale:

Test Procedures:

1. Simulate process variable (flow, pressure, temperature, etc.) and measure output with appropriate meter.

Calibration

% of Range Input Expected Output Actual Output Deviation

0

25

50

75

100

Deviation Allowed:

Test Equipment Used


Contract #: 40 61 21 C4 – Transmitter Calibration Test


40 61 21 C4 Page 2 of 2

Comments:

Witness Block



Contract #: 40 61 21 C5 – Input and Output Test


40 61 21 C5 Page 1 of 5

Attachments:

1. Root Square Sum calculation sheet for all loop devices

2. Loop Diagram & P&ID

Test Procedures:

1. Verify individual component calibration tests are complete prior to starting test (either on-site or factory calibration).

2. Loop Resistance Test:

a. Measure and record the loop voltage at 20mA.

b. Calculate the resistance and record the value.

c. Perform additional loop resistance test for each loop segment separated by powered isolation module.

3. Field Loop Ground Test:

a. Disconnect the field signal leads of the circuit being tested and connect them together.

b. Connect a 25V (min.) ohmmeter between the leads and the panel ground bus and measure the resistance.

c. Resistance values less than 2 million ohms are not acceptable.

d. Perform additional loop ground tests for each loop segment separated via isolation module.

4. I/O Test:

a. Complete all expected RSS readings and record on form prior to conducting the test.

b. Disconnect the transmitter output signal leads and connect an electronic signal generator.

c. Simulate the process signal at 0, 25, 50, 75 & 100% of span.

d. Observe and record the actual value of the injected signal.

e. Record values of all intermediate components on subsequent sheet(s).

f. Verify the correct operation of trip devices on applicable increasing and/or decreasing signal.

5. In Addition For Outputs:

a. Manually set the analog output to 0, 25, 50, 75, 100% of span.

b. Observe and confirm the response of the final control element.



40 61 21 C5 Page 2 of 5

Analog Input

Loop #: P&ID #: Main Equip. Location ID #:

Description:

Loop Diagram #(s): Loop Resistance:

Loop Test (circle): Pass Fail

Loop Ground Test (circle): Pass Fail

Injected Signal PLC

% of Range Input (mA) Actual Value

Calculated RSS Value Actual

Reading Pass or Fail Min Max

0

25

50

75

100

Comments:

Witness Block





40 61 21 C5 Page 3 of 5

Analog Trip Devices


Loop Diagram #(s):

Description:

Location ID# Serial # Description Trip Value Reset Value Comments

Comments:

Witness Block





40 61 21 C5 Page 4 of 5

Analog Output


Loop Diagram #(s):

Description:

Manually Set Output Final Element Response

% of Range Input (mA) Actual

Reading

Calculated RSS Value Actual

Reading Pass or Fail Min Max

0

25

50

75

100

Comments:

Witness Block





40 61 21 C5 Page 5 of 5

Analog Devices


Description:

Loop Diagram #(s): Loop Resistance:

Loop Test (circle): Pass Fail

Loop Ground Test (circle): Pass Fail

% of Range

Input (mA)

Location ID # or Pt ID: Location ID # or Pt ID:

Calculated RSS Value

Actual Reading

Pass or Fail

Calculated RSS Value

Actual Reading

Pass or Fail Min Max Min Max

0

25

50

75

100

Comments:

Witness Block



Contract #: 40 61 21 C6 – Control and Logic Test


40 61 21 C6 Page 1 of 1



Control & Logic Diagram #: Control Narrative #:

P&ID Drawing #:

Test Procedures:

1. Attach the equipment’s approved Site Acceptance Test (SAT) plan.

Comments:

Witness Block



Contract #: 40 61 21 C7 – Pressure Gauge Test


40 61 21 C7 Page 1 of 2




Range:

Test Procedures:

1. Use a separate form for each type of gauge range being tested.

2. Compare gauge to be installed to calibrated gauge or to dead weight pressure gauge calibration system.

3. For vacuum & combination gauges, use both pressure + vacuum calibration tables.

Pressure Calibration

Location ID. # Serial #

% Full scale difference at 25% full scale



Returns to zero after test, Y/N

Vacuum Calibration (For Vacuum & Combination Gauges)

Location ID # Serial #

% Vacuum scale difference at 25% full scale



Returns to zero after test, Y/N

Contract #: 40 61 21 C7 – Pressure Gauge Test


40 61 21 C7 Page 2 of 2

Comments:

Witness Block



Contract #: 40 61 21 C8 – Final Element Calibration Test (Modulating Valve or Gate)


40 61 21 C8 Page 1 of 3





Specified Range: to Accuracy Required:

Units of Measurement:

Pre-Operational Checks

Have the mechanical limits been checked (circle)? Yes No N-A

Fully close limit is set at:

Fully open limit is set at:

Transition Time Checks

Full open to full close:

Full close to full open:



40 61 21 C8 Page 2 of 3

Accuracy Checks

Generate input signal and record results for ramp-up and ramp-down.

Allowable error = Accuracy x Range = units, units

Ramp Up/Down Expected Position / Output Actual Position / Output

Pass or Fail % of

Range Input (mA)

Units Units

Units Units Min Max Min Max

0 4.0

25 8.0

50 12.0

75 16.0

100 20.0

75 16.0

50 12.0

25 8.0

0 4.0

Hysteresis Checks

Maximum allowable: Hysteresis = 2 x allow. error = Units, Units

% of Range

Maximum Allowable Hysteresis Actual Hysteresis

Pass or Fail Units Units Units Units

25

50

75



40 61 21 C8 Page 3 of 3

Test Equipment Used


Comments:

Witness Block





Attachment B

Site Acceptance Test Plans

Gas Management System GMS-SAT-1: Modulating Actuator SAT Plan


Draft

August 2018

GMS-SAT-1: Modulating Actuator SAT Plan

Sacramento Regional County Sanitation District 1 Digester Gas Management Project

This SAT plan serves as the basis for verifying the operation of the Modulating Actuators identified in Table 1.

Table 1. Modulating Actuator Schedule

Description Equipment Tag No. Failure Position

FSG Flow to GF 1 CV87318A Fail Last Position



WGB Backpressure Valve CV870007A Fail Open

Recycle Valve CV87007A Fail Closed

Dump Valve CV87110A Fail Closed

FSG PRV 1 CV870015A Fail Closed

FSG PRV 2 CV870017A Fail Closed



Table 2. Modulating Actuator SAT Procedures

Asset Description: Asset Tag Number: Start Date: Finish Date:

Start Time: Finish Time:

Step

Verify Indication/Action/Function: Verification of the expected indication, action, or function.

Notes: If applicable, record time, operational data, irregularities, or problems observed while conducting the procedure.

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Local Operation

1 Verify the following:

a. Valve pre-operational tests completed.

b. Final element calibration test.

c. Network and communication systems inspections completed.

d. I/O checkouts completed.

e. Equipment tags and wire tags in accordance with the loop drawings.

f. Contract drawings reflect as-built conditions.

g. The PLC and remote I/O panels are energized and functional.

h. Inspect the factory configuration sheets for the proper settings of the limit and torque switches.

i. Confirm the circuit breaker switch set points are in accordance with the manufacturer recommendations.

2 Check power and verify the following:

a. Turn Off the breaker and verify no power to the actuator.

b. Turn On the breaker and verify power to the actuator.

3 Test: Local operation

a. Place the LSR switch in Local.

b. Verify the PCCS displays the valve in the Local control mode and no alarms are present on the alarm summary screen.

c. Select the valve from the PCCS control overlay display and verify the valve Open commands are inhibited.

d. At the actuator, turn the O/C switch to Open until the valve is 100% Open.

e. Verify the actuator Open light is On and the panel displays 100% Open.






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f. Verify the PCCS displays the valve in the Local control mode, the valve is 100% Open, and no alarms are present on the alarm summary screen.

g. At the actuator, turn the O/C switch to Close until the valve is 0% Open.

h. Verify the actuator Close light is On and the panel displays 0% Open.

i. Verify the PCCS displays the valve in the Local control mode, the valve is 0% Open, and no alarms are present on the alarm summary screen.

End of Test.

Proceed to Remote | Manual Operation.

Remote | Manual Operation 1 Test: Full open and close operation

a. Place the LSR switch in Remote.

b. Select the valve from the PCCS and select Manual.

c. Verify the PCCS displays the valve in the Remote | Manual control mode, the valve is Closed, and no alarms are present on the alarm summary screen.

d. At the actuator, verify the O/C switch does not Open the valve.

e. Select the valve from the PCCS and enter a 100% Open set point.

f. Verify the PCCS displays the valve in the Remote | Manual control mode, the valve is Traveling, the valve is 100% Open, and no alarms are present on the alarm summary screen.

g. Verify the actuator Open light is On and the panel displays 100% Open.

h. At the actuator, verify the O/C switch does not Close the valve.

i. Select the valve from the PCCS control overlay display and enter a 0% Open set point.

j. Verify the PCCS displays the valve in the Remote | Manual control mode, the valve is Traveling, the valve is 0% Open, and no alarms are present on the alarm summary screen.






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k. Verify the actuator Close light is On and the panel displays 0% Open.

2 Test: Partial open and close operation

a. Select the valve from the PCCS and enter a 25% Open set point.

b. Verify the PCCS HMI displays the valve in the Remote | Manual control mode, the valve is 25% Open, and no alarms are present on the alarm summary screen.

c. Verify the actuator panel displays 25% Open.

d. Select the valve from the PCCS and enter a 50% Open set point.

e. Verify the PCCS HMI displays the valve in the Remote | Manual control mode and the valve is 50% Open.

f. Verify the actuator displays 50% Open.

g. Select the valve from the PCCS HMI and enter a 75% Open set point.

h. Verify the PCCS displays the valve in the Remote | Manual control mode and the valve is 75% Open.

i. Verify the actuator displays 75% Open.

j. Select the valve from the PCCS and enter a 100% Open set point.

k. Verify the PCCS HMI displays the valve in the Remote | Manual control mode and the valve is 100% Open.

l. Verify the actuator Open light is On and the actuator displays 100% Open.

3 Test: Valve Fail to Close

a. Simulate a Valve Fail to Close condition (software alarm). Note: This may be done by shortening the timer delay.

b. Select the valve from the PCCS and enter a 0% Open set point.

c. Verify the PCCS displays an Alarm.

4 Test: Valve Fail to Open






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a. Simulate a Valve Fail to Open condition (software alarm). set point.

b. Select the valve from the PCCS and enter a 100% Open set point.

c. Verify the PCCS displays an alarm.

5 Test: Communications Loss

a. Select the valve from the PCCS and enter a 100% Open set point.

b. While traveling, simulate a Communications Loss condition (e.g., unplug the communications cable) and verify the valve fails in the correct position.

Note: Refer to Table 1 for the correct failure position.

c. Verify the PCCS Communications Loss alarm is displayed on the alarm summary screen.

d. Clear the Communications Loss condition (e.g., plug in the communications cable).

e. Verify the alarm clears and the valve responds correctly. Does the valve resume moving to meet the set point?

f. Select the valve from the PCCS and enter a 0% Open set point.

g. Verify the PCCS HMI displays the valve in the Remote | Manual control mode, the valve is Traveling, the valve is 0% Open, and no alarms are present on the alarm summary screen.

End of Test.

Proceed to Remote | Automatic Operation.

Remote | Automatic Operation

1 Test: Automatic Control

a. Select the valve from the PCCS and select Automatic.

b. Verify the PCCS displays the valve in the Remote | Automatic control mode and no alarms are present on the alarm summary screen.

c. At the actuator, verify the O/C switch does not Open the valve.

2 Additional Remote | Automatic testing conducted during the SITs.






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3 Place the LSR switch in Stop.

End of Test.


GMS-SAT-2: Non-Modulating Actuator


Draft

August 2018

GMS-SAT-2: Non-Modulat ing Actuator

Regional San 1 Digester Gas Management System Project

This SAT plan serves as the basis for verifying the operation of the Non-Modulating Actuators identified in Table 1.

Table 1. Schedule

Asset Description Location ID Failure Position

GF 1 Isolation Valve V87314A Fail Closed



Scrubber Inlet Fire Valve V87521A Fail Closed

Scrubber Inlet Fire Valve V87522A Fail Closed

Scrubber Outlet Fire Valve V87523A Fail Closed

MSG Building Fire Valve V87524A Fail Closed

FSG Fire Valve V870012A Fail Closed

FSG Fire Valve V870013A Fail Closed



FSG High Pressure Bleed CV870018A Fail Closed

FSG High Pressure Bleed CV870019A Fail Closed

WGB 1 Isolation V80201A Fail Open







Regional San 2 Digester Gas Management Project

Table 2. Test Procedures

Asset Description: Location ID: Start Date: Finish Date:


Step Procedure Notes Contractor Initials

Local Operation

Verify the following:

a. Valve pre-operational tests completed.

b. Actuator pre-operational tests completed.

c. Network/communication systems inspections completed.

d. I/O checkouts completed.

e. Equipment tags and wire tags are in accordance with the loop drawings.

f. Contract drawings reflect as-built conditions.

g. The PLC and remote I/O panels are energized and functional.

h. Inspect the factory configuration sheets for the proper settings of the limit and torque switches.

i. Confirm the circuit breaker switch setpoints are in accordance with the manufacturer’s recommendations.

Check Power

a. Turn Off the breaker and verify no power to the actuator.

b. Turn On the breaker and verify power to the actuator.

Local Operation

a. Place the LSR switch in Local and verify the PCCS displays the valve as Local. Verify the Valve Not Remote is displayed on the alarm summary screen.

b. Select the valve from the PCCS and verify the valve Open command is inhibited.

c. Turn and release the O/C switch to Open and verify the valve Fully Opens.

d. Verify the actuator Open light is On if applicable.







e. Verify the PCCS displays the valve as Local and Open.

f. Place the LSR switch in Stop and verify the PCCS displays the valve as Off.

g. Verify the actuator O/C switch does not Close the valve.

h. Select the valve from the PCCS and verify the valve Close command is inhibited.

i. Place the LSR switch in Local.

j. Select the valve from the PCCS and verify the valve Close command is inhibited.

k. Turn and release the O/C switch to Close and verify the valve Fully Closes.

l. Verify the actuator Close light is On if applicable.

m. Verify the PCCS displays the valve as Local and Closed.

Remote | Manual Operation

Full Open and Close Operation

a. Place the LSR switch in Remote, verify the PCCS displays the valve as either Auto or Manual, and no alarms for the valve are displayed on the alarm summary screen.

b. Select the valve from the PCCS and select Manual.

c. Verify the PCCS displays the valve as Manual, the valve is Closed, and no alarms for the valve are displayed on the alarm summary screen.

d. Verify the O/C switch does not Open the valve.

e. Select the valve from the PCCS and select Open.

f. Verify the PCCS displays the valve as Manual, the valve Fully Opens, and no alarms for the valve are displayed on the alarm summary screen.

g. Verify the O/C switch does not Close the valve.







h. Select the valve from the PCCS and select Close.

i. Verify the PCCS HMI displays the valve as Manual, the valve Fully Closes, and no alarms for the valve are displayed on the alarm summary screen.

Fail to Open

a. Simulate a Fail to Open condition. Note: This may be done by shortening the alarm delay timer.

b. Select the valve from the PCCS HMI and select Open.

c. Verify the valve is Moving, the PCCS annunciator sounds within the adjustable time delay, an Alarm is displayed on the alarm summary screen, and Fail to Open is displayed within the valve’s alarm diagram.

d. Remove the Fail to Open condition.

e. Select the valve from the PCCS and select Close.

f. Verify the PCCS displays the valve as Manual, the valve is Fully Closed, and no alarms for the valve are displayed on the alarm summary screen.

Fail to Close

a. Simulate a Fail to Close condition.

b. Select the valve from the PCCS and select Close.

c. Verify the valve is Moving, the PCCS annunciator sounds within the adjustable time delay, a Common Alarm is displayed on the alarm summary screen, and Fail to Close is displayed within the valve’s alarm diagram.

d. Remove the Fail to Close condition.

e. Select the valve from the PCCS and select Close.







f. Verify the PCCS HMI displays the valve as Manual, the valve Fully Closes, and no alarms for the valve are displayed on the alarm summary screen.

Communications Fail

a. Select the valve from the PCCS and select Open.

b. Verify the PCCS displays the valve as Manual and the valve is Moving.

c. While moving, simulate a Communications Fail condition (e.g., unplug the communications cable) and verify the valve fails in the correct position (Open or Closed)..

Note: Refer to Table 1 for the correct Failure Position

d. Verify the PCCS annunciator sounds, an Alarm is displayed on the alarm summary screen, and Communications Fail is displayed within the valve’s alarm diagram.

e. Remove the Communications Fail condition (e.g., plug in the communications cable).

f. Select the valve from the PCCS and select Close.

g. Verify the PCCS displays the valve as Manual, the valve is Closed, and no alarms for the valve are displayed on the alarm summary screen.

Remote | Automatic Operation

Automatic Control

a. Select the valve from the PCCS and select Auto.

b. Verify the PCCS displays the valve as Auto, the valve is Closed, and no alarms for the valve are displayed on the alarm summary screen.

c. Verify the O/C switch does not Open the valve.

Additional Auto testing conducted during the SITs.

Place the LSR switch in Stop.

End of Test



DCS: Non-Modulating Actuator Issues Log

Issue No. Date Received Description Action By Finished By Evaluation and Action Date Completed



Attachment C

Site Integration Test Plans

GMS Fire Valves SIT Plan

Gas Management System GMS-SIT-1: GMS Fire Valves SIT Plan


Draft

August 2018

GMS-SIT-1: GMS Fire Valves SIT Plan

Sacramento Regional County Sanitation District 1 Digester Gas Management System Project

1.0 Overview

When a flame is detected by the fire detection camera, the fire-rated valves close.

2.0 Prerequisites

In addition to the prerequisites identified in the front-end section of the commissioning plan, the following prerequisites are required prior to conducting this SIT:

• A pre-test walkthrough to confirm the equipment’s initial operating configurations, positions, and set points. During the pre-test walkthrough, the commissioning team will verify the proper labeling of the equipment and piping and will confirm the equipment is ready for operation.



GMS Fire Valves SIT Procedures

System Description: Start Date: Finish Date:


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Site Integration Test

1 Set test configurations

Configure follows: a. Place all fire valves in REMOTE AUTOMATIC control mode.

2 Test: Detection of Fire

a. Simulate a Detection of Fire condition.

b. Verify all GMS Fire Valves close and alarm is generated.

c. Clear the fire condition and verify the system returns to normal.

d. Continue operating for next test.

3 Test: Plant Emergency Trip Alarm

a. Simulate a Plant Emergency Trip Alarm condition.

b. Verify all GMS Fire Valves close and alarm is generated.

c. Clear the alarm condition and verify the system returns to normal.

End of Test.



GMS: GMS Fire Valves Issues Log

Issue No. Date Received

Sent By (Initials) Description

Action By (Initials)

Finished By (Initials) Evaluation and Action Comments

Date Completed

GMS LSG Recycle Valve and MSG Dump Valve SIT Plan

Gas Management System GMS-SIT-2: LSG Recycle Valve and MSG Dump

Valve SIT Plan


Draft

August 2018

GMS-SIT-2: LSG Recycle Valve and MSG Dump Valve SIT Plan


1.0 Overview

The Recycle Valve (CV87007) is used to recycle some of the compressor discharge flow and transfer gas from medium-pressure (MSG) to low-pressure (LSG) in order to maintain the compressor suction line pressure (LSG pressure), initially set to 7” WC.

The Dump Valve (CV87110) is used to blow-off excess compressor discharge flow and transfer gas from medium-pressure (MSG) to low-pressure (LSG) in order to maintain the compressor discharge pressure (MSG pressure), initially set to 11.5 psig.

2.0 Prerequisites

In addition to the prerequisites identified in the front end section of the commissioning plan, the following prerequisites are required prior to conducting this SIT:




LSG Recycle Valve/MSG Dump Valve SIT Procedures



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Configure CV87007 and CV87110 as follows: a. Verify CV87007 and CV87110 are in the REMOTE AUTOMATIC control mode.

2 Test: Recycle Valve CV87007 Modulation

a. At the PCCS, select either PIT8391 or PIT8392.

b. Simulate a pressure above the LSG PRESSURE SET POINT. Initially set to 7”WC.

c. Verify CV87007 closes to meet the set point.

d. Simulate a pressure below the LSG PRESSURE SET POINT.

e. Verify CV87007 opens to meet the set point.

f. Repeat these steps with the second transmitter selected.

3 Test: Dump Valve CV87110 Modulation

a. Simulate a pressure (PIT8766) above the MSG PRESSURE SET POINT. Initially set to 11.5 psig.

b. Verify CV87110 starts to open to meet the set point.

c. Simulate a pressure below the MSG PRESSURE SET POINT.

d. Verify CV87007 starts to close to meet the set point.

4 Test: Recycle Valve Pressure Transmitter Failure (Loss of Communication)

a. Create a pressure transmitter failure condition for the selected transmitter.

b.

c. Verify an alarm is generated.

d. Restore the pressure transmitter, verify the alarm clears and the system returns to normal.



LSG Recycle Valve/MSG Dump Valve SIT Procedures



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5 Test: Dump Valve Pressure Transmitter Failure (Loss of communication)

a. Create a transmitter failure condition for PIT8766.

b.

c. Verify an alarm is generated at the PCCS.

d. Restore PIT8766, verify the alarm clears, and the system returns to normal.

End of Test.



GMS: LSG Recycle/MSG Dump Valves Set Points Log

Data Point Tag No. Design Set Point New Value Reason for Change Date Contractor Initials

District Initials

Instrumentation

Recycle Valve Set Point PIT8391 PIT8392

7” WC

Dump Valve Set Point PIT8766 11.5 psig



GMS: LSG Recycle/MSG Dump Valves Issues Log





Date Completed

GMS Waste Gas Burners SIT Plan

Gas Management System GMS-SIT-3: Waste Gas Burners SIT Plan


Draft

August 2018

GMS-SIT-3: Waste Gas Burners SIT Plan


1.0 Overview

The Waste Gas Burners (WGBs) are the first line pressure relief devices for disposing of digester gas in the Low Pressure Sludge Gas (LSG) system and are a critical component in the prevention of uncontrolled digester gas venting through the digester pressure relief valves. Un-scrubbed digester gas is routed to the WGB backpressure control valve (CV870007) from the digesters upstream of the gas scrubbers. Gas is then routed from the WGB control valve to the six Waste Gas Burners through individual pneumatically-actuated isolation valves. Each burner uses a pilot unit that lights a pilot flame, provides a continuous pilot flame, and monitors the status of the pilot and the presence of a pilot flame.

2.0 Prerequisites





Waste Gas Burners SIT Procedures



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Configure CV870007 and the Waste Gas Burners as follows: a. From the PCCS, select the pressure transmitters to be used by the “High-Pressure

Selector”. b. Simulate a pressure below the WGB OFF SET POINT (6.5” WC) c. Verify the FLOW MODE FLOWRATE SET POINT is set to zero. d. Place the LSR switch for CV870007 in the REMOTE position. Verify the valve is in

the REMOTE-AUTOMATIC mode at the PCCS. e. Verify CV870007 is fully closed. f. Verify at least one Waste Gas Burner is available.

2 Test: Modulating Set Point

a. Simulate a pressure equal to the MODULATING FLOW SET POINT. Modulating Flow Set Point initially set to 8.5” WC.

b. Verify CV870007 pops fully open.

c. After approximately 3 seconds, verify CV870007 starts modulating to maintain pressure.

d. Verify the WGB is functioning properly (e.g., inlet valve is open, pilot flame is on etc.)

e. Continue operating for next test.

3 Test: Full Open Set Point

a. Simulate a pressure above the MODULATING FLOW SET POINT.

b. Verify CV870007 pops opens to 100% and maintains the full open position.

c. Simulate a pressure equal to or below the MODULATING FLOW SET POINT and verify CV870007 resumes modulating to meet the pressure set point.







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4 Test: WGB Off Set Point

a. Simulate a pressure equal to or less than the WGB OFF SET POINT. WGB Off Set Point initially set to 6.5” WC.

b. Verify CV870007 closes to 0% and maintains the full closed position.

5 Test: High-High Alarm Set Point

a. Simulate a pressure equal to or greater than the HIGH-HIGH ALARM SET POINT. High-High Alarm Set Point initially set to 10” WC.

b. Verify CV870007 pops open to 100% and maintains the full open position

c. Verify the High-High Alarm is received at the PCCS.

d. Simulate a pressure equal to the HIGH-HIGH ALARM RESET SET POINT. High-High Alarm Reset Set Point initially set to 9.5” WC.

e. Verify the High-High Alarm clears.

f. Simulate a pressure equal to the MODULATING FLOW SET POINT and verify CV870007 resumes modulating to meet the pressure set point.

6 Test: Pressure Transmitter Loss of Communication

a. With the valve modulating, simulate a Pressure Transmitter Loss of Communication condition.

b. Verify the PLC continues to use the remaining online pressure transmitters.

c. Reconnect the PIT, verify the alarm clears, and CV870007 resumes modulating.

d. Repeat this step for each transmitter.

7 Test: WGB Out-Of_Service

a. Place all WGBs out-of-service and verify an alarm is generated at the PCCS.

b. Place at least on WGB into service and verify the alarm clears.

8 Test: Flowmeter Loss of Communication

a. Simulate a Flow Transmitter Loss of Communication condition for FIT8112.






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b. Verify a Communication Loss Alarm is generated at the PCCS.

c. Reconnect the FIT8112 and verify the alarm clears.

9 Test: Flow Control Mode

a. Enter a Flow Mode flow rate set point greater than zero. Note: Max flow set point is 3000 cfm.

b. Verify CV870007 modulates to meet the flow rate set point. Note: The Flow Rate Mode will only function if the pressure remains between 6.5 and 8.5” WC.

c. Simulate a pressure outside the allowable range. Verify the system switches to Pressure Control Mode and CV870007 responds accordingly (i.e., full open if above 8.5”WC and full closed if below 6.5”WC).

d. Simulate a pressure within the allowable range. Verify the system returns to the Flow Control Mode.

10 Test: Pilot Flame Interlock

a. Simulate a failure of each WGB’s pilot flame.

b. Verify the WGB Natural Gas and LSG Isolation Valves close, an alarm is generated, and the WGB is shown as unavailable.

c. Restore the pilot flame and verify the alarm clears and the system returns to normal.

End of Test.



GMS: Waste Gas Burners Set Points Log


District Initials

Instrumentation

Modulating Flow Pressure Set Point

PIT87009 PIT8391 PIT8392

8.5” WC

Full Flow Pressure Set Point 9.0” WC

WGB Off Pressure Set Point 7.5” WC

High-High Pressure Alarm 10.0” WC

High-High Pressure Alarm Reset 9.5” WC



GMS: Waste Gas Burners Issues Log





Date Completed

GMS Ground Flare Gas Supply SIT Plan

Gas Management System GMS-SIT-4: Ground Flare Gas Supply SIT Plan


Draft

August 2018

GMS-SIT-4: Ground Flare Gas Supply SIT Plan


1.0 Overview

The gas supply for the ground flares comes from the MSG system through a set of two pressure reducing valves in series to produce Flare Supply Gas (FSG). The first pressure reducing valve, CV870015, reduces MSG pressure to the intermediate pressure of 3 psi, monitored in the PCCS by PIT870016. The second pressure reducing valve, CV870017, reduces pressure from the intermediate pressure down to the FSG pressure of approximately 20” WC, monitored in the PCCS by PIT870014.

2.0 Prerequisites





Ground Flare Gas Supply SIT Procedures



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Configure the Flare Supply Gas valves as follows: a. Place CV8700015, CV870017, CV870018, and CV870019 in the REMOTE

AUTOMATIC control mode. b. Select either PIT8786A or PIT8786B as the backup pressure transmitter.

2 Test: Intermediate Pressure Control (CV870015)

a. Simulate pressure for PIT870016 and verify the control valve modulates to meet the set point.

Initially set to 3 psig.

b. Continue operating for next test.

3 Test: Flare Supply Gas Pressure Control (CV870017)

a. Simulate pressure for PIT870014 and verify the control valve modulates to meet the set point.

Initially set to 20”WC.

b. Continue operating for next test.

4 Test: FSG Bleed Valve Control

a. Simulate a pressure equal to or greater than the HIGH-PRESSURE set point. Initially set to 23”WC.

b. Verify CV870018 and CV870019 open and remain open.

c. Simulate a pressure equal to the BLEED VALVE CLOSE set point. Initially set to 20”WC.

d. Verify CV870018 and CV970019 close.

5 Test: Pressure Transmitter Failure (Loss of communication)

a. Create a transmitter failure condition for PIT870014 Note: Conduct this step for each of the backup Pressure Transmitters (PIT8786A and PIT8786B)

b. Verify the PLC switches to the designated backup transmitter (PIT8786A or PIT8786B).



Ground Flare Gas Supply SIT Procedures



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c. Verify an alarm is generated at the PCCS.

d. Restore PIT870014, verify the alarm clears, and the system returns to normal.

e. Repeat this test with a set point above the HIGH-PRESSURE set point to verify the bleed valves function with the backup PITs.

f. Repeat this test without a backup PIT selected and verify CV870015 and CV870017 close when PIT870014 is in alarm.

6 Test: Control Valve Failure

a. Create a control valve failure condition for CV870015.

b. Verify both control valves (CV870015 and CV870017) close and an alarm is generated.

c. Clear the failure condition and verify the system returns to normal.

d. Repeat this test for CV870017.

End of Test.



GMS: Ground Flare Gas Supply Set Points Log


District Initials

Instrumentation

Intermediate Pressure Set Point (CV870015) PIT870016 3 psig

FSG Pressure Set Point (CV870017) PIT870014 PIT8786A PIT8786B

20”WC

FSG High-Pressure Alarm PIT870014 PIT8786A PIT8786B

23”WC

FSG High-Pressure Reset PIT870014 PIT8786A PIT8786B

20”WC



GMS: Ground Flare Gas Supply Issues Log





Date Completed

GMS Ground Flares SIT Plan

Gas Management System GMS-SIT-5: Ground Flares SIT Plan


Draft

August 2018

GMS-SIT-5: Ground Flares SIT Plan


1.0 Overview

The individual vendor-provided Ground Flare PLC control panels monitor and control the Ground Flare warmup and shutdown cycle including the modulating valve feeding the individual Ground Flare system that is currently controlled by the PCCS. The call to start in the “Pressure Mode” initiates a warmup cycle when the LSG pressure exceeds its high set point.

The Ground Flare can also be used in “Flow Mode”, where a desired flow to the flares is set from a PCCS HMI input. The individual Ground Flare flow is maintained by the Ground Flare PLC through modulating the individual flare’s control valve. The allowable flow setpoint must be within the limits of the Ground Flare, 500 to 3000 cfm (operator adjustable)

If the flare temperature falls below the minimum temperature required by the air quality permit of the flow drops below the minimum flow of 500 cfm, the flare will shut down. The three flares are operated in a Duty/Standby configuration.

2.0 Prerequisites





Ground Flares SIT Procedures



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Configure the Ground Flare system as follows: a. Verify each Ground Flare’s isolation valve is in REMOTE AUTOMATIC mode. b. Verify each Ground Flare’s control valve is in REMOTE AUTOMATIC mode. c. Designate a DUTY flare.

2 Test: Ground Flare On

a. From the PCCS, select “Pressure Control Mode”.

b. Simulate an LSG gas pressure (PIT8391/PIT8392) greater than the HIGH PRESSURE set point.

High Pressure Set Point initially set to 8.5”WC.

c. Verify the Duty Flare turns on and the associated valves open and modulate accordingly.


3 Test: Ground Flare Off

a. Simulate an LSG gas pressure (PIT8391/PIT8392) less than the DUTY FLARE OFF set point.

Duty Flare Off Set Point initially set to 6.5”WC.

b. Verify the Duty Flare turns off and the associated valves close accordingly.

c. Restart the flare and continue operating for the next test.

4 Test: Duty Flare Failure

a. Create a Duty Flare Failure condition.

b. Verify an alarm is generated at the PCCS and the Standby Flare starts.

5 Test: High-High Pressure Alarm

a. Simulate a pressure above the HIGH-HIGH PRESSURE set point. Initially set to 10.5”WC



Ground Flares SIT Procedures



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b. Verify the High-High Pressure Alarm is generated.

c. Simulate a pressure equal to the HIGH-HIGH ALARM RESET set point.

d. Verify the alarm clears.

6 Test: Pilot Flame and Purge Interlock

a. Simulate a failure of the pilot flame. Is alarm generated?

b. Verify the Ground Flare isolation valve is prohibited from opening.

c. Restore the pilot flame and verify the system returns to normal.

d. Repeat this test with a failure of the purge system.

End of Test.



GMS: Ground FLare System Set Points Log


District Initials

Instrumentation

Duty Flare On

PIT8391 PIT8392

8.5” WC

Duty Flare Off 6.5” WC

High-High Pressure Alarm 10.5” WC

High-High Pressure Alarm Reset 9.5” WC



GMS: Waste Gas Burners Issues Log





Date Completed

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