REQUEST FOR QUOTATION (RFQ) No. 1618 · 03/01/2016 Page 3 RFQ No. 1618 within the last five years....

375 Eleventh Street, Oakland, CA 94607 Website: ebmud.com

Note: EBMUD is committed to reducing environmental impacts across our entire supply chain. If printing this document, please print only what you need, print double-sided, and use recycled-content paper.

EAST BAY MUNICIPAL UTILITY DISTRICT

REQUEST FOR QUOTATION (RFQ) No. 1618 for

Sobrante and Upper San Leandro Water Treatment Plants Ozone Systems Equipment and Services

For complete information regarding this project, see RFQ posted at http://www.ebmud.com/business-opportunities or contact the EBMUD representative

listed below. Thank you for your interest!

Contact Person: Ali Sheikholeslami, Associate Civil Engineer Phone Number: (510) 287-2047 E-mail Address: [email protected]

Please note that prospective bidders are responsible for reviewing http://ebmud.com/business, during the RFQ process, for any published addenda regarding

this RFQ.

RESPONSE DUE

by 1:30 p.m.

on April 6, 2016

at EBMUD, Purchasing Division 375 Eleventh St., First Floor

Oakland, CA 94607

http://www.acgov.org/gsa/departments/purchasing/

http://www.ebmud.com/business-opportunities

http://ebmud.com/business

03/01/2016 Page 1 RFQ No. 1618

EAST BAY MUNICIPAL UTILITY DISTRICT RFQ No. 1618

for Sobrante and Upper San Leandro Water Treatment Plants Ozone

Systems Equipment and Services

TABLE OF CONTENTS

I. STATEMENT OF WORK ........................................................................................................... 2

A. SCOPE................................................................................................................................... 2

B. BIDDER QUALIFICATIONS .................................................................................................... 2

C. SPECIFIC REQUIREMENTS .................................................................................................... 4

D. DELIVERABLES ...................................................................................................................... 5

E. FAILURE TO MEET SPECIFICATIONS ..................................................................................... 6

F. INSPECTION ......................................................................................................................... 6

II. CALENDAR OF EVENTS ........................................................................................................... 6

A. PRE-BID CONFERENCE ......................................................................................................... 7

III. DISTRICT PROCEDURES, TERMS, AND CONDITIONS ................................................................ 7

A. RFQ ACCEPTANCE AND AWARD .......................................................................................... 7

B. DEVIATIONS, AND EXCEPTIONS ........................................................................................... 7

C. PRICING ................................................................................................................................ 8

D. PROTESTS ............................................................................................................................. 8

E. TERM / TERMINATION / RENEWAL ..................................................................................... 9

F. WARRANTY .......................................................................................................................... 9

G. INVOICING ........................................................................................................................... 9

H. LIQUIDATED DAMAGES ....................................................................................................... 9

I. BONDS ................................................................................................................................. 9

IV. RFQ RESPONSE SUBMITTAL INSTRUCTIONS AND INFORMATION ......................................... 10

A. DISTRICT CONTACTS .......................................................................................................... 10

B. SUBMITTAL OF RFQ RESPONSE ......................................................................................... 11

C. RESPONSE FORMAT ........................................................................................................... 12

ATTACHMENTS

EXHIBIT A - RFQ NO. 1618 RESPONSE PACKET EXHIBIT B - CERTIFICATES OF INSURANCE & BOND FORMS EXHIBIT C - GENERAL REQUIREMENTS AND SUPPLEMENTARY GENERAL REQUIREMENTS EXHIBIT D - OZONE EQUIPMENT SUPPLY AGREEMENT (SUPPLIER AGREEMENT) EXHIBIT E - ASSIGNMENT AGREEMENT EXHIBIT F - TECHNICAL SPECIFICATIONS AND DRAWINGS

Sobrante and USL WTPs Ozone Systems Equipment and Services

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I. STATEMENT OF WORK

A. SCOPE

1. It is the intent of these specifications, terms, and conditions to describe the requirements for furnishing equipment and providing services for six (6) 1,750 pound per day ozone generators, ozone gas destruct units, and ancillary systems for the East Bay Municipal Utility District (District or Owner) Sobrante and Upper San Leandro Water Treatment Plants (WTPs) Ozone Systems Improvements Project (Project). The ozone system equipment will be furnished by the successful Bidder (Supplier or OSS) under an agreement (Supplier Agreement) with the District. In addition, the Supplier shall provide design coordination, submittals, start-up, testing, and training services as described in the Supplier Agreement. The equipment will be installed by a Construction Contractor (Contractor) to be selected by the District at a later date.

2. The Supplier Agreement between the District and Supplier will be assigned to the Contractor after the Contractor is selected and construction contract awarded by the District.

3. The District intends to award the Supplier Agreement to the Bidder who meets the minimum qualifications specified herein and proposes the lowest 20-year present worth life cycle cost consisting of capital bid costs and annual energy costs.

B. BIDDER QUALIFICATIONS

1. Bidder Minimum Qualifications

a. Bidders shall have designed, procured the equipment for, and supplied a minimum of four (4) ozone generation systems for installation at municipal facilities in the United States and/or Canada. The referenced ozone systems shall be Liquid Oxygen (LOX)-based systems, shall include ozone generators and power supplies, ozone destruct units, control systems, and shall have a maximum ozone production capacity of not less than 1,800 pounds per day using multiple generators at a minimum ozone product gas concentration of 8 percent by weight. The referenced systems shall have been in successful operation for a minimum of two years within the previous ten (10) years as of this RFQ date. Bidder shall provide references on the form included in Exhibit A.

b. Bidder's Project Manager, start-up personnel, and training personnel who will be assigned to this Project and will be responsible for all specified deliverables shall have successfully completed a minimum of three projects of comparable scope of supply and complexity to this Project


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within the last five years. The resume of the Bidder's Project Manager, start-up, and training personnel shall be provided in the RFQ response.

c. Bidders shall have under employment in the United States personnel who have a minimum of five years of experience in servicing and supervising installation and start-up of LOX-based ozone systems. The experience shall include installation and start-up of at least one facility with ozone production capacity of not less than 1,800 pounds per day using multiple generators within the last ten (10) years as of the RFQ date. The resumes of service personnel who will be assigned to this Project shall be provided in the RFQ response.

d. Bidders shall possess all permits, licenses, and professional credentials necessary to supply product and perform services as specified under this RFQ.

2. Bidders shall be one of the following or pre-approved equal:

a. SUEZ Treatment Solutions, Inc. , Leona, NJ

b. Metawater Co., Rutherford, NJ

c. Wedeco, a Xylem Inc. Brand, Charlotte, NC

d. Mitsubishi Electric Power Products, Inc., Freedom, PA

3. Pre-approval requirements:

a. Bidders other than the four listed above shall submit a proposal for "pre-approval or equal" to the District to demonstrate compliance with all the qualifications listed herein at least 21 days prior to the proposal date.

b. Proposals for “pre-approved or equal” substitutions requested during the bidding period shall be furnished in writing to:

Purchasing Division East Bay Municipal Utility District P. O. Box 24055 Oakland, CA 94623-1055

c. Proposals shall be accompanied by complete technical and descriptive data necessary to determine equality of the material including shop drawings and supporting documents for all the equipment supplied for the referenced ozone projects. Samples shall be provided when requested. The burden of proof as to availability, comparative quality, suitability, and performance of the proposed substitution shall be upon the bidder. The


03/01/2016 Page 4 RFQ No. 1618

bidder will not be reimbursed for any work and costs necessary for making the substitution workable. Proposals will be evaluated and deemed accepted, rejected, or incomplete by the District; the District will be the sole judge as to such matters. If the pre-approval is accepted, Bidders will be notified by addenda no later than ten days prior to the RFQ response date.

C. SPECIFIC REQUIREMENTS

1. Article 21 of the Supplier Agreement defines the Contract Documents for the Project, which generally consist of the following:

a. This RFQ including the Bid Forms and Reference Forms in Exhibit A;

b. Certificates of Insurance and Bonds Forms - Exhibit B;

c. General Requirements & Supplementary General Requirements – Exhibit C;

d. Supplier Agreement - Exhibit D;

e. Assignment Agreement - Exhibit E;

f. Technical Specifications and Drawings - Exhibit F;

g. Refer to Article 21 of the Supplier Agreement for additional information

2. Risk of loss as it relates to the equipment and materials provided hereunder shall be borne by Supplier until delivery to the project sites and acceptance by the Contractor, and thereafter shall be borne by the Contractor until final acceptance by the District.

3. All products shall be in new and unused condition and shall be of the most current and up to date model.

4. Materials in Contact with Drinking Water.

a. All materials, equipment, or products that will be in contact with drinking water (potable water) shall be tested and certified as meeting the specifications of NSF/ANSI 61 Standard in accordance with California Code of Regulations, Title 22, Section 64591. Examples include, but are not limited to, valves, pumps, flow meters, protective materials (coatings, linings, liners), joining and sealing materials, pipes, tanks, pipe fittings, filters, cleaning chemicals, and lubricants.

b. All materials, equipment, or products that will be in contact with drinking water (potable water) and may contain lead shall be tested and certified


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as “lead-free” per California Health and Safety Code Section 116875 and NSF 61 Annex G or NSF 372.

D. DELIVERABLES

Goods and services to be furnished by the Supplier include, but are not limited to, the following:

1. Instruments indicated on the instrumentation drawings and/or indicated in the technical specification sections.

2. Supplemental nitrogen generation systems.

3. Skid-mounted ozone generators, including on-skid interconnecting piping, valving, instrumentation, pressure relief valves, and separately mounted power supply units.

4. Closed-loop cooling water pumps and ancillary equipment to meet any specific cooling requirements.

5. Ozone destruct systems.

6. Master Ozone Control Panels.

7. Remote I/O Panels.

8. Programming of the PLCs and panel-mounted HMIs in control panels provided by the Ozone System Supplier

9. Miscellaneous process and control equipment specifically required for the Ozone System Supplier equipment.

10. Factory testing.

11. Software testing.

12. Testing, training, commissioning and supervision of ozone equipment installation.

13. Special tools and spare parts.

14. Operation and maintenance manuals.

15. Warranties.

16. Bonds and Insurance.

17. Design assistance, review of construction drawings, and preparation of shop drawing submittals.


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18. Delivery of equipment to the project sites within the specified timeframes.

E. FAILURE TO MEET SPECIFICATIONS

In the event any shipment or shipments of the Supplier’s product do not meet the specification or delivery requirements, the District may reject the shipment or shipments and, at its option, may purchase this material from any supplier on the open market who can meet the District’s specification requirements, or the District may demand immediate replacement by Supplier of the non-conforming product. Any costs over and above the original contract price will be charged back to the Supplier. In addition, Supplier shall bear the costs of removal and disposition for any delivery which fails to conform to the specifications.

F. INSPECTION

The District will inspect material after its arrival at the delivery point. If the rejection rate of a sample of components is 10% or higher, all components will be rejected. Supplier is solely responsible for ensuring the material arrives at the District’s ship-to location free of defects and manufactured in strict conformance with the specifications. The District reserves the right-of-access to the Supplier’s facility to verify conformance to this specification at the District’s expense.

II. CALENDAR OF EVENTS

EVENT DATE/LOCATION

RFQ Issued March 2, 2016

Pre-Bid Conference RSVP by March 14, 2016, please email Ali Sheikholeslami at [email protected]

March 16, 2016 at 10 a.m.

at: Sobrante WTP Ozone Control Room

5500 Amend Rd El Sobrante, CA 94803

RFQ Related Questions Deadline March 28, 2016 by 5 p.m.

Response Due Date April 6, 2016 by 1:30 p.m.

Anticipated Board Award of Contract April 26, 2016

Delivery of Major Equipment Submittals Refer to Article 17 of Supplier Agreement

Required Delivery Date of Ozone System Equipment.

Refer to Article 17 of Supplier Agreement

Note: All dates are subject to change by the District.

Bidders are responsible for reviewing http://ebmud.com/business for any published addenda. Hard copies of addenda will not be mailed out.

http://ebmud.com/business


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A. PRE-BID CONFERENCE

A pre-bid conference will be held on Wednesday March 16, 2016 at 10 a.m. at Sobrante WTP. Please RSVP by the end of March 14, 2016 by emailing to Ali Sheikholeslami at [email protected]. The purpose of the meeting is to:

1. Allow the District to discuss the scope of the project.

2. Provide Bidders an opportunity to view a site, receive documents, etc., necessary to respond to this RFQ.

3. Provide an opportunity for Bidders to ask specific questions about the project and request RFQ clarifications.

4. Provide the District with an opportunity to receive feedback regarding the project and RFQ.

Although the pre-bid conference is not mandatory, Bidders are strongly encouraged to attend. All questions deemed to be pertinent by the District will be addressed in an Addendum following the site walk/bid conference.

III. DISTRICT PROCEDURES, TERMS, AND CONDITIONS

A. RFQ ACCEPTANCE AND AWARD

1. RFQ responses will be evaluated to determine that they are responsive, responsible, and that they meet the specifications as stated in this RFQ.

2. The District has the right to decline to award this contract or any part of it for any reason.

3. Any specifications, terms or conditions, issued by the District, or those included in the bidder’s submission, in relation to this RFQ, may be incorporated into any PO or contract that may be awarded as a result of this RFQ.

4. Award of Supplier Agreement. The right is reserved to reject any or all bids and to waive technical defects, as the interest of the District may require. Award will be made or bids rejected by the District as soon as possible after bids have been opened.

B. DEVIATIONS AND EXCEPTIONS

Taking exception to the RFQ, or failure on the part of the Bidder to comply with all requirements and conditions of this RFQ may subject the RFQ response to rejection. If no deviations are shown, the Bidder will be required to furnish the goods and services exactly as specified. The burden of proof of compliance with the specifications will be the responsibility of the Bidder.

mailto:[email protected]


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C. PRICING

1. All prices are to be F.O.B. destination. Any freight/delivery charges are to be included including insurance.

2. All prices quoted shall be in United States dollars.

D. PROTESTS

Protests must be in writing and must be received no later than seven (7) business days after either of the following: posting of the RFQ results on the District’s website (www.ebmud.com), or notification of selection/non-selection, whichever is sooner. The District will reject the protest as untimely if it is received after this specified time frame. Protests will be accepted from Bidders or potential Bidders only. If the protest is mailed and not received by the District, the protesting party bears the burden of proof to submit evidence (e.g., certified mail receipt) that the protest was sent in a timely manner so that it would be received by the District within the RFQ protest period. Bid protests must contain a detailed and complete written statement describing the reason(s) for protest. The protest must include the name and/or number of the bid, the name of the firm protesting, and include a name, telephone number, email address and physical address of the protestor. If a firm is representing the protestor, they shall include their contact information in addition to that of the protesting firm. Protests must be mailed or hand delivered to the Manager of Purchasing, East Bay Municipal Utility District, 375 Eleventh Street, Oakland, CA 94607 or P.O. Box 24055, Oakland, California 94623. Facsimile and electronic mail protests must be followed by a mailed or hand delivered identical copy of the protest and must arrive within the seven day time limit. Any bid protest filed with any other District office shall be forwarded immediately to the Manager of Purchasing.

The bid protester can appeal the determination to the requesting organization’s Department Director. The appeal must be submitted to the Department Director no later than five working days from the date of receipt of the requesting organization’s determination on the protest. Such an appeal must be made in writing and must include all grounds for the appeal and copies of the original protest and the District’s response. The bid protester must also send the Purchasing Division a copy of all materials sent to the Department Director. The Department Director will make a determination of the appeal and respond to the protester by certified mail in a timely manner. If the appeal is denied, the letter will

http://www.ebmud.com/


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include the date, time, and location of the Board of Directors meeting at which staff will make a recommendation for award and inform the protester it may request to address the Board of Directors at that meeting. The District may transmit copies of the protest and any attached documentation to all other parties who may be affected by the outcome of the protest. The decision of the District as to the validity of any protest is final. This District’s final decision will be transmitted to all affected parties in a timely manner.

E. TERM / TERMINATION / RENEWAL

1. Article 17 of the Supplier Agreement specifies the term of the Supplier Agreement.

2. Article 12 of the Supplier Agreement specifies provisions for termination and suspension of the Supplier Agreement.

F. WARRANTY

1. Warranties for ozone equipment are specified in Article 4 of the Supplier Agreement.

G. INVOICING

1. Invoicing and payment procedures are specified in Article 7 of the Supplier

Agreement.

H. LIQUIDATED DAMAGES

1. Liquidated damages are specified in Article 17 of the Supplier Agreement.

I. BONDS

1. All Bids must be accompanied by a Bid security made payable to District for an amount of five percent of Bidder’s Total Capital Bid Cost shown in the Bid Form in Exhibit A:

a. The proposal security form options are a certified check, bank money order, or a Bid Bond in the form provided in Exhibit B issued by a surety. The proposal security shall be made payable without condition to the District.

b. The Bid security of the selected Bidder will be will be returned within thirty (30) days after Bidder has executed the Supplier Agreement with the District and met all other requirements.


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c. The Bid security of other Bidders whom the District believes to have a reasonable chance of receiving the award may be retained until the earlier of seven days after executing the Supplier Agreement with the selected Bidder or one hundred eighty (180) days after the Bid opening, whereupon Bid security furnished by such Proposers will be returned.

d. Bid security of other proposers whom District believes do not have a reasonable chance of receiving the award will be returned within seven days after the Bid opening.

2. The selected Bidder will be required to post and maintain the following bonds included in Exhibit E for 100 percent of the Total Capital Bid Cost in the Bid Form:

a. Payment bond

b. Faithful Performance bond

c. Warranty bond for ozone system equipment provided by the Supplier

3. Refer to Section 2 of the General Requirements for additional requirements.

IV. RFQ RESPONSE SUBMITTAL INSTRUCTIONS AND INFORMATION

A. DISTRICT CONTACTS

All contact during the competitive process is to be through the contact listed on the first page of this RFQ. The following persons are only to be contacted for the purposes specified below. Any RFQ related questions shall be submitted to the District no later than Monday March 28, 2015 at 5 p.m.

TECHNICAL SPECIFICATIONS: Attn: Ali Sheikholeslami, Associate Civil Engineer EBMUD – Engineering Design E-Mail: [email protected] PHONE: (510) 287-2047 CONTRACT EQUITY PROGRAM: Attn: Contract Equity Office PHONE: (510) 287-0114 AFTER AWARD: Attn: Ali Sheikholeslami, Associate Civil Engineer EBMUD – Engineering Design E-Mail: [email protected] PHONE: (510) 287-2047


03/01/2016 Page 11 RFQ No. 1618

B. SUBMITTAL OF RFQ RESPONSE

1. Late and/or unsealed responses will not be accepted.

2. RFQ responses submitted via electronic transmissions will not be accepted. Electronic transmissions include faxed RFQ responses or those sent by electronic mail (“e-mail”).

3. RFQ responses will be received only at the address shown below, must be SEALED, and must be received at the District Purchasing Division by 1:30 p.m. on the due date specified in the Calendar of Events. Any RFQ response received after that time or date, or at a place other than the stated address cannot be considered and will be returned to the bidder unopened.

All RFQ responses must be received and time stamped at the stated address by the time designated. The Purchasing Division's timestamp shall be considered the official timepiece for the purpose of establishing the actual receipt of RFQ responses.

4. RFQ responses are to be addressed/delivered as follows:

Mailed: Andrew Akelman, Manager of Purchasing East Bay Municipal Utility District Sobrante and USL WTPs Ozone Systems Equipment and Services - RFQ No. 1618 EBMUD–Purchasing Division P.O. Box 24055 Oakland, CA 94623 Hand Delivered or delivered by courier or package delivery service: Andrew Akelman, Manager of Purchasing East Bay Municipal Utility District Sobrante and USL WTPs Ozone Systems Equipment and Services – RFQ No. 1618 EBMUD – Purchasing Division 375 Eleventh Street, First Floor Oakland, CA 94607 Bidder's name, return address, and the RFQ number and title must also appear on the mailing package.

5. Bidders are to submit one (1) original hardcopy RFQ response (Exhibit A – RFQ Response Packet, including Contract Equity Program forms and all additional documentation stated in the “Required Documentation and Submittals” section of Exhibit A), all with original ink signatures.


03/01/2016 Page 12 RFQ No. 1618

6. Bidders shall also submit an electronic copy of their RFQ response, with their hardcopy RFQ response package. The file must be on a disk or USB flash drive and enclosed with the sealed original hardcopy of the RFQ response. The electronic copy should be in a single file (PDF) format, and shall be an exact scanned image of the original hard copy Exhibit A – RFQ Response Packet, Contract Equity Program forms and all additional documentation stated in the “Required Documentation and Submittals” section of Exhibit A.

7. All costs required for the preparation and submission of an RFQ response shall be borne by the Bidder.

8. California Government Code Section 4552: In submitting an RFQ response to a public purchasing body, the bidder offers and agrees that if the RFQ response is accepted, it will assign to the purchasing body all rights, title, and interest in and to all causes of action it may have under Section 4 of the Clayton Act (15 U.S.C. Sec. 15) or under the Cartwright Act (Chapter 2, commencing with Section 16700, of Part 2 of Division 7 of the Business and Professions Code), arising from purchases of goods, materials, or services by the bidder for sale to the purchasing body pursuant to the RFQ response. Such assignment shall be made and become effective at the time the purchasing body tenders final payment to the bidder.

9. Bidder expressly acknowledges that it is aware that if a false claim is knowingly submitted (as the terms “claim” and “knowingly” are defined in the California False Claims Act, Cal. Gov. Code, §12650 et seq.), the District will be entitled to civil remedies set forth in the California False Claim Act.

10. The RFQ response shall remain open to acceptance and is irrevocable for a period of one hundred eighty (180) days, unless otherwise specified in the RFQ documents.

11. It is understood that the District reserves the right to reject any or all RFQ responses.

C. RESPONSE FORMAT

1. Bidders shall not modify any part of Exhibits A, B, C, D, E, or F, or qualify their RFQ responses. Bidders shall not submit to the District a re-typed or otherwise re-created version of these documents or any other District-provided document.

2. RFQ responses, in whole or in part, are NOT to be marked confidential or proprietary. The District may refuse to consider any RFQ response or part thereof so marked. RFQ responses submitted in response to this RFQ may be subject to public disclosure. The District shall not be liable in any way for disclosure of any such records.

03/01/2016 Page 1 Exhibit A - RFQ No. 1618

EXHIBIT A RFQ NO. 1618 RESPONSE PACKET


To: The EAST BAY MUNICIPAL UTILITY District (“District”)

From:

(Official Name of Bidder) RFQ RESPONSE PACKET GUIDELINES

AS DESCRIBED IN SECTION IV- RFQ RESPONSE SUBMITTAL INSTRUCTIONS AND INFORMATION, BIDDERS ARE TO SUBMIT ONE (1) ORIGINAL HARDCOPY RFQ RESPONSE WITH ORIGINAL INK SIGNATURES, FOUR (4) HARDCPIES, AND ONE (1) ELECTRONIC COPY (preferably in PDF format and on a CD or flash drive) CONTAINING THE FOLLOWING, IN THEIR ENTIRETY:

o EXHIBIT A – RFQ RESPONSE PACKET, INCLUDING CONTRACT EQUITY PROGRAM FORMS AND ALL ADDITIONAL REQUIRED DOCUMENTATION AS DESCRIBED IN EXHIBIT A - “REQUIRED DOCUMENTATION AND SUBMITTALS”

ALL PRICES AND NOTATIONS MUST BE PRINTED IN INK OR TYPEWRITTEN; NO ERASURES ARE PERMITTED; ERRORS MAY BE CROSSED OUT AND CORRECTIONS PRINTED IN INK OR TYPEWRITTEN ADJACENT, AND MUST BE INITIALED IN INK BY PERSON SIGNING THE RFQ RESPONSE.

BIDDERS THAT DO NOT COMPLY WITH THE REQUIREMENTS, AND/OR SUBMIT AN

INCOMPLETE RFQ RESPONSE MAY BE SUBJECT TO DISQUALIFICATION AND THEIR RFQ RESPONSE REJECTED IN TOTAL.

IF BIDDERS ARE MAKING ANY CLARIFICATIONS AND/OR AMENDMENTS, OR TAKING

EXCEPTION TO ANY PART OF THIS RFQ, THESE MUST BE SUBMITTED IN THE EXCEPTIONS, CLARIFICATIONS, AND AMENDMENTS SECTION OF THIS EXHIBIT A – RFQ RESPONSE PACKET. THE DISTRICT, AT ITS SOLE DISCRETION, MAY ACCEPT AMENDMENTS/EXCEPTIONS, OR MAY DEEM THEM TO BE UNACCEPTABLE, THEREBY RENDERING THE RFQ RESPONSE DISQUALIFIED.


BIDDER INFORMATION AND ACCEPTANCE 1. The undersigned declares that all RFQ documents, including, without limitation, the RFQ, Addenda,

and Exhibits, have been read and that the terms, conditions, certifications, and requirements are agreed to.

2. The undersigned is authorized to offer, and agrees to furnish, the articles and services specified in accordance with the RFQ documents of RFQ No. 1618.

3. The undersigned acknowledges acceptance of all addenda related to this RFQ. List Addenda for this RFQ on the lines below:

Addendum # Date

4. The undersigned hereby certifies to the District that all representations, certifications, and statements

made by the bidder, as set forth in this RFQ Response Packet and attachments, are true and correct and are made under penalty of perjury pursuant to the laws of California.

5. The undersigned acknowledges that the bidder is, and will be, in good standing in the State of California, with all the necessary licenses, permits, certifications, approvals, and authorizations necessary to perform all obligations in connection with this RFQ and associated RFQ documents.

6. It is the responsibility of each bidder to be familiar with all of the specifications, terms, and conditions and, if applicable, the site condition. By the submission of an RFQ response, the bidder certifies that if awarded a contract it will make no claim against the District based upon ignorance of conditions or misunderstanding of the specifications.

7. Patent indemnity: Contractors who do business with the District shall hold the District, its Directors, officers, agents, and employees, harmless from liability of any nature or kind, including cost and expenses, for infringement or use of any patent, copyright, or other proprietary right, secret process,


patented or unpatented invention, article, or appliance furnished or used in connection with the contract or purchase order.

8. Insurance certificates are not required at the time of submission. However, by signing Exhibit A – RFQ Response Packet, the bidder agrees to meet the minimum insurance requirements stated in the RFQ. This documentation must be provided to the District prior to execution of an agreement by the District, and shall include an insurance certificate which meets the minimum insurance requirements, as stated in the RFQ.

9. The undersigned bidder hereby submits this RFQ response and binds itself on award to the District under this RFQ to execute in accordance with such award a contract and to furnish the bond or bonds and insurance required by the RFQ. The RFQ, subsequent Addenda, bidder’s Response Packet, and any attachments, shall constitute the Contract, and all provisions thereof are hereby accepted.

10. The undersigned acknowledges ONE of the following (please check only one box)*:

Bidder is not an SBE and is ineligible for any bid preference; OR

Bidder is an SBE or DVBE as described in the Contract Equity Program (CEP) and Equal Employment Opportunity (EEO) Guidelines, is requesting a 5% bid preference, and has completed the Contract Equity Program and Equal Employment Opportunity forms at the hyperlink contained in the Contract Equity Program and Equal Opportunity section of this Exhibit A.

*If no box is checked, it will be assumed that the bidder is ineligible for bid preference and none will be given. For additional information on SBE bid preference, please refer to the Contract Equity Program and Equal Employment Opportunity Guidelines at the above referenced hyperlink.

Official Name of Bidder (exactly as it appears on Bidder’s corporate seal and invoice): Street Address Line 1: Street Address Line 2: City: State: Zip Code: Webpage: Type of Entity / Organizational Structure (check one):

Corporation Joint Venture

Limited Liability Partnership Partnership

Limited Liability Corporation Non-Profit / Church

Other: Jurisdiction of Organization Structure:


Date of Organization Structure: Federal Tax Identification Number:

Primary Contact Information:

Name / Title: Telephone Number: Fax Number: E-mail Address:

Street Address Line 1: City: State: Zip Code:

SIGNATURE: Name and Title of Signer (printed): Dated this day of 20

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BID FORM and ENERGY CONSUMPTION

1. BID FORM Bidders shall provide all information required in Bid Form below which consists of Parts A, B, and C. No alterations or changes of any kind to the Bid Form are permitted. Part A is the Capital Bid Cost is the cost the District will pay for goods and services included in the Contract Documents. Part B is the Present Worth Energy Cost as described below. Part C is the Total Present Worth Cost, consisting of Part A plus Part B, and will be the basis for selection by the District.

1. In the event the addition of the bid item amounts does not equal the total amounts in the Bid Form, , the corrected addition of all bid items will govern and the District will correct the total costs accordingly.

2. If the Bid Form does not contain the price for an item, then it shall he deemed incomplete and

the Bid shall be deemed non-responsive by the District.

3. In case of discrepancy between words and figures, words will prevail. Part A. Capital Bid Costs

Bidders shall indicate their proposed lump sum cost in the Bid Form below for furnishing goods and services specified in Contract Documents.

1. Bid Item 1 is an allowance for goods and services to be provided in accordance with Article 3 of the Supplier Agreement prior to executing the Assignment Agreement with the Contractor and District. If the Bidder considers the cost for these services to be greater than shown, the additional cost for goods and services should be included by the Bidder in other bid items in the Bid Form. Payment for Bid Item 1 will be made by the District in accordance with Article 7 of the Supplier Agreement.

At the District's discretion, goods and services associated with other bid items in the Bid Form may be authorized by the District prior to executing the Assignment Agreement. Payment for these items will be made by the District in accordance with Article 7 of the Supplier Agreement.

Part B. Present Worth Energy Cost

Bidders shall indicate in the Bid Form the Present Worth Energy Cost for both plants calculated using the following equation:

Present Worth Energy Cost = $0.1070 x 670 x 250 x 12.46 x SECAVE x 2


Where:

(a) $0.1070 = average cost of electrical power ($/kWh) at both plants

(b) 670 = average daily ozone production at each water treatment plant (lb/day)

(c) 250 = days per year of average operation at each water treatment plant

(d) 12.46 = Equal Series Present Worth (20 year period at 5 percent interest)

(e) SECAVE = Average Specific Energy Consumption (kWh/lb Ozone produced) as defined in Section 46_31_52

(f) 2 = Number of treatment plants

Part C - Total Present Worth Cost

Bidders shall indicate in the Bid Form the Total Present Cost for both plants calculated using the following equation:

Total Present Worth Cost = Part A (Total Capital Bid Cost) + Part B (Present Worth Energy Cost)


BID FORM for RFQ No. 1618 Sobrante and USL WTPs Ozone Systems Equipment and Services

BID ITEM LUMP SUM COST

Part A - Capital Bid Items

1. Design Assistance, Shop Drawing Submittals, Bonds, Insurance, and Warranties, exclusive of items below.

$150,000

2. Ozone Equipment, exclusive of items listed below and taxes. $

3. Witness Factory Tests $

4. F.O.B. Freight (to both WTP sites) $

5. Supervision of Installation, Testing, Training, and Commissioning

$

6. Operation and Maintenance Manuals $

Part A Total Capital Bid Cost (Items 1-6) $

Part B Energy Present Worth Cost $

Part C Total Present Worth Cost (Part A + Part B) $

Part C Total Present Worth Cost In Words:

2. ENERGY CONSUMPTION Bidders shall indicate in the form below the Average Specific Energy Consumption (SECAVE) used in the present worth energy calculation. The selected Supplier shall pay the District the penalties defined in Section 46_31_52 if the measured Actual Specific Energy Consumption is greater than the SECAVE indicated below.

ENERGY CONSUMPTION Sobrante and USL WTPs Ozone Systems Equipment and Services

AVERAGE SPECIFIC ENERGY CONSUMPTION kWh/lb

Average Specific Energy Consumption in Number

Average Specific Energy Consumption in Words:


REQUIRED DOCUMENTATION AND SUBMITTALS All of the specific documentation listed below is required to be submitted with the Exhibit A – RFQ Response Packet. Bidders shall submit all documentation, in the order listed below, and clearly label each section of the RFQ response with the appropriate title. 1. Description of the Proposed Equipment/System: Bidders shall provide a description of the

proposed equipment/system as it will be finally configured. The description shall include diagrams, data sheets, and other information to demonstrate the approximate equipment dimensions, and how the proposed equipment/system will meet or exceed the requirements of the Contract Documents.

2. Harmonic Distortion Mitigation Equipment and Calculations: In addition to equipment

descriptions in Item 1, Bidders shall provide detailed information about equipment included in their system to mitigate harmonic distortion as specified in Section 46_31_55. Bidders shall provide calculations stamped by a registered Professional Electrical Engineer in the U.S. that demonstrate conformance with the specified requirements.

3. Bid Security: Bidders shall provide a Bid Security as specified in Section III.M of the RFQ.

4. References: Bidders shall provide references for the ozone facilities they claim as qualifying

experience for meeting the minimum qualifications described in Section I.B of the RFQ. (a) Bidders must use the templates in the “References” section of this Exhibit A – RFQ

Response Packet to provide references. (b) Bidders must verify the contact information for all references provided is current and

valid. (c) Bidders are strongly encouraged to notify all references that the District may be contacting

them to obtain a reference.

5. Project Manager, Start-up and Training Personnel Resumes: Bidders shall provide the resumes of their Project Manager, start-up, and training personnel who will be assigned to this Project demonstrating the experience necessary to meet the minimum qualifications described in Section I.B of the RFQ.

6. Exceptions, Clarifications, Amendments:

(a) The RFQ response shall include a separate section calling out all clarifications, exceptions, and amendments, if any, to the RFQ and associated RFQ documents, which shall be submitted with Bidder’s RFQ response using the template in the “Exceptions, Clarifications, Amendments” section of this Exhibit A – RFQ Response Packet.


(b) THE DISTRICT IS UNDER NO OBLIGATION TO ACCEPT ANY EXCEPTIONS, AND SUCH EXCEPTIONS MAY BE A BASIS FOR RFQ RESPONSE DISQUALIFICATION.

REFERENCES


RFQ No. 1618 - Sobrante and Upper San Leandro Water Treatment Plants Ozone Systems Equipment and Services

Bidder Name:

Bidder must provide a minimum of four (4) references as described in the Bidder Qualifications.

1. Utility Name: Contact Person:

Address: Telephone Number:

City, State, Zip: E-mail Address:

Ozone System Capacity / Date Installed/Operational Dates:














EXCEPTIONS, CLARIFICATIONS, AMENDMENTS

RFQ No. 1618 Sobrante and Upper San Leandro WTPs Ozone Systems Equipment and Services

Bidder Name: List below requests for clarifications, exceptions, and amendments, if any, to the RFQ and associated RFQ Documents, and submit with bidder’s RFQ response. The District is under no obligation to accept any exceptions and such exceptions may be a basis for RFQ response disqualification.

Reference to: Description

Section No.

Page No.

Article/Paragraph/Subparagraph

*Print additional pages as necessary


CONTRACT EQUITY PROGRAM & EQUAL EMPLOYMENT OPPORTUNITY

The District’s Board of Directors adopted the Contract Equity Program (CEP) to enhance equal opportunities for business owners of all races, ethnicities, and genders who are interested in doing business with the District. The program has contracting objectives, serving as the minimum level of expected contract participation for the three availability groups: white-men owned businesses, white-women owned businesses, and ethnic minority owned businesses. The contracting objectives apply to all contracts that are determined to have subcontracting opportunities, and to all General or Professional Service Providers regardless of their race, gender, or ethnicity. All Contractors and their subcontractors performing work for the District must be Equal Employment Opportunity (EEO) employers, and shall be bound by all laws prohibiting discrimination in employment. There shall be no discrimination against any person, or group of persons, on account of race, color, religion, creed, national origin, ancestry, gender including gender identity or expression, age, marital or domestic partnership status, mental disability, physical disability (including HIV and AIDS), medical condition (including genetic characteristics or cancer), genetic information, or sexual orientation. Contractor and its subcontractors shall abide by the requirements of 41 CFR §§ 60-1.4(a), 60-300.5(a) and 60-741.5(a). These regulations prohibit discrimination against qualified individuals based on their status as protected veterans or individuals with disabilities, and prohibit discrimination against all individuals based on their race, color, religion, sex, sexual orientation, gender identity, or national origin in the performance of this contract. Moreover, these regulations require that covered prime contractors and subcontractors take affirmative action to employ and advance in employment individuals without regard to race, color, religion, sex, national origin, protected veteran status or disability. All Contractors shall include the nondiscrimination provisions above in all subcontracts. Please include the required completed forms with your proposal. Non-compliance with the Guidelines may deem a proposal non-responsive, and therefore, ineligible for contract award. Your firm is responsible for:

1) Reading and understanding the CEP guidelines.

2) Filling out and submitting with your bid the appropriate forms. The CEP guidelines and forms can be found at the following direct link: Contract Equity Program Guidelines and Forms

The CEP guidelines and forms can also be downloaded from the District website at the following link: http://ebmud.com/business-center/contract-equity-program/ If you have questions regarding the Contract Equity Program please call (510) 287-0114.

https://www.ebmud.com/index.php/download_file/force/2808/821/?CEP_EEO_Guidelines_with_Forms_July.pdf

http://ebmud.com/business-center/contract-equity-program/

03/01/2016 Page 1 Exhibit B – RFQ No. 1618

EXHIBIT B INSURANCE REQUIREMENTS & BOND FORMS

Insurance certificates are not required at the time of submission; however, by signing Exhibit A – RFP Response Packet, the Proposer agrees to meet the minimum insurance requirements stated in the RFP. This documentation must be provided to the District, prior to award. The following are the minimum insurance limits, required by the District, to be held by the GENERAL

OR PROFESSIONAL SERVICE PROVIDER performing on this RFP: INDEMNIFICATION AND INSURANCE A. Indemnification

GENERAL OR PROFESSIONAL SERVICE PROVIDER expressly agrees to defend, indemnify, and hold harmless the District and its Directors, officers, agents, and employees from and against any and all loss, liability, expense, claims, suits, and damages, including attorneys' fees, arising out of or resulting from GENERAL OR PROFESSIONAL SERVICE PROVIDER's, its associates', employees', subcontractors’, or other agents' negligent acts, errors or omissions, or willful misconduct, in the operation and/or performance under this Agreement.

B. Insurance Requirements

GENERAL OR PROFESSIONAL SERVICE PROVIDER shall take out and maintain during the life of the Agreement all the insurance required in this section, and if requested shall submit certificates for review and approval by the District. The Notice to Proceed shall not be issued, and GENERAL OR PROFESSIONAL SERVICE PROVIDER shall not commence work until such insurance has been approved by the District. The certificates shall be on forms approved by the District. Acceptance of the certificates shall not relieve GENERAL OR PROFESSIONAL SERVICE PROVIDER of any of the insurance requirements, nor decrease the liability of GENERAL OR PROFESSIONAL SERVICE PROVIDER. The District reserves the right to require GENERAL OR PROFESSIONAL SERVICE PROVIDER to provide insurance policies for review by the District.

C. Workers Compensation Insurance

GENERAL OR PROFESSIONAL SERVICE PROVIDER shall take out and maintain during the life of the Agreement Workers Compensation Insurance for all of its employees on the project. In lieu of evidence of Workers Compensation Insurance, the District will accept a Self-Insured Certificate from the State of California. GENERAL OR PROFESSIONAL SERVICE PROVIDER shall require any subcontractor to provide it with evidence of Workers Compensation Insurance.


D. Commercial General Liability Insurance

GENERAL OR PROFESSIONAL SERVICE PROVIDER shall take out and maintain during the life of the Agreement Automobile and General Liability Insurance that provides protection from claims which may arise from operations or performance under this Agreement. If GENERAL OR PROFESSIONAL SERVICE PROVIDER elects to self-insure (self-fund) any liability exposure during the contract period above $50,000, GENERAL OR PROFESSIONAL SERVICE PROVIDER is required to notify the District immediately. Any request to self-insure must first be approved by the District before the changed terms are accepted. GENERAL OR PROFESSIONAL SERVICE PROVIDER shall require any subcontractor or Professional Service Provider to provide evidence of liability insurance coverages.

The amounts of insurance shall be not less than the following: $2,000,000/Occurrence, Bodily Injury, Property Damage -- Automobile. $2,000,000/Occurrence, Bodily Injury, Property Damage -- General Liability. $4,000,000 for Excess Liability.

The following coverages or endorsements must be included in the policy(ies):

1. The District, its Directors, officers, and employees are Additional Insureds in the

policy(ies) as to the work being performed under the contract.

2. The coverage is Primary and non-contributory to any other applicable insurance carried by the District.

3. The policy(ies) covers contractual liability. 4. The policy(ies) is written on an occurrence basis. 5. The policy(ies) covers the District’s Property in Consultant’s care, custody, and control. 6. The policy(ies) covers personal injury (libel, slander, and wrongful entry and eviction)

liability. 7. The policy(ies) covers explosion, collapse, and underground hazards. 8. The policy(ies) covers products and completed operations. 9. The policy(ies) covers the use of owned, non-owned, and hired automobiles.

10. The policy(ies) will not be canceled nor the above coverages/endorsements reduced

without 30 days written notice to East Bay Municipal Utility District at the address above.


INSURANCE FORMS

SPECIMENS FORMS: The forms of workers’ compensation insurance

and public liability insurance included in the following pages shall be

examined by each bidder, but they are SPECIMENS ONLY and not to be

filled out. They are identical to the forms the successful bidder will be

required to execute upon award.


CERTIFICATE OF COMMERCIAL GENERAL AND AUTO LIABILITY INSURANCE

THIS IS TO CERTIFY TO:

East Bay Municipal Utility District (EBMUD)

Department:

Street Address:

Mailing Address:

City, State, Zip:

THE FOLLOWING DESCRIBED POLICY HAS BEEN ISSUED TO:

District Contract Number:

Insured:

Address:

LOCATION AND DESCRIPTION OF PROJECT/AGREEMENT:

TYPE OF INSURANCE: Commercial General and Automobile Liability Coverage/Endorsements as required by agreement. LIMITS OF LIABILITY: (MINIMUM) $2,000,000/Occurrence, Bodily Injury, Property Damage-General Liability

$2,000,000/Occurrence, Bodily Injury, Property Damage-Auto Liability

SELF INSURED RETENTION ($): (Auto) (GL) (if applicable)

Aggregate Limits (AUTO) (GL) (if applicable)

INSURANCE COMPANY(IES): (Auto) (GL)

POLICY NUMBER(S): (Auto) (GL)

POLICY TERM: From: (Auto) (GL) To: (Auto) (GL)

THE FOLLOWING COVERAGES OR ENDORSEMENTS ARE INCLUDED IN THE POLICY(IES):

1. The District, its Directors, Officers and Employees are Additional Insureds in the policy(ies) as to work being performed

under this agreement. ENDORSEMENT NO.

2. The coverage is Primary and non-contributory to any other applicable insurance carried by the District. 3. The policy(ies) covers contractual liability.

4. The policy(ies) is written on an occurrence basis. 5. The policy(ies) covers District’s Property in Consultant’s care, custody and control. 6. The policy(ies) covers personal injury (libel, slander, and wrongful entry and eviction) liability. 7. The policy(ies) covers explosion, collapse, and underground hazards.

8. The policy(ies) covers products and completed operations. 9. The policy(ies) covers the use of owned, non-owned and hired automobiles.

10. The policy(ies) and/or a separate pollution liability policy(ies) shall cover pollution liability for claims related to the

release or the threatened release of pollutants into the environment arising out of or resulting from Consultant’s performance under this agreement.

11. The policy(ies) will not be canceled nor the above coverages/endorsements reduced without 30 days written notice to

East Bay Municipal Utility District at the address above. IT IS HEREBY CERTIFIED that the above policies provide liability insurance as required by the agreement between the East Bay Municipal Utility District and the insured.

Signed Firm

Address Date

Phone


RM 015 8/11

CERTIFICATE OF WORKERS’ COMPENSATION INSURANCE

THIS IS TO CERTIFY TO: East Bay Municipal Utility District (EBMUD)

Department:

Street Address: 375 11th

Street, MS 102

Mailing Address: P.O. Box 24055

City, State, Zip: Oakland, CA 94623-1055

THE FOLLOWING DESCRIBED POLICY HAS BEEN ISSUED TO:

District Purchase Order

Number:

(Completed by EBMUD)

Insured:

Address:

LOCATION AND DESCRIPTION OF PROJECT/AGREEMENT:

TYPE OF INSURANCE: Workers’ Compensation Insurance as required by California State Law.

The Workers’ Compensation Carrier agrees to waive rights of recovery against District regardless of the applicability of

any insurance proceeds, and to require all indemnifying parties to do likewise. All Workers’ Compensation coverage

maintained or procured by permit Holder shall be endorsed to delete the subrogation condition as to District, or must

specifically allow the named insured to waive subrogation prior to a loss.

INSURANCE COMPANY:

POLICY NUMBER:

POLICY

TERM:

From: To:

The policy will not be canceled nor the above coverage reduced without 30 days written

notice to East Bay Municipal Utility District at the address above.

IT IS HEREBY CERTIFIED the above policy provides insurance as required by the

agreement between East Bay Municipal Utility District at the Insured.

Signed:

Date: Firm:

E-mail Address:

Phone: “This certificate or verification of insurance is not an insurance policy and does not amend, extend, or alter the coverage afforded by the policies listed

herein. Notwithstanding any requirement, term or conditions of any contract or other document with respect to which this certificate or verification or

insurance may be issued or may pertain, the insurance afforded by the policies described herein is subject to all the terms, exclusions, and conditions of the policies.”

RM-017 3/26/10 UF020-29.doc

BOND FORMS

BIDDER’S BOND

KNOW ALL PERSONS BY THESE PRESENTS:

That

as Principal (name and California address where service may be effected), and

as Surety (name and California address where service may be effected), are held and firmly bound unto the EAST BAY MUNICIPAL UTILITY DISTRICT, hereinafter called the District, in the sum equal to Ten Per Cent of the Total Amount of the Bid submitted by the Principal to the District under the Specifications accompanying this bond and which are incorporated by reference herein, or One Thousand Dollars ($1,000), whichever is greater, for the payment of which sum in lawful money of the United States of America to the District we bind ourselves, our heirs, executors, administrators, successors and assigns, jointly and severally, firmly by these presents. The condition of the above obligation is such that, whereas the Principal has submitted said bid to the District; NOW, THEREFORE, if the Principal is awarded a contract by the District and, within the time and in the manner required by said Specifications, enters into a written contract with the District and furnishes the requisite bond or bonds, then this obligation shall become null and void, otherwise to remain in full force and effect. In the event suit is brought upon this bond by the District and judgment is recovered, the Surety shall pay all costs incurred by the District in such suit, including a reasonable attorney’s fee to be fixed by the Court. DATE: Principal

By

*Title

By

**Title

(SEAL OF SURETY) Surety

By

Title

Note: The signature of the Surety on this bond must be acknowledged before a Notary Public. An executed Power of Attorney indicating that the Surety’s representative is authorized to bind the Surety must accompany this bond.

Specifications / Proposal No.

E-103 • 3/07 UE010-8B.doc _______________________________________________________________________________________________________________________________ *If corporation, Corporate President or CEO; if Partnership, Partner. ** Corporate Secretary or financial officer

00 43 13 - 1

DATE FAITHFUL PERFORMANCE BOND CONTRACTOR (Name and California address where service may be effected)

SURETY (Name and California address where service may be effected)

AMOUNT OF BOND (Sum in words and figures)

CONTRACT DOCUMENTS (As named in the Contract)


THAT, the contractor named above, hereinafter called the Contractor, as Principal, and the Surety named above, as Surety, are held and firmly bound unto the East Bay Municipal Utility District, hereinafter called the District, in the sum entered above, lawful money of the United States of America, for the payment of which sum well and truly to be made to the District, we, and each of us, bind ourselves, our heirs, executors, administrators, successors, and assigns, jointly and severally, firmly by these presents.

The condition of the above obligation is such that whereas the Contractor and the District entered into a Contract of even date herewith, by the terms and conditions of which the Contractor agreed to perform and complete the work, or manufacture, complete, and deliver the material or equipment, set forth in the Contract Documents named in the Contract, all now on file in the office of the Secretary of the District, as will more fully appear by reference to said Contract, which is made a part of this bond;

E-199.1 • 12/06 1 of 2

FAITHFUL PERFORMANCE BOND

NOW, THEREFORE, if the Contractor shall well and truly carry out, execute and perform all things by the Contractor to be carried out, executed and performed, according to the terms and conditions of said Contract, including any and all warranty and guaranty obligations contained therein, then this obligation shall become null and void, otherwise to remain in full force and effect throughout the period of performance, including any warranty or guaranty period.

No prepayment or delay in payment, and no change, extension, addition, or alteration of any provision of said Contract or Contract Documents agreed to between the Contractor and the District, and no forbearance on the part of the District shall operate to release the Surety from liability on this Bond, and consent to make such alterations without further notice to or consent by the Surety is hereby given, and the Surety hereby waives the provisions of Section 2819 of the Civil Code and Section 359.5 of the Code of Civil Procedure of the State of California.

Each signator to this bond hereby declares under penalty of perjury under the laws of the State of California that the foregoing is true and correct.

Dated the day and year entered on the first page hereof.

Contractor

By

*Title

By

**Title


By

Title


The foregoing Bond was accepted and approved this day of , 20

, East Bay Municipal Utility District


____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

*If corporation, Corporate President or CEO; if Partnership, Partner. **Corporate Secretary or financial officer.

E-199.1 • 12/06 2 of 2

DATE PAYMENT BOND CONTRACTOR (Name and California address where service may be effected)

SURETY (Name and California address where service may be effected)

AMOUNT OF BOND (Sum in words and figures)

CONTRACT DOCUMENTS (As named in the Contract)


THAT, WHEREAS, the contractor named above, hereinafter called the Contractor, has this day entered into a Contract with East Bay Municipal Utility District, hereinafter called the District, to perform and complete the work set forth in the Contract Documents named in the Contract, all now on file in the office of the Secretary of the District, as will more fully appear by reference to said Contract, which is made a part hereof; and

WHEREAS, Sections 9550 to 9566 inclusive of the Civil Code of the State of California, and any amendments thereof, require contractors upon public work to file with the body by whom such contract was awarded a good and sufficient bond to secure the claims to which reference is made in said sections, NOW THESE PRESENTS

WITNESSETH: That the Contractor, as Principal, and the Surety named above, as Surety, are held and firmly bound unto any and all materialmen, persons, firms, or corporations furnishing materials, provisions, or other supplies used in, upon, for, or about the performance of the work contracted to be done, and to all persons, firms or corporations renting or hiring implements or machinery for or contributing to the said work to be done and to all persons who perform work or labor of any kind or nature thereon, or in connection therewith, and to all persons who supply both work and materials, in the sum entered on the first page hereof, lawful money of the United States of America, being not less than the total amount payable by the terms of said Contract, for which payment well, truly and promptly to be made we bind ourselves, our heirs, executors, administrators, successors, and assigns, jointly, and severally, firmly by these presents.

E-008 • 04/13 1 of 2

PAYMENT BOND

The condition of the above obligation is such that if the Contractor, or the Contractor’s subcontractors, fail to pay for any materials, provisions or other supplies used in, upon, for, or about the performance of the work contracted to be done, or for any work or labor thereon of any kind, or for amounts due under the Unemployment Insurance Act with respect to such work or labor, the Surety will pay for the same, in an amount not exceeding the sum specified in this Bond, provided that any and all claims hereinunder shall be filed and proceedings had in connection therewith as required by the provisions of said Sections 9550 to 9566 inclusive of the Civil Code of the State of California, and any amendments thereof: PROVIDED ALSO, that in case suit is brought upon this Bond a reasonable attorney’s fee shall be awarded by the court to the prevailing party in said suit, said attorney’s fee to be fixed as costs in said suit, and to be included in the judgment therein rendered.

No prepayment or delay in payment and no change, extension, addition, or alteration of any provision of said Contract or Contract Documents agreed to between the Contractor and the District, and no forbearance on the part of the District, shall operate to release the Surety from liability on this Bond, and consent to make such alterations without further notice to or consent by the Surety is hereby given, and the Surety hereby waives the provisions of Section 2819 of the Civil Code of the State of California.

Dated the day and year entered on the first page hereof.

Each signator to this bond hereby declares under penalty of perjury under the laws of the State of California that the foregoing is true and correct.

Contractor

By

*Title

By

**Title


By

Title


The foregoing Bond was accepted and approved this day of , 20

, East Bay Municipal Utility District


____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

*If corporation, Corporate President or CEO; if Partnership, Partner. **Corporate Secretary or financial officer.

E-008 • 04/13 2 of 2

RFQ No. 1618

EXHIBIT C - GENERAL REQUIREMENTS AND SUPPLEMENTARY GENERAL REQUIREMENTS

REV. 3/15 GR-1

EXHIBIT C Effective: 1 Apr 15 Supersedes: 1 Apr 88 GENERAL REQUIREMENTS CONTENTS 1. DEFINITIONS 2. BOND 3. CONTRACTOR’S FINANCIAL OBLIGATION 4. SAMPLES OR SPECIMENS 5. MATERIAL AND WORKMANSHIP 6. DEFECTIVE WORK 7. WARRANTY OF TITLE 8. WARRANTY OF FITNESS 9. SAFETY AND ACCIDENT PREVENTION 10. CHARACTER OF WORKFORCE 11. PREVAILING WAGES 12. PAYROLL RECORDS 13. HOURS OF LABOR 14. EMPLOYMENT OF APPRECTICES 15. CHANGES 16. EFFECT OF EXTENSIONS OF TIME 17. DELAYS 18. TERMINATION 19. DAMAGES 20. ORDER OF PRECIDENCE 21. INDEMNIFICATION/RESPONSIBILITY 22. ASSIGNMENTS 23. NEWS RELEASES 24. TRANSFER OF INTEREST 25. SEVERABILITY 26. COVENANT AGAINST GRATUITIES 27. RIGHTS AND REMEDIES OF THE DISTRICT 28. WAIVER OF RIGHTS 29. CONFIDENTIALITY 1. DEFINITIONS The following terms shall be given the meaning shown, unless context requires otherwise or a unique meaning is otherwise specified.

a. “Change Order” A Change Order is a written instrument used for modifying the contract with regards to the scope of Work, contract sum, and/or Contract Time. An approved Change Order is a Change Order signed by the District. An executed Change Order is a Change Order signed by both the District and the Contractor.

REV. 3/15 GR-2

b. “Contract” means the agreement between the District and Contractor as memorialized in the Contract Documents.

c. “Business Entity” means any individual, business, partnership, joint venture, corporation, sole proprietorship, or other private legal entity recognized by statute.

d. “Buyer” means the District’s authorized contracting official.

e. “Contract Documents” comprise the entire agreement between the District and the Contractor and can include the District’s contract form if used, any purchase order, RFP, RFQ or Contractor response packet, and any addenda, appendices and District approved changes or amendments. The Contract Documents are intended to be complementary and include all items necessary for the Contractor’s proper execution and completion of the Work. Any part of the Work not shown or mentioned in the Contract Documents that is reasonably implied, or is necessary or usual for proper performance of the Work, shall be provided by the Contractor at its expense.

f. “Contractor” means the Business Entity with whom the District enters into a contractual agreement. Contractor shall be synonymous with “supplier”, “vendor”, "consultant" or other similar term.

g. “Day” unless otherwise specified, days are calendar days, measured from midnight to the next midnight.

h. “District” means the East Bay Municipal Utility District, its employees acting within the scope of their authority, and its authorized representatives.

i. “Goods” means off the shelf software and all types of tangible personal property, including but not limited to materials, supplies, and equipment.

j. “Project Manager” shall be the District designated individual responsible for administering and interpreting the terms and conditions of the Contract Documents, for matters relating to the Contractor’s performance under the Contract with the District, and for liaison and coordination between the District and Contractor.

k. “Work” means all labor, tasks, materials, supplies, and equipment required to properly fulfill the Contractor’s obligations as required in the Contract Documents.

l. “Work Day” Unless otherwise specified, work day includes all days of the year except Saturdays, Sundays and District holidays.

2. BOND a. When required in the District’s bid or proposal solicitation documents, the Contractor to

whom award is made shall furnish a good and approved faithful performance bond and/or payment bond within ten business days after receiving the forms for execution.

b. The bonds shall be executed by a sufficient, admitted surety insurer (i.e.: as listed on website http://interactive.web.insurance.ca.gov/webuser/idb_co_list$.startup) admitted to transact such business in California by the California Department of Insurance. After acceptance of the bond(s) by the District, a copy of the bond(s) will be

http://interactive.web.insurance.ca.gov/webuser/idb_co_list$.startup

REV. 3/15 GR-3

returned to the Contractor.

c. If, during the continuance of the Contract, any of the sureties, in the opinion of the District, are or become irresponsible, the District may require other or additional sureties, which the Contractor shall furnish to the satisfaction of the District within ten days after notice. If the Contractor fails to provide satisfactory sureties within the ten-day period, the Contract may be terminated for cause under Article 18.

3. CONTRACTOR’S FINANCIAL OBLIGATION The Contractor shall promptly make payments to all persons supplying labor and materials used in the execution of the contract.

4. SAMPLES OR SPECIMENS The Contractor shall submit samples or prepare test specimens of such materials to be furnished or used in the work as the Project Manager may require.

5. MATERIAL AND WORKMANSHIP a. All goods and materials must be new and of the specified quality and equal to approved

sample, if samples have been required. In the event any goods or materials furnished or services provided by the Contractor in the performance of the Contract fail to conform to the requirements, or to the sample submitted by the Contractor, the District may reject the same, and it shall become the duty of the Contractor to reclaim and remove the item promptly or to correct the performance of services, without expense to the District, and immediately replace all such rejected items with others conforming to the Contract. All work shall be done and completed in a thorough, workmanlike manner, notwithstanding any omission from these specifications or the drawings, and it shall be the duty of the Contractor to call attention to apparent errors or omissions and request instructions before proceeding with the work. The Project Manager may, by appropriate instructions, correct errors and supply omissions, which instructions shall be binding upon the Contractor as though contained in the original Contract Documents.

b. All materials furnished and all Work must be satisfactory to the Project Manager. Work, material, or machinery not in accordance with the Contract Documents, in the opinion of the Project Manager, shall be made to conform.

6. DEFECTIVE WORK The Contractor shall replace at its own expense any part of the work that has been improperly executed, as determined by the Project Manager. If Contractor refuses or neglects to replace such defective work, it may be replaced by the District at the expense of the Contractor, and its sureties shall be liable therefor.

7. WARRANTY OF TITLE Contractor shall warrant to the District, its successors and assigns, that the title to the materials, supplies or equipment covered by the Contract, when delivered to the District or to its successors or assigns, is free from all liens and encumbrances.

REV. 3/15 GR-4

8. WARRANTY OF FITNESS Contractor hereby warrants that all materials furnished shall meet the requirements and conditions of the Contract Documents; shall be fit for the purposes intended and fulfill its design functions; be free of all patent and latent defects in design, materials and workmanship; and perform satisfactorily. It is understood and agreed that by acceptance of this warranty and the acceptance of the materials or supplies to be manufactured or assembled pursuant to these specifications, the District does not waive any warranty either expressed or implied in Sections 2312 to 2317, inclusive, of the Commercial Code of the State of California or any products liability of the Contractor as determined by any applicable decision of a court of the State of California or of the United States.

9. SAFETY AND ACCIDENT PREVENTION In performing work under the Contract on District premises, Contractor shall conform to any specific safety requirements contained in the Contract or as required by law or regulation. Contractor shall take any additional precautions as the District may reasonably require for safety and accident prevention purposes. Any violation of such rules and requirements, unless promptly corrected, shall be grounds for termination of this Contract or Contractor’s right to precede in accordance with the default provisions of the Contract Documents.

10. CHARACTER OF WORKFORCE The Contractor shall employ none but skilled competent qualified personnel to perform the Work, and shall maintain discipline and order in the conduct of the Work at all times.

11. PREVAILING WAGES & DIR REGISTRATION a. Please see www.dir.ca.gov for further information regarding the below.

b. All Contractors and Subcontractors of any tier bidding on, or offering to performing

work on a public works project shall first be registered with the State Department of Industrial Relations (DIR) pursuant to Section 1725.5 of the Labor Code. No bid will be accepted nor any contract entered into without proof of the Contractor and Subcontractors’ current registration with the DIR (LC § 1771.1).

c. All public works projects awarded after January 1, 2015, are subject to compliance monitoring and enforcement by the DIR (LC § 1771.4) and all Contractors are required post job site notices, “as prescribed by regulation” (LC § 1771.4).

d. To the extent applicable, pursuant to Section 1773 of the Labor Code, the District has obtained from the Director of Industrial Relations of the State of California, the general prevailing rates of per diem wages and the general prevailing rates for holiday and overtime work in the locality in which the Work is to be performed, for each craft, classification, or type of worker needed to execute the contract. Pursuant to Section 1773.2 of the Labor Code, a copy of the prevailing wage rates is on file with the District and available for inspection by any interested party at www.dir.ca.gov.

e. The holidays upon which such rates shall be paid shall be all holidays recognized in the collective bargaining agreement applicable to the particular craft, classification, or type

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of worker employed on the Work.

f. The Contractor shall post a copy of the general prevailing rate of per diem wages at the jobsite pursuant to Section 1773.2 of the Labor Code.

g. Pursuant to Section 1774 of the Labor Code, the Contractor and any of its Subcontractors shall not pay less than the specified prevailing rate of wages to all workers employed in the execution of the contract.

h. As set forth with more specificity in Section 1773.1 of the Labor Code, "per diem" wages include employer payments for health and welfare, pension, vacation, travel, subsistence and, in certain instances, apprenticeship or other training programs, and shall be paid at the rate and in the amount spelled out in the pertinent prevailing wage determinations issued by the Director of Industrial Relations.

i. The Contractor shall, as a penalty to the State or the District, forfeit not more than the maximum set forth in Section 1775 of the Labor Code for each calendar day, or portion thereof, for each worker paid less than the prevailing rates for the work or craft in which the worker is employed under the contract by the Contractor or by any Subcontractor under him. The difference between the prevailing wage rates and the amount paid to each worker for each calendar day or portion thereof for which such worker was paid less than the stipulated prevailing wage rate shall be paid to such worker by the Contractor.

j. The specified wage rates are minimum rates only and the District will not consider and shall not be liable for any claims for additional compensation made by the Contractor because of its payment of any wage rate in excess of the general prevailing rates. All disputes in regard to the payment of wages in excess of those specified herein shall be adjusted by the Contractor at its own expense.

k. General prevailing wage determinations have expiration dates with either a single asterisk or a double asterisk. Pursuant to California Code of Regulations, Title 8, Section 16204, the single asterisk means that the general prevailing wage determination shall be in effect for the specified contract duration. The double asterisk means that the predetermined wage modification shall be paid after the expiration date. No adjustment in the Contract Sum will be made for the Contractor’s payment of these predetermined wage modifications.

12. PAYROLL RECORDS & ELECTRONIC SUBMISSION a. The Contractor and each Subcontractor shall keep an accurate payroll record, showing

the name, address, social security number, work classification, straight time and overtime hours worked each day and week, and the actual per diem wages paid to each journeyman, apprentice, worker or other employee employed in connection with the Work. The payroll records shall be certified and shall be available for inspection in accordance with the provisions of Section 1776 of the Labor Code. Certified payroll records shall be on the forms provided by the DIR or contain the same information required on the Department’s form.

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b. The Contractor shall submit for each week in which any contract Work is performed a copy of all payroll records to the Engineer. The Contractor shall be responsible for submission of copies of payroll records of all Subcontractors.

c. The Contractor or Subcontractor shall certify the payroll records as shown on the DIR form. In addition, the records shall be accompanied by a statement signed by the Contractor or Subcontractor certifying that the classifications truly reflect the Work performed and that the wage rates are not less than those required to be paid.

d. For public works projects awarded on or after April 1, 2015, or that are still ongoing after April 1, 2016, no matter when awarded, each Contractor and Subcontractor shall furnish the certified payroll related records as more specifically described above and in Labor Code section 1776 directly to the Labor Commissioner (see LC § 1771.4). These records shall be provided to the Labor Commissioner at least monthly or more frequently if required by the terms of the Contract. For exception on projects covered by collective bargaining agreements like a PLA, please see Labor Code section 1771.4.

e. In the event of noncompliance with the requirements of Section 1776 of the Labor Code, the Contractor shall have 10 days in which to comply subsequent to receipt of written notice specifying in what respects such Contractor must comply with said Section. Should noncompliance still be evident after such 10-day period, the Contractor shall, as a penalty to the State or the District, forfeit the amount set forth in Section 1776 of the Labor Code for each calendar day, or portion thereof, for each worker, until strict compliance is effectuated. Upon the request of the Division of Apprenticeship Standards or the Division of Labor Standards Enforcement, such penalties shall be withheld from progress payments then due.

f. The Contractor and every Subcontractor shall post at the workplace and comply with all required wage related workplace postings. Copies of the required postings may be downloaded or ordered electronically from the Department of Industrial Relations website at http://www.dir.ca.gov/wpnodb.html.

13. HOURS OF LABOR Pursuant to the provisions of Sections 1810, et seq. of the Labor Code and any amendments thereof: a. Eight hours of labor constitutes a legal day's Work under the contract.

b. The time of service of any worker employed upon the work shall be limited and

restricted to eight hours during any one calendar day, and forty hours during any one calendar week except as provided in Article 13.iv below.

c. The Contractor shall, as a penalty to the State or the District, forfeit the amount set forth in Section 1813 of the Labor Code for each worker employed in the execution of the contract by the Contractor or by any Subcontractor for each calendar day during which such worker is required or permitted to work more than eight hours in any calendar day and forty hours in any one calendar week in violation of this Article and the provisions of Labor Code, Sections 1810, et seq.

d. Work performed by employees of the Contractor in excess of eight hours per day, and forty hours during any one calendar week, shall be permitted upon compensation for all

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hours worked in excess of eight hours per day at not less than one and one-half times the basic rate of pay.

e. The Contractor and every Subcontractor shall keep an accurate record showing the name of and the actual hours worked each calendar day and each calendar week by each worker employed by him in connection with the Work; the record shall be kept open at all reasonable hours to the inspection of the District and to the Division of Labor Standards Enforcement of the State of California.

14. EMPLOYMENT OF APPRENTICES a. In the performance of the contract, the Contractor and any Subcontractor shall comply

with the provisions concerning the employment of apprentices in Section 1777.5 of the Labor Code and any amendments thereof.

b. In the event the Contractor or any Subcontractor willfully fails to comply with the aforesaid section, such Contractor or Subcontractor shall be subject to the penalties for noncompliance in Labor Code, Section 1777.7.

15. CHANGES a. Changes in the Work can only be made in writing signed by an authorized employee of

the District. If the change causes an increase or decrease in the contract sum, or a change in the time for performance under the Contract, an adjustment may be made as determined by the Project Manager.

b. The District reserves the right to make changes in the design of materials, equipment, or machinery, to make alterations or additions to or deviations or subtractions from the Contract and any specifications and drawings, to increase or decrease the required quantity of any item or portion of the Work or to omit any item or portion of the Work, as may be deemed by the Project Manager to be necessary or advisable and to order such extra work as may be determined by the Project Manager to be required for the proper execution and completion of the whole Work contemplated. Any such changes will be ordered in writing by the Project Manager. The determination of the Project Manager on all questions relating to changes, including extra work, shall be conclusive and binding.

c. Prior to issuing an amendment or change to the Contract, the Project Manager may request that the Contractor submit a proposal covering the changes. Within 10 business days of receiving the request, the Contractor shall submit its proposal to the Project Manager of all costs associated with the proposed amendment or change and any request for an extension of Contract time. Contractor’s proposal shall include detailed estimates with cost breakdowns, including labor, material, equipment, overhead, and profit. Labor shall be broken down into hours and rate per hour. If applicable, the proposal shall include a breakdown for off-site labor (including factory labor, engineering, etc.). The Contractor’s proposal shall include an analysis of schedule impact when the Contractor is requesting an adjustment in contract time. The Contractor shall be responsible for any delay associated with its failure to submit its change proposal within the time specified. If the Project Manager decides not to issue an amendment or change after requesting a proposal from the Contractor, the Contractor will be notified in writing. The Contractor is not entitled to reimbursement for Change Order

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preparation costs if the Contractor’s proposal is not accepted by the Project Manager.

d. If the Contractor agrees with the terms and conditions of the approved Change Order, the Contractor shall indicate its acceptance by signing the original copy and returning it to the Project Manager within 10 Work Days after receipt or with reasonable promptness and in such sequence as to not delay the Work or activities of the District or of separate contractors, whichever is sooner. If notice of any change is required to be given to a surety by the provisions of any bond, the Contractor shall provide notice and the amount of each applicable bond shall be adjusted separately. Payment in accordance with the terms and conditions set forth in the executed Change Order shall constitute full compensation for all Work included in the Change Order and the District will be released from any and all claims for direct, indirect, and impact expenses and additional time impact resulting from the Work. If the Contractor disagrees with the terms and conditions of the approved Change Order, the Contractor shall indicate specific areas of disagreement and return the approved Change Order to the Project Manager with a detailed written dispute. No payment will be made on the disputed work until the approved Change Order is returned to the Project Manager. However, whether or not the Contractor agrees with the terms and conditions of an approved Change Order, the Contractor shall immediately revise its sequence of operations as required to facilitate timely completion of the changed work and shall proceed with the revised work sequence.

e. The Project Manager may, after having received a written cost quotation from the Contractor, order the Contractor, in writing, to proceed with the work prior to issuance of an approved Change Order through a change directive. The change directive will authorize the Contractor to proceed with the work subject to the cost quotation submitted by the Contractor. Within five days following receipt of the change directive, the Contractor shall submit a detailed change proposal documenting the amount of compensation. The Project Manager will review the change proposal and, at its option, will either issue an approved Change Order for the work or direct the Contractor to perform the work through Force Account. Until the method of compensation is determined and the approved Change Order is received, the Contractor shall keep full and complete time and material records of the cost of the ordered work and shall permit the Project Manager to have access to such records. An approved Change Order shall supersede any previously issued written change directive covering the same Work.

16. EFFECT OF EXTENSIONS OF TIME The granting, or acceptance, of extensions of time to complete the Work or furnish the labor, supplies, materials or equipment, or any one of the aforementioned, will not operate as a release of Contractor or the surety on Contractor’s faithful performance bond.

17. DELAYS a. The Contractor shall take reasonable precautions to foresee and prevent delays to the

Work. When the Contractor foresees a delay event, and upon the occurrence of a delay event, the Contractor shall immediately notify the Project Manager of the probability or the actual occurrence of a delay, and its cause. With respect to all delays (compensable, excusable or inexcusable), the Contractor shall reschedule the Work and revise its operations, to the extent possible, to mitigate the effects of the delay. Within 15 days from the beginning of a delay the Contractor shall provide the Project Manager with a

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detailed written description of the delay, its cause, its impact and the Contractor’s mitigation plans. Failure to provide the notification required above waives the Contractor’s right to any additional time or compensation resulting from the delay for whatever cause. The Project Manager will investigate the facts and ascertain the extent of the delay, and the Project Manager’s findings thereon shall be final and conclusive, except in the case of gross error. An extension of time must be approved by the Project Manager to be effective, but an extension of time, whether with or without consent of the sureties, shall not release the sureties from their obligations, which shall remain in full force until the discharge of the contract.

b. For inexcusable delays (delays caused by circumstances with in the Contractor’s control, the control of its subcontractors or supplies of any tier, or within the scope of the Contractor’s contract responsibilities) the Contractor shall not be entitled to an extension of time or additional compensation for any loss, cost, damage, expense or liability resulting directly or indirectly from the inexcusable delay.

c. For excusable delays (delays to completion of the Work within the time limits set forth in the Contract Documents directly caused by events beyond the control of both the Contractor and the District, which delay is not concurrent with an inexcusable delay and which could not have been avoided by the Contractor through reasonable mitigation measures).

d. For compensable delays (delays to completion of the Work within the time limits set forth in the Contract Documents that could not be avoided by Contractor mitigation, caused directly and solely by the District or by causes within the exclusive control of the District, and which were not concurrent with any other type of delay) the Project Manager will grant the Contractor an extension of the time to perform under the Contract and compensation in an amount that represents the Contractor’s actual direct costs incurred as a direct result of the compensable delay. The Contractor may recover its direct costs only and may not recover (and waives) all other types of indirect, consequential, special and incidental damages.

e. For concurrent delays (two or more independent causes of delay directly preventing the Contractor from completing the Work within the time limits set forth in the Contract Documents where the delays occur at the same time during all or a portion of the delay period being considered, and where each of the delays would have caused delay to the Contractor even in the absence of any of the other delays, and none of the delays could have been avoided by Contractor mitigations) the following rules apply: i. One or more of the concurrent delays are excusable or compensable, then the

period of concurrent delay will be treated as an excusable delay; and

ii. All of the concurrent delays are inexcusable, then the period of concurrent delay will be inexcusable.

18. TERMINATION a. Termination by the District for Cause:

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i. District may terminate the Contractor’s right to proceed under the Contract, in whole or in part, for cause at any time after the occurrence of any of the following events, each of which constitutes a default: 1. The Contractor becomes insolvent or files for relief under the

bankruptcy laws of the United States.

2. The Contractor makes a general assignment for the benefit of its creditors or fails to pay its debts as the same become due.

3. A receiver is appointed to take charge of the Contractor's property.

4. The Contractor fails to supply skilled supervisory personnel, an adequate number of properly skilled workers, proper materials, or necessary equipment to prosecute the Work in accordance with the Contract Documents.

5. The Contractor fails to make progress so as to endanger performance of the Work within the contractually required time.

6. The Contractor disregards legal requirements of agencies having jurisdiction over the Work, the Contractor, or the District.

7. The Contractor fails to provide the District with a written plan to cure a District identified default within five business days after the District’s request for a plan to cure; the District does not accept the Contractor’s plan for curing its default;, or the Contractor does not fully carry out an accepted plan to cure.

8. The Contractor abandons the Work. Abandonment is conclusively presumed when the District requests a written plan to cure a default and the Contractor does not submit the plan within five business days of the District’s request.

9. The Contractor materially fails to meet its obligations in accordance with the Contract Documents.

10. The Contractor is in default of any other material obligation under the Contract Documents.

ii. If any of the above events occur, the District may, in its discretion, require that the Contractor submit a written plan to cure its default, which plan must be provided to the District within 5 business days of the request and must include a realistic, executable plan for curing the noted defaults.

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iii. Upon any of the occurrences referred to in Article 18.a.i. above, the District may, at its election and by notice to the Contractor, terminate the Contract in whole or in part; accept the assignment of any or all of the subcontracts; and then complete the Work by any method the District may deem expedient. If requested by the District, the Contractor shall remove any part or all of the Contractor's materials, supplies, equipment, tools, and machinery from the site of the Work within seven days of such request; and, if the Contractor fails to do so, the District may remove or store, and after 90 days sell, any of the same at the Contractor's expense.

iv. No termination or action taken by the District after termination shall prejudice any other rights or remedies of the District provided by law or by the Contract Documents.

v. Conversion: If, after termination for other than convenience, it is determined that the Contractor was not in default or material breach, or that the default or material breach was excusable, the rights and obligations of the parties shall be the same as if the termination had been issued for convenience pursuant to Article 18.b. below.

b. Termination by the District for Convenience:

i. The District may, at its option, and for its convenience, terminate the

Contract at any time by giving written notice to the Contractor specifying the effective date of termination. Upon such termination, the Contractor agrees to comply with the notice and further agrees to waive any claims for damages, including loss of anticipated profits, on account of the termination; and, as the sole right and remedy of the Contractor, the District shall pay the Contractor as set forth below.

ii. Upon receipt of a notice of termination for convenience, the Contractor shall, unless the notice directs otherwise, do the following: 1. Immediately discontinue its performance of the Contract to the

extent specified in the notice.

2. Place no further orders or subcontracts for materials, equipment, services, or facilities, except as may be necessary for completion of a portion of the Work that is not discontinued or that is necessary for an orderly cessation of the Work.

3. Promptly cancel, on the most favorable terms reasonably possible, all subcontracts to the extent they relate to the performance of the discontinued portion of the Work.

4. Thereafter, do only such Work as may be necessary to preserve and protect Work already in progress and to protect materials,

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plants, and equipment in transit to or on the site of performance.

iii. Upon such termination for convenience, the District will pay to the Contractor the sum of the following: 1. The amount of the contract sum allocable to the portion of the

Work properly performed by the Contractor as of the effective date of termination, less sums previously paid to the Contractor.

2. Previously unpaid costs of any items delivered to the project site that were already fabricated for subsequent incorporation into the Work.

3. Any proven losses with respect to materials and equipment directly resulting from the termination.

4. Reasonable demobilization costs.

iv. The above reimbursement is the sole and exclusive remedy to which the Contractor is entitled in the event the contract is terminated for convenience; and the Contractor expressly waives any other claims, damages, demands, compensation or recovery related to this contract or project. The Contractor agrees to sign a general release incorporating this waiver.

c. Effect of Termination: Upon termination, the obligations of the Contract shall continue as to portions of the Work already performed and, subject to the Contractor's obligations under Article 18.b.ii, as to bona fide obligations assumed by the Contractor prior to the date of termination.

d. Force Majeure: If the contract is suspended or terminated by the District because Contractor’s performance is prevented or delayed by an event including an irresistible, superhuman cause, or by the act of public enemies of the State of California or of the United States (“Force Majeure”) , the Contractor will be paid for Work performed prior to the Force Majeure event at either (i) the unit prices named in the Contract; or (ii) in the event no unit prices are named, a sum equal to the percentage of the total contract amount that matches the percentage of the total contract Work performed prior to the Force Majeure event.

19. DAMAGES

All losses or damages to material or equipment to be furnished pursuant to the Contract Documents occurring prior to receipt and final acceptance of the Work shall be sustained by the Contractor. The Contractor shall sustain all losses arising from unforeseen obstructions or difficulties, either natural or artificial, encountered in the prosecution of the Work, or from any action of the elements prior to final acceptance of the work, or from an act or omission on the part of the Contractor not authorized by the Contract Documents.

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20. ORDER OF PRECEDENCE a. In the case of conflicts, errors, or discrepancies in any of the Contract Documents, the

order of precedence is as follows. Within the same order of precedence, specific requirements shall take precedence over general requirements. i. Approved Change Orders.

ii. Addenda.

iii. RFQ or RFP.

iv. Referenced Standard Specifications and Drawings.

v. Contractor’s Response Packet

b. With reference to drawings:

i. Numerical dimensions govern over scaled dimensions.

ii. Detailed drawings govern over general drawings.

iii. Addenda/Change Order drawings govern over contract drawings.

iv. Contract drawings govern over standard drawings.

v. Notes apply only to the drawing where the notes appear, unless classified as

“typical” or intended to apply elsewhere in which case they apply to all drawings where the conditions or circumstance noted occurs.

vi. Typical details apply to all drawings unless a specific different detail is shown

21. INDEMNIFICATION/RESPONSIBILITY a. Contractor shall indemnify, keep and save harmless the District and each of its directors,

officers, agents and employees against any and all suits, claims or actions arising out of any of the following: i. Any injury to persons or property that may occur, or that may be alleged to have

occurred, arising from the performance or implementation of this Contract; or ii. Any allegation that materials or services developed, provided or used for this Contract

infringe or violate any copyright, trademark, patent, trade secret, or any other intellectual-property or proprietary right of any third party.

b. Contractor further agrees to defend any and all such actions, suits or claims and pay all charges of attorneys and all other costs and expenses of defenses as they are incurred. If any judgment is rendered, or settlement reached, against the District or any of the other agencies or individuals enumerated above in any such action, Contractor shall, at its expense, satisfy and discharge the same.

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c. This indemnification shall survive termination or expiration of the Contract.

22. PROHIBITION OF ASSIGNMENT The Contractor shall not assign, transfer, or otherwise dispose of any of its rights, duties or obligations under this Contract.

23. NEWS RELEASES The Contractor, its employees, subcontractors, and agents shall not refer to the District, or use any logos, images, or photographs of the District for any commercial purpose, including, but not limited to, advertising, promotion, or public relations, without the District's prior written consent. Such written consent shall not be required for the inclusion of the District's name on a customer list.

24. TRANSFER OF INTEREST Contractor shall not assign, transfer or otherwise substitute its interest in the Contract or any of the contract obligations without prior written consent from the District.

25. SEVERABILITY Should any part of the Contract be declared by a final decision by a court or tribunal of competent jurisdiction to be unconstitutional, invalid or beyond the authority of either party to enter into or carry out, such decision shall not affect the validity of the remainder of the Contract, which shall continue in full force and effect, provided that the remainder of the Contract can be interpreted to give effect to the intentions of the parties.

26. COVENANT AGAINST GRATUITIES The Contractor warrants that no gratuities (in the form of entertainment, gifts, or otherwise) were offered or given by the Contractor, or any agent or representative of the Contractor, to any officer or employee of the District with a view toward securing the Contract or securing favorable treatment with respect to any determinations concerning the performance of the Contract. For breach or violation of this warranty, the District shall have the right to terminate the Contract, either in whole or in part, and any loss or damage sustained by the District in procuring on the open market any items which Contractor agreed to supply shall be borne and paid for by the Contractor. The rights and remedies of the District provided in this clause shall not be exclusive and are in addition to any other rights and remedies provided by law or in equity.

27. RIGHTS AND REMEDIES OF THE DISTRICT The rights and remedies of the District provided herein shall not be exclusive and are in addition to any other rights and remedies provided by law or under the Contract.

28. WAIVER OF RIGHTS Any action or inaction by the District or the failure of the District on any occasion, to enforce any right or provision of the Contract, shall not be construed to be a waiver by the District of its rights and shall not prevent the District from enforcing such provision or right on any future

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occasion. Rights and remedies are cumulative and are in addition to any other rights or remedies that the District may have at law or in equity.

29. CONFIDENTIALITY Contractor agrees to maintain in confidence and not disclose to any person or entity, without the District's prior written consent, any trade secret or confidential information, knowledge or data relating to the products, process, or operation of the District. Contractor further agrees to maintain in confidence and not to disclose to any person or entity, any data, information, technology, or material developed or obtained by Contractor during the term of the Contract. The covenants contained in this paragraph shall survive the termination of this Contract for whatever cause.

03/01/2016 Exhibit C - RFQ No. 1618

SUPPLEMENTARY GENERAL REQUIREMENTS The following supplements shall modify, delete, and/or add to the General Requirements. Where any article, paragraph, or subparagraph in the General Requirements is supplemented by one of the following paragraphs, the provisions of such article, paragraph, or subparagraph shall remain in effect and the supplemental provisions shall be considered as added thereto. Where any article, paragraph, or subparagraph in the General Requirements is amended, voided, or superseded by any of the following paragraphs, the provisions of such article, paragraph, or subparagraph not so amended, voided, or superseded shall remain in effect.

1. Add the following to Section 1 - DEFINITIONS M. "Contract Completion", means the Work has been fully completed in accordance with the Contract Documents as determined by the Engineer and all governmental authorities with jurisdictions over the project have issued acceptance or a certificate of occupancy.

N. "Engineer", as defined in Article 5 of the Supplier Agreement.

2. Modify Section 17 – DELAYS

Subsection 17.c shall read: "…… which could not have been avoided through reasonable mitigation measures), the Project Manager will grant the Contractor an extension of time to perform under the Contract."

3. Modify Section 18 - TERMINATION

The first sentence of Subsection 18.b.iii shall read: "……. less sums previously paid to the Contractor, and less the market value of work that could be recouped by the Supplier at the time of termination."

4. Modify Section 20 - ORDER OF PRECEDENCE, as follows:

The order of precedence under Subsection 20.a. shall read: "i. Approved Change Orders ii. Supplier Agreement iii. Addenda iv. RFQ v. Referenced Standard Specifications and Drawings vi. Contractor's Response Packet"

5. Modify Section 21 - INDEMNIFICATION/RESPONSIBILITY

Subsection a shall read: "Contractor shall indemnify, keep and save harmless the District, Engineer, and each of its ……."

END OF DOCUMENT

RFQ No. 1618

EXHIBIT D - OZONE EQUIPMENT SUPPLY AGREEMENT (SUPPLIER AGREEMENT)

OZONE SYSTEM EQUIPMENT

SUPPLIER AGREEMENT FOR

EAST BAY MUNICIPAL UTILITIES DISTRICT SOBRANTE AND UPPER SAN LEANDRO WATER TREATMENT PLANTS

OZONE SYSTEMS EQUIPMEMT AND SERVICES This Supplier Agreement, made and entered into this ____ day of ______, 2016, by and between the EAST BAY MUNICIPAL UTILITY DISTRICT, a public entity hereinafter referred to as "DISTRICT," and _____________, a _________ _________, hereinafter referred to as "SUPPLIER."

WITNESSETH: WHEREAS, DISTRICT requires equipment and services to replace ozone systems at their Sobrante and Upper San Leandro Water Treatment Plants and Services; and WHEREAS, SUPPLIER has submitted a quotation for providing equipment and services under the guidance set forth in DISTRICT's Request for Quotation (RFQ) titled Sobrante and Upper San Leandro Water Treatment Plants Ozone Systems Equipment and Services; and, WHEREAS, SUPPLIER is capable of performing all of said work in a workmanlike manner and in compliance with DISTRICT specifications, and WHEREAS, DISTRICT Board of Directors has authorized the contract by Motion Number ____; and NOW, THEREFORE, it is mutually agreed by DISTRICT and SUPPLIER that for the considerations

hereinafter set forth, SUPPLIER shall provide said goods and services to DISTRICT, as set forth in

greater detail herein.

ARTICLE 1 - EFFECTIVE DATE

1.01 The effective date of this AGREEMENT shall be _____________________, 2016.

ARTICLE 2 - THE PROJECT

2.01 The Project shall mean the DISTRICT'S Sobrante and Upper San Leandro Water Treatment Plants Ozone Systems Improvements Project and all related activities.

ARTICLE 3 - GOODS AND SERVICES

3.01 SUPPLIER shall furnish the Goods and Services as specified or indicated in the Contract Documents, further defined in Article 21.

03/01/2016 Page 2 Exhibit D – RFQ No. 1618

A. Bid Item 1 in the Bid Form includes an allowance for Goods and Services generally described below.

1. Design support to ENGINEER, as defined in Article 5, during, and be actively involved in, development of the construction contract documents, including:

a. Participate in weekly progress calls with ENGINEER. b. Respond to ENGINEER's questions. c. Review and provide comments to construction bid documents prepared by

ENGINEER at 50, 90, and 100 percent completion levels. d. Attend up to four (4) design coordination meetings with ENGINEER and/or

DISTRICT during the design phase at the ENGINEER's office in Walnut Creek, CA or at DISTRICT office in Oakland, CA. Meetings will be up to 8 hours each and may require attendance by two or more of the Supplier's engineering and technician staff including electrical, instrumentation, and controls.

e. Furnish information for use by bidders for the construction contract, which shall include the following:

1) Final scope of supply with equipment data sheets.

2) Special shipping/handling information and requirements.

3) Special installation requirements.

4) Draft start-up plan and schedule.

5) Approved submittals.

6) Other requirements of the Contract Documents.

2. Prepare and submit all shop drawings as specified in the Technical Specifications.

3. Provide warrantees, bonds, and insurance in accordance with this Supplier Agreement.

4. If the cost of the Goods and Services in Section 3.01.A exceed the allowance amount shown in the Bid Form (Part A, Item 1), the SUPPLIER shall include the extra costs to provide these Goods and Services in Bid Form Part A, Item 2.

B. Delivery of the complete equipment packages in accordance with the Contract Documents, to the Sobrante and Upper San Leandro Water Treatment Plants sites in El Sobrante, California and Oakland, California, respectively.

C. Prepare and submit operation and maintenance manuals as specified in the Technical Specifications.

D. Coordinate with DISTRICT, CONTRACTOR and ENGINEER prior to and during construction, including the following:

1. Attend the Preconstruction meeting at the Project site. 2. Attend weekly conference calls with the ENGINEER, DISTRICT, and

CONTRACTOR. 3. Conduct site visits, inspections, and other construction-related activities in

accordance with the Technical Specifications.


E. Perform all equipment testing specified in the Technical Specifications.

F. Provide start-up, training, and other commissioning services in accordance with the Technical Specifications. .

3.02 Assignment of Agreement: This Supplier Agreement will be assigned to a Construction Contractor (CONTRACTOR) following award of the construction contract as defined in the Assignment Agreement, subject to the following terms and conditions:

A. CONTRACTOR shall provide DISTRICT with a Faithful Performance Bond and a Payment Bond in the full amount of the general contract, including SUPPLIER’s Base Bid Cost amount;

B. Supplier Agreement shall be assigned ‘as is’, with no new or additional terms and conditions being imposed upon SUPPLIER by the CONTRACTOR;

C. SUPPLIER reserves the right, at its sole discretion, to revise the payment terms in Supplier Agreement if CONTRACTOR’s credit status is not to SUPPLIER’s satisfaction;

D. SUPPLIER’s sale of goods and services to CONTRACTOR is tax exempt, and DISTRICT has paid all applicable taxes. CONTRACTOR shall not be responsible for any applicable taxes arising out of the assignment of the Supplier Agreement;

E. CONTRACTOR shall not have the right to re-assign the Supplier Agreement, other than to re-assign it back to DISTRICT, without SUPPLIER’s prior written approval, such approval may be withheld at SUPPLIER’s sole discretion;

F. SUPPLIER shall deliver the fully executed Assignment Agreement with CONTRACTOR to DISTRICT within fifteen (15) calendar days after receipt of notice from DISTRICT that DISTRICT has awarded a contract for Construction with CONTRACTOR.

G. Without limiting the foregoing, the following obligations of SUPPLIER to DISTRICT as set forth in the Supplier Agreement shall survive and remain in full force and effect following the assignment:

1. ARTICLE 4 – WARRANTEES AND GUARANTEES; 2. ARTICLE 6 – COPYRIGHTS; 3. ARTICLE 8 – INDEMNIFICATION; 4. ARTICLE 11 – INSURANCE. DISTRICT shall be named as an additional insured as

required by the AGREEMENT. 5. ARTICLE 12 - TERMINATION AND SUSPENSION, Sections 12.01 and 12.02

shall be exempt from the assignment and shall inure solely to the benefit of the DISTRICT.

6. ARTICLE 17 – CONTRACT TIMES, 17.03 Liquidated Damages. 7. ARTICLE 18 – LIQUIDATED DAMAGES FOR FAILURE OF PERFORMANCE.

3.03 Unless the Project is suspended or terminated by DISTRICT, at its sole discretion, DISTRICT agrees that all Good and Services will be purchased from SUPPLIER, provided that SUPPLIER performs all Goods and Services to the reasonable satisfaction of DISTRICT and ENGINEER.


The timing of any authorization to proceed with the execution of this Supplier Agreement shall be at the sole discretion of DISTRICT.

A. Prices for Goods and Services shall include any anticipated escalation of costs due to inflation, costs of raw materials, or any other cause for escalation, assuming the Contract Times remain as stated in Article 17.02 herein.

B. If DISTRICT extends the Contract Times, SUPPLIER shall submit a written request to DISTRICT for a price adjustment. The request for an adjustment shall be made on the basis of a comparison to changes in the Producer Price Index (“PPI”) Series Title: PPI- All Commodities: 1982-100 NSA (available at www.bls.gov) and supported by other documentation as required. DISTRICT will evaluate this information to determine if an adjustment to the pricing is fair and reasonable, and to the satisfaction of DISTRICT.

C. The parties hereto recognize that such change will only be evaluated if the PPI has increased following a change in the Contract Times. The parties recognize that if the PPI has decreased at that time, that there will be not changes in the contract price.

D. SUPPLIER shall note that the PPI will remain the basis for all cost adjustment requests. There are no provisions for adjustments due to changes in foreign exchange rates.

ARTICLE 4 - WARRANTEES AND GUARANTEES

4.01 SUPPLIER agrees that upon completion, installation, and acceptance of the ozone equipment, as defined in the CONTRACTOR's contract with DISTRICT, all rights, benefits, warranties, guarantees, and other ongoing obligations of SUPPLIER shall immediately be conveyed to and enforceable by DISTRICT.

4.02 SUPPLIER agrees, at DISTRICT's request, to provide documentation to demonstrate to the satisfaction of DISTRICT that the warrantor of the ozone equipment is financially capable to provide all warrantees and guarantees called for by the Contract Documents.

4.03 DISTRICT shall have the right to participate in and witness any and all tests, inspections, and approvals of the Goods and Services permitted or required by agreements, and as part of the Contract Documents.

4.04 FIELD PERFORMANCE TESTING - Operating equipment and systems will be performance tested at multiple times by the SUPPLIER as specified in the Technical Specifications, in cooperation with the CONTRACTOR, in the presence of ENGINEER, to demonstrate compliance with the Contract Documents. Penalties for failure to meet performance objections are described in the Technical Specifications.

4.05 WARRANTEES

A. SUPPLIER shall provide a bonded warranty for all equipment provided by SUPPLIER in the Contract Documents as follows:

1. SUPPLIER expressly warrants that all goods and services to be furnished shall conform to the descriptions and specifications contained herein and in supplier catalogs, product brochures and other representations, depictions or models, and will be free from defects, of merchantable quality, good material, and workmanship.


2. SUPPLIER expressly warrants that all goods and services to be furnished shall be fit and sufficient for the purpose(s) intended. This warranty shall survive any inspections, delivery, acceptance, payment, or contract termination for any reason, by DISTRICT.

3. Unless otherwise specified, SUPPLIER warrants that all work and services furnished hereunder shall be guaranteed for a period of five (5) years from the date of acceptance by DISTRICT.

B. SUPPLIER shall provide the following warranty for Ozone Generator Dielectrics. The bonded warranty in 4.05.A shall be in effect for the specified warranty period.

1. SUPPLIER shall warrant the dielectrics and fuses, if applicable, of the ozone generators against excessive failure or breakage for a total period of ten (10) years after acceptance by DISTRICT inclusive of the period specified in 4.05.A:

a. Excessive dielectric and fuse failure or breakage shall be defined as more than one percent (1%) failure or breakage in any ozone generator in any year of the 5-year warranty period.

b. SUPPLIER shall furnish and install any failed or broken dielectrics and fuses over and above the warranty failure rates.

c. New dielectrics and fuses required under this paragraph shall be provided and installed by SUPPLIER within 21 calendar days of notification by DISTRICT.

d. SUPPLIER shall furnish all gaskets, seals, nuts, bolts, tools, and other materials as required opening and resealing the generators.

ARTICLE 5 - ENGINEER

5.01 The Contract Documents for the Goods and Services have been prepared by Carollo Engineers, Inc. (ENGINEER) and who is to assume all duties and responsibilities, and have the rights and authority assigned to ENGINEER in the Contract Documents.

ARTICLE 6 - COPY RIGHTS AND WORK PRODUCTS

6.01 All materials that SUPPLIER develops rendering Services hereunder, including any inventions or copyrightable work products, shall become the sole and exclusive property of DISTRICT without limitation at the time of their creation excluding any modification and improvement to SUPPLIER’s own proprietary intellectual property which shall remain the sole and exclusive property of the SUPPLIER. SUPPLIER shall deliver all such materials to DISTRICT at the completion, suspension, or termination of this AGREEMENT, unless otherwise directed by DISTRICT. SUPPLIER agrees to execute all documents and to take all steps that DISTRICT deems necessary or desirable to protect DISTRICT's ownership of and property rights in these materials and hereby assigns all such rights to the DISTRICT. Nothing in this AGREEMENT transfers any right, title, or interest in any proprietary, intellectual property of SUPPLIER to the DISTRICT, ENGINEER, or any other party.

ARTICLE 7 - CONTRACT PRICE AND PAYMENT PROCEDURES


7.01 DISTRICT shall pay SUPPLIER, in U.S. dollars, for furnishing the Goods and Services in accordance with the Contract Documents and as indicated in the Base Bid Form.

A. CONTRACT PRICE (to be completed after Bidder is selected)

BID ITEM LUMP SUM COST Part A - Capital Bid Items

1. Design Assistance, Shop Drawing Submittals, Bonds, Insurance, and Warranties, exclusive of items below. $150,000

2. Ozone Equipment, exclusive of items listed below and taxes. $ 3. Witness Factory Tests $ 4. F.O.B. Freight (to both WTP sites) $

5. Supervision of Installation, Testing, Training, and Commissioning $

6. Operation and Maintenance Manuals $ Part A Total Capital Bid Cost (Items 1-6) $ Part B Energy Present Worth Cost $ Part C Total Present Worth Cost (Part A + Part B) $

Part C Total Present Worth Cost in Words:

B. ENERGY CONSUMPTION (to be completed after Bidder is selected)

AVERAGE SPECIFIC ENERGY CONSUMPTION kWh/lb

Average Specific Energy Consumption in Number

Average Specific Energy Consumption in Words:

7.02 SUPPLIER shall submit Applications for Payment for Bid Item 1 in accordance with the DISTRICT standards. Applications for Payment will be processed by the DISTRICT within thirty (30) calendar days following receipt of a correct application.

7.03 Schedule of Payments. SUPPLIER shall be entitled to claim payments for Goods and Services in accordance with the following schedule:

A. Payment to SUPPLIER by District for Bid Item 1 will be as follows:

1. Twenty five percent (25%) upon receipt of all required bonds and insurance certificates.

2. Fifty percent (50%) upon receipt of final approved shop drawings. 3. The remaining twenty five percent (25%) upon receipt of all warranties and

completion of all design support services.


B. Bid Items 2 through 6 are anticipated to be paid by CONTRACTOR to SUPPLIER after the Assignment Agreement is executed. However, DISTRICT has the option of authorizing SUPPLIER to proceed with any portions of Bid Items 2 through 6 in advance of executing the Assignment Agreement. In this case, DISTRICT will pay SUPPLIER directly for the authorized work in accordance with the schedule below. CONTRACTOR will pay SUPPLIER the balance of remaining payments in accordance with the schedule below after the Assignment Agreement is executed.

1. Seventy Five percent (75%) of the sum of Bid Items 2, 3, and 4 upon completion of successful factory testing of equipment, delivery to sites and acceptance by DISTRICT;

2. Twenty percent (20%) of the sum of Bid Items 2,3, and 4 plus ninety five percent (95%) of Bid Item 5 upon successful installation and commissioning of all equipment;

3. Ninety five percent (95%) of Bid Item 6 upon receipt of all final approved Operation and Maintenance manuals;

4. Remaining five percent (5%) of the sum of Bid Items 2 through 6 upon successful completion of ozone system performance testing and all training.

C. District shall notify SUPPLIER of any invoice adjustments required.

ARTICLE 8 - INDEMNIFICATION.

8.01 SUPPLIER shall provide indemnity in accordance with Section 21 of the General Requirements.

ARTICLE 9 - INDEPENDENT CONTRACTOR

9.01 SUPPLIER undertakes performance of the Services as an independent contractor and shall be wholly responsible for the means and methods of its performance. ENGINEER shall be the general administrator and coordinator of SUPPLIER's Services and shall facilitate the exchange of information. DISTRICT and ENGINEER shall have the right to observe performance of the Services.

ARTICLE 10 - COMPLIANCE WITH LAWS

10.01 In performance of the Services, SUPPLIER shall comply with all applicable regulatory requirements including without limitation, federal, state, and local laws, rules, regulations, orders, codes, criteria, and standards. SUPPLIER shall procure the permits, certificates, and licenses necessary to allow SUPPLIER to perform the Services. SUPPLIER shall not be responsible for procuring permits, certificates, and licenses required for any construction unless such responsibilities are specifically assigned to SUPPLIER in the Contract Documents.

ARTICLE 11 - INSURANCE

11.01 SUPPLIER shall take out and maintain during the life of this Supplier Agreement all the insurance required in this section, and shall submit certificates for review and approval by the


DISTRICT. The certificates shall be on forms approved by DISTRICT (refer to Exhibit B of RFQ for examples). Acceptance of the certificates shall not relieve SUPPLIER of any of the insurance requirements, nor decrease the liability of SUPPLIER. DISTRICT reserves the right to require SUPPLIER to provide insurance policies for review by DISTRICT.

A. Workers Compensation Insurance

1. SUPPLIER shall take out and maintain during the life of the Agreement Workers Compensation Insurance for all of its employees on the project. In lieu of evidence of Workers Compensation Insurance, the DISTRICT will accept a Self-Insured Certificate from the State of California. SUPPLIER shall require any subcontractor to provide it with evidence of Workers Compensation Insurance.

B. Commercial General Liability and Auto Liability Insurance

1. SUPPLIER shall take out and maintain during the life of the Agreement Automobile, General Liability, and Excess Liability Insurance that provides protection from claims which may arise from operations or performance under this Agreement. The amounts of insurance shall be not less than the following:

a. $2,000,000 for the Commercial General Liability policy.

b. $2,000,000 for the Auto Liability policy.

c. $4,000,000 for Excess Liability policy.

C. The following coverages or endorsements must be included in the policy(ies):

1. The ENGINEER its Directors, officers, and employees are Additional Insureds in the policy(ies) as to the work being performed under the contract.

2. The DISTRICT, its Directors, officers, and employees are Additional Insureds in the policy(ies) as to the work being performed under the contract.

3. The coverage is Primary and non-contributory to any other applicable insurance carried by DISTRICT.

4. The policy(ies) covers contractual liability. 5. The policy(ies) is written on an occurrence basis. 6. The policy(ies) covers the District’s Property in SUPPLIER’s care, custody, and

control. 7. The policy(ies) covers personal injury (libel, slander, and wrongful entry and

eviction) liability. 8. The policy(ies) covers explosion, collapse, and underground hazards. 9. The policy(ies) covers products and completed operations. 10. The policy(ies) covers the use of owned, non-owned and hired automobiles. 11. The policy(ies) and/or a separate pollution liability policy(ies) shall cover pollution

liability for claims related to the release or the threatened release of pollutants into the environment arising out of or resulting from SUPPLIER’s performance under this agreement.


12. The policy(ies) shall not be canceled nor the above coverages/endorsements reduced without 30 days written notice to East Bay Municipal Utility District at the address above.

D. Workers’ Compensation and Employer’s Liability. Supplier shall procure and maintain for the duration of this Supplier Agreement Workers’ Compensation for all its employees on the project. In lieu of evidence of Worker's Compensation Insurance, the DISTRICT will accept a Self-Insuring Certificate from the State of California.

ARTICLE 12 - TERMINATION AND SUSPENSION

12.01 This Agreement may be terminated for convenience or cause by DISTRICT in accordance with Section 18 of the General Requirements.

ARTICLE 13 - NONDISCLOSURE OF CONFIDENTIAL INFORMATION

13.01 Confidentiality shall be maintained by SUPPLIER in accordance with Section 29 of the General Requirements.

ARTICLE 14 - GOVERNING LAW

14.01 This Supplier Agreement shall be governed by the laws of the State of California, U.S.A. without giving effect to the principles thereof relating to conflicts of law,

ARTICLE 15 - ASSIGNMENTS/SUBCONTRACTS

15.01 SUPPLIER shall not assign or subcontract any rights or duties under this Supplier Agreement without the prior written consent of DISTRICT. Any such purported assignment or subcontract without DISTRICT's prior written consent shall be null and void. Unless otherwise stated in the written consent to an assignment, no assignment will release or discharge the SUPPLIER from any obligation under this Supplier Agreement.

ARTICLE 16 - THIRD PARTY RIGHTS

16.01 Nothing in this Supplier Agreement shall be construed to give any rights or benefits to anyone other than DISTRICT, ENGINEER, and SUPPLIER.

ARTICLE 17 - CONTRACT TIMES

17.01 Term:

A. The term of this Supplier Agreement, which may be awarded pursuant to this RFQ, will be two (2) years. The Supplier's proposed cost shall include any anticipated escalation of costs during this term, as specified in Article 3.04.

B. At the sole discretion of DISTRICT, any contract which may be awarded pursuant to this RFQ, may be extended for two (2) additional one-year terms. If the term is extended,


SUPPLIER may request an adjustment of the original proposed as specified in Article 3.04 of the Supplier Agreement. All other terms and conditions remaining the same.

C. Termination of the Supplier Agreement is specified in Article 12 of the Supplier Agreement.

D. All time limits for completion and readiness for final payment as stated in the Contract Documents are of the essence of the Contract.

17.02 Dates for Milestones, Contract Completion, and Final Payment shown below are predicated upon DISTRICT award the Supplier Agreement to Supplier by May 31, 2016, award of the installation construction contract to CONTRACTOR and/or authorization to SUPPLIER to begin equipment fabrication by January 31, 2017. Adjustments to Milestone dates shown below will be made by DISTRICT if the above dates are delayed:

A. Milestone 1: Begin Design Assistance Services During Final Design: Within 30 days after DISTRICT issues Notice to Proceed to SUPPLIER.

B. Milestone 2: Submit all general arrangement shop drawings required in the Contract Documents: Within 45 days after Notice to Proceed.

C. Milestone 3: Submit and obtain favorable review by ENGINEER of all shop drawings required in the Contract Documents. ENGINEER will finish their review and return comments within 15 days of receiving complete submittal and re-submittal packages from SUPPLIER: Within 120 days after Notice to Proceed.

D. Milestone 4: Furnish equipment: Unless otherwise agreed or requested in writing by DISTRICT, begin delivery of equipment to both plants no earlier than August 1, 2017 and complete delivery of equipment no later than September 1, 2017. Contractor shall be responsible for unloading equipment and providing proper storage at the sites.

E. Milestone 5: Complete successful start-up and Process Operational Period as specified in Section 01_75_17 at both plants: No later than April 30, 2018.

F. Milestone 6: Complete all testing, training, and submit final approved Operation and Maintenance Manuals required in the Contract Documents at both plants: No later than August 31, 2018.

17.03 Liquidated Damages:

A. SUPPLIER and DISTRICT recognize that time is of the essence of this Supplier Agreement and that DISTRICT will suffer financial loss if the Work is not completed within the times specified in paragraph 17.02, plus any extensions thereof allowed in accordance with the General Provisions. The parties also recognize that it will be impracticable to determine actual damages, which DISTRICT will sustain in the event of or by reason of the delay.

Accordingly, instead of requiring any such proof, DISTRICT and SUPPLIER agree that as liquidated damages for delay (but not as a penalty). SUPPLIER shall pay DISTRICT liquidated damages, but only to the extent that such delays are attributable to SUPPLIER's failure to perform any of its obligations, in accordance with the following schedule:


Contract Times

Description Liquidated damages for each day that expires after the specified time in paragraph 17.02 for completion until the Work listed under each deadline.

Milestone 1 Failure to begin Design Assistance Services During Final Design, and/or failure to assign a qualified project manager, and/or failure to provide technical assistance by the time specified in Article 17.02

$ 5,000 per day

Milestone 2 Failure to submit general arrangement Shop Drawings within the time frame specified in Article 17.02.

$5,000 per day

Milestone 3 Failure to submit and obtain favorable review by ENGINEER of all shop drawings required in the Contract Documents within the time frame specified in Article 17.02.

$ 5,000 per day

Milestone 4 Failure to deliver the ozone systems to both the Sobrante and Upper San Leandro Water Treatment Plants within the time frame specified in Article 17.02.

$5,000 per day

Milestone 5 Failure to successfully perform ozone system start-up and Process Operational Period within the time frame specified in Article 17.02.

$2,000 per day

Milestone 6 Failure to submit final approved O&M Manuals $500 per day

It is further agreed that the amount stipulated for liquidated damages per day of delay is a reasonable estimate of the damages that would be sustained by DISTRICT, and SUPPLIER agrees to pay such liquidated damages as herein provided. In case the liquidated damages are not paid, SUPPLIER agrees that DISTRICT may deduct the amount thereof from any money due or that may become due to SUPPLIER by progress payments or otherwise under the AGREEMENT, or if said amount is not sufficient, recover the total amount.

ARTICLE 18 - PENALTIES FOR FAILURE OF PERFORMANCE

18.01 Penalties as defined in the Contract Documents will be assessed should SUPPLIER fail to meet specific contract performance requirements and for failure to provide equipment that meets the proposed energy usage as entered in the Energy Consumption Form.

ARTICLE 19 - SUPPLIER'S REPRESENTATIONS

19.01 SUPPLIER makes the following representations:


A. SUPPLIER has examined and carefully studied the Contract Documents and the other related data identified in the Contract Documents.

B. If specified or if, in SUPPLIER's judgment, any local condition may affect cost, progress or the furnishing of the Goods and Services, SUPPLIER has become familiar with and is satisfied as to the local conditions that may affect cost, progress, or the furnishing of the Goods and Services.

C. SUPPLIER is familiar with and is satisfied as to all local federal, state, and local Laws and Regulations that may affect cost, progress, and the furnishing of the Goods and Services.

D. SUPPLIER has carefully studied and correlated the information known to SUPPLIER, and information and observations obtained from SUPPLIER's visits, if any, to the Sites, with the Contract Documents.

E. SUPPLIER has given DISTRICT or ENGINEER written notice of all conflicts, errors, ambiguities, or discrepancies that SUPPLIER has discovered in the Contract Documents, and the written resolution thereof by DISTRICT or ENGINEER is acceptable to SUPPLIER.

F. The Contract Documents are sufficient to indicate and convey understanding of all terms and conditions for furnishing Goods and Services.

19.02 SUPPLIER shall exercise that degree of skill and judgment commensurate with that, which is normally exercised by experienced SUPPLIER’s specializing in providing goods and services comparable to those provided for in the Contract Documents. SUPPLIER shall comply with all applicable federal, state, and local laws, rules, ordinances and regulations, including without limitation, applicable occupational safety and health acts and rules and regulations promulgated to implement such acts, in the performance of, and shall possess all required licenses to perform the work under this Supplier Agreement. SUPPLIER shall re-perform, at no cost or expense to DISTRICT, any work that is deficient because of SUPPLIER's failure to perform such services in accordance with the standards set forth in this Supplier Agreement. SUPPLIER shall correct any incomplete, inaccurate, or defective work at no additional cost or expense to DISTRICT.

19.03 SUPPLIER agrees to provide technically qualified personnel that meet the qualifications listed in the RFQ and who are employed full-time by SUPPLIER. DISTRICT shall have the right to reject any or all personnel for immediate replacement at any time during performance, if submitted qualifications are not representative of personnel's actual experience or abilities, at the sole discretion of DISTRICT. DISTRICT will notify SUPPLIER prior to taking such action. SUPPLIER shall notify DISTRICT of any proposed change in key personnel (including without limitation SUPPLIER's Project Manager and Project Engineer) at least twenty-one (21) days before such change is made, and DISTRICT shall have the right to review and reject as insufficient the qualifications of any such replacement personnel.

19.04 DISTRICT's rights hereunder to inspect, or otherwise review, comment on, test, accept or approve, the work to be performed by SUPPLIER, or any part of it, shall not impose any duty, obligation or liability on DISTRICT with respect to the work, nor shall they impose any duty to inspect, review or approve the methods by which the work is performed. Nor shall any such action, or failure to take such action, by DISTRICT prejudice any claim, right or privilege that DISTRICT may have arising out of defective or nonconforming work or the use thereof, or


relieve SUPPLIER of its responsibility for the performance and condition of the work or of its contractual responsibility.

19.05 Drawings, reports and other documents pertaining to existing facilities or conditions that are provided by DISTRICT or its representatives are provided for informational purposes only. DISTRICT does not guarantee the accuracy of the information contained therein and SUPPLIER shall be responsible for confirming all locations, measurements and other critical information. All drawings, reports and other documents, including manuals and other information, provided to DISTRICT or ENGINEER by SUPPLIER shall be the property of DISTRICT and DISTRICT shall own the copyright and have the full right and authority to copy, distribute and use such documents in any manner and for any purpose DISTRICT deems appropriate.

19.06 SUPPLIER agrees that all information disclosed by DISTRICT or ENGINEER and identified in writing as proprietary shall be held in confidence and be used only in the performance of the Goods and Services. SUPPLIER further agrees that, except as mandated by law, SUPPLIER shall not, disclose to any person or entity, or use for its own benefit, any such information supplied to it by DSIRTICT or ENGINEER; provided, however, that any information which is or becomes publicly known and made generally available through no wrongful act in violation of this Paragraph shall not be considered proprietary.

19.07 SUPPLIER represents and warrants that it has the legal right to provide the Goods and Services for DISTRICT's use, and SUPPLIER agrees to indemnify and hold harmless DISTRICT, ENGINEER and their directors, officers, employees and agents, and each of them, from and against any and all actions, claims, liabilities, costs, expenses (including reasonable attorney's fees and costs) and other damages arising out of or in any way connected with any suit or proceeding which claims that any patent, copyright, trademark or other intellectual property , or use by DISTRICT of same, infringe any third party's patent, copyright, trademark or other intellectual property or proprietary right, or any misrepresentation whatsoever with respect to the preceding, provided such infringement is based exclusively on products designed and manufactured by the SUPPLIER. SUPPLIER shall have the right to be notified and shall have the right to remedy such claims.

ARTICLE 20 - PERFORMANCE OF WORK AND FINAL COMPLETION

20.01 In SUPPLIER's performance of the work, the following provisions shall apply, in addition to other applicable provisions of this Contract:

A. SUPPLIER, its agents, and employees, shall be qualified and competent to perform the work; and all tools and equipment furnished by SUPPLIER in its performance of the work shall be kept in good working order.

B. The work shall be performed in accordance with accepted standards and shall conform to the requirements of the Contract Documents. Any work not so performed or not in conformity herewith shall be corrected by SUPPLIER. If such deficiencies are not corrected within 24 hours, DISTRICT may cause the same to be corrected for the account of SUPPLIER. The above-described remedy is in addition to any other remedies, in law or equity, available to DISTRICT.


C. Except as stated in this Article, or elsewhere in the Contract Documents, all cranes, rigging, tools, facilities, equipment, and material, together with sufficient labor, necessary for the off-loading, storage, and installation of the ozone equipment shall be provided by CONTRACTOR during construction phase.

D. When SUPPLIER deems the work completed, SUPPLIER shall give DISTRICT notice thereof in writing. Within a reasonable time after receipt of such notice, DISTRICT will determine if the work has been completed in accordance with the Contract Documents; if so, DISTRICT will advise SUPPLIER, in writing, of its final acceptance thereof, if not, DISTRICT will notify SUPPLIER of its lack or failure of performance and SUPPLIER will take remedial action and will repeat the procedure stated herein until the work has been satisfactorily completed and accepted.

ARTICLE 21 - CONTRACT DOCUMENTS

21.01 Contract Documents Contents.

A. The Contract Documents consist of the following:

1. The Request for Quotation; 2. Bonds and Certificates of Insurance; 3. General Requirements; 4. Supplementary General Requirements; 5. This Supplier Agreement; 6. Technical Specifications and Drawings; 7. Addenda 8. The following which may be delivered or issued on or after the Effective Date of the

AGREEMENT and are not attached hereto: a. Notice to Proceed; b. Written Amendment(s); c. Change Order(s); d. Field Order(s); e. ENGINEER'S Written Interpretation(s). f. Final approved shop drawings

B. The documents listed in paragraph 21.01.A are attached to this Supplier Agreement (except as expressly noted otherwise above).

C. The Contract Documents may only be amended, or supplemented as provided in Section 15 of the General Requirements.

D. In the event of any conflict between terms and conditions in the Supplier Agreement and terms and conditions elsewhere in the Contract Documents, the terms and conditions in the Supplier Agreement shall prevail and take precedence.


ARTICLE 22 - MISCELLANEOUS

22.01 Defined Terms. Terms used in this Supplier Agreement will have the meanings indicated in the General Requirements.

22.02 Successors and Assignees. DISTRICT and SUPPLIER each binds itself, its partners, successors, assigns and legal representatives to the other party hereto, its partners, successors, assigns and legal representatives in respect to all covenants, agreements and obligations contained in the Contract Documents.

22.03 Severability. Severability shall be in accordance with Section 25 of the General Requirements.

22.04 Any notice, request, demand or other communication required or permitted hereunder shall be deemed properly given when delivered either by personal delivery in writing, or by mail, registered or certified, postage prepaid with return receipt requested, addressed as follows:

SUPPLIER: DISTRICT:

Director of Engineering and Construction Dept. P. O. Box 24055, MS# 803 Oakland, CA 94623-1055

Attention: IN WITNESS WHEREOF, the parties hereto each herewith subscribe the same in duplicate. EAST BAY MUNICIPAL UTILITY DISTRICT

By: Date:

APPROVED AS TO FORM:

By:

SUPPLIER

By: Date:

RFQ No. 1618

EXHIBIT E - ASSIGNMENT AGREEMENT

03/01/2016 Page 1 Exhibit E - RFQ No. 1681

ASSIGNMENT OF SUPPLIER AGREEMENT

The Agreement between the EAST BAY MUNICIPAL UTILITY DISTRICT (DISTRICT) and

(SUPPLIER) for the procurement of goods and services under the Supplier

Agreement for East Bay Municipal Utility District Sobrante and Upper San Leandro Ozone

Systems Equipment and Services (Supplier Agreement) documents with specific reference to

the terms and conditions of assignment specified in the Supplier Agreement is hereby assigned,

transferred, and set over to , the CONSTRUCTION CONTRACTOR

(CONTRACTOR) for the General Construction Work, who shall be totally responsible for all work

performed by the assigned and for DISTRICT'S obligations and rights contained in the Contract

Documents unless otherwise specified in the Supplier Agreement between DISTRICT and

SUPPLIER. Without limiting the foregoing, the following obligations of SUPPLIER to DISTRICT as

set forth in the Supplier Agreement shall survive and remain in full force and effect following

the assignment:

ARTICLE 4 - WARRANTEES AND GUARANTEES;

ARTICLE 6 - COPYRIGHTS;

ARTICLE 8 - INDEMNIFICATION;

ARTICLE 11 - INSURANCE, DISTRICT shall be named as an additional insured as required by the

Supplier Agreement;

ARTICLE 12 - TERMINATION AND SUSPENSION, Sections 12.01 and 12.02 shall be exempt from

the assignment and shall inure solely to the benefit of DISTRICT;

ARTICLE 17 - CONTRACT TIMES, Section 17.03 Liquidated Damages;

ARTICLE 18 - PENALTIES FOR FAILURE OF PERFORMANCE.


ASSIGNMENT DIRECTED BY:

DISTRICT

BY:

(Signature) (Title)

ASSIGNMENT CONSENTED TO BY:

SUPPLIER

By:

(Signature) (Title)

ASSIGNMENT ACCEPTED BY:

CONSTRUCTION CONTRACTOR

By:

(Signature) (Title)

END OF DOCUMENT


SURETY’S AGREEMENT TO ASSIGNMENT

SURETY hereby acknowledges and agrees that the Supplier Agreement for the procurement of

goods and services for the East Bay Municipal Utility District Sobrante and Upper San Leandro

Water Treatment Plants Ozone Systems Improvements Project and between

, (SUPPLIER) and the East Bay Municipal Utility District (DISTRICT) shall be

assigned, transferred, and set over to , the CONSTRUCTION

CONTRACTOR (CONTRACTOR) for General Construction Work, in accordance with the Contract

Documents.

SURETY further agrees that, upon assignment of the Supplier Agreement, the CONTRACTOR

shall have all the rights previously conferred upon the DISTRICT under the Faithful Performance

Bond.

(Corporate Seal) SURETY

Company:

Signature:

Name/Title:

END OF DOCUMENT

RFQ No. 1618

EXHIBIT F - TECHNICAL SPECIFICATIONS AND DRAWINGS


SOBRANTE AND UPPER SAN LEANDRO WATER TREATMENT PLANTS

OZONE SYSTEMS IMPROVEMENTS PROJECT OZONE SYSTEM EQUIPMENT AND SERVICES

RFQ 1618 - EXHIBIT F TECHNICAL SPECIFICATIONS

FINAL SUBMITTAL

February 2016

2/26/2016

February 2016 i RFQ 1618


SOBRANTE AND UPPER SAN LEANDRO WATER TREATMENT PLANTS

OZONE SYSTEMS IMPROVEMENTS PROJECT

OZONE SYSTEM EQUIPMENT AND SERVICES

EXHIBIT F - TECHNICAL SPECIFICATIONS

TABLE OF CONTENTS

TECHNICAL SPECIFICATIONS DIVISION 01 - GENERAL REQUIREMENTS

SECTION NO. TITLE 01_11_00 SUMMARY OF WORK 01_31_23.10 WEB-BASED CONSTRUCTION DOCUMENT MANAGEMENT 01_33_00 SUBMITTAL PROCEDURES 01_41_00 REGULATORY REQUIREMENTS 01_75_17 COMMISSIONING AND PROCESS START-UP 01_78_23 OPERATION AND MAINTENANCE DATA 01_81_01 PROJECT DESIGN CRITERIA 01_81_02 SEISMIC DESIGN CRITERIA

DIVISION 03 - CONCRETE SECTION NO. TITLE 03_21_17 ADHESIVE-BONDED REINFORCING BARS AND ALL THREAD

RODS DIVISION 05 - METALS

SECTION NO. TITLE 05_05_24 MECHANICAL ANCHORING AND FASTENING TO CONCRETE

DIVISION 09 - FINISHES SECTION NO. TITLE 09_96_56.05 HIGH-BUILD EPOXY COATINGS

DIVISION 26 - ELECTRICAL SECTION NO. TITLE 26_05_19 LOW VOLTAGE ELECTRICAL POWER CONDUCTORS AND

CABLES

February 2016 ii RFQ 1618

DIVISION 26 - ELECTRICAL (CONTINUED) SECTION NO. TITLE 26_05_29 HANGERS AND SUPPORTS 26_05_33 RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS 26_05_53 IDENTIFICATION FOR ELECTRICAL SYSTEMS 26_05_83 LOW VOLTAGE MOTORS 26_09_13 ELECTRICAL POWER MONITORING AND CONTROL 26_28_16 ENCLOSED SWITCHES AND CIRCUIT BREAKERS 26_29_13 ACROSS-THE-LINE MOTOR CONTROLLERS 26_29_23 LOW-VOLTAGE VARIABLE-FREQUENCY MOTOR CONTROLLERS

DIVISION 33 - UTILITIES SECTION NO. TITLE 33_12_01 BASIC MECHANICAL MATERIALS AND METHODS

DIVISION 40 - PROCESS INTEGRATION SECTION NO. TITLE 40_05_00.01 COMMON WORK RESULTS FOR GENERAL PIPING 40_05_00.09 PIPING SYSTEMS TESTING 40_05_23.01 STAINLESS STEEL PIPE AND TUBING 40_05_52 SPECIALTY VALVES 40_05_57.13 MANUAL ACTUATORS 40_05_57.23 ELECTRIC ACTUATORS 40_05_63 BALL VALVES 40_05_64 BUTTERFLY VALVES 40_05_65.01 GATE, GLOBE, AND ANGLE VALVES 40_05_67.37 PRESSURE REDUCING AND PRESSURE RELIEF VALVES 40_61_00 COMMON WORK RESULTS FOR PROCESS CONTROL AND

INSTRUMENTATION SYSTEMS 40_61_05 PACKAGED CONTROL SYSTEM 40_61_16 SPECIFIC CONTROL STRATEGIES 40_71_13 FLOW MEASUREMENT: MAGNETIC FLOWMETERS 40_71_23.21 FLOW MEASUREMENT: ORIFICE PLATE 40_71_79 FLOW MEASUREMENT: SWITCHES 40_73_13 PRESSURE/VACUUM MEASUREMENT: GAUGES 40_73_23 PRESSURE/VACUUM MEASUREMENT: DIRECT 40_73_29 PRESSURE/VACUUM MEASUREMENT: DIFFERENTIAL 40_73_36 PRESSURE/VACUUM MEASUREMENT: SWITCHES

February 2016 iii RFQ 1618

DIVISION 40 - PROCESS INTEGRATION (CONTINUED) SECTION NO. TITLE 40_73_63 PRESSURE/VACUUM MEASUREMENT: DIAPHRAGM AND

ANNULAR SEALS 40_73_64 PRESSURE/VACUUM MEASUREMENT: INSTRUMENT VALVES 40_74_13 TEMPERATURE MEASUREMENT: RTD 40_74_43 TEMPERATURE MEASUREMENT: TEMPERATURE GAUGE 40_74_66 TEMPERATURE MEASUREMENT: TEMPERATURE SWITCH 40_75_85 ANALYZERS: DEW POINT 40_76_13.1 ANALYZERS: GAS MONITORS 40_80_01 TESTING, CALIBRATION, AND COMMISSIONING 40_94_33 OPERATOR INTERFACE UNITS 40_94_43 PROGRAMMABLE LOGIC PROCESS CONTROLLERS 40_95_13 PROCESS CONTROL PANELS AND HARDWARE 40_96_15 SCHEDULES: I/O LIST

DIVISION 46 - WATER AND WASTEWATER EQUIPMENT SECTION NO. TITLE 46_05_94 MECHANICAL EQUIPMENT TESTING 46_31_52 OZONE SYSTEMS: GENERAL

46_31_54 SUPPLEMENTAL NITROGEN EQUIPMENT 46_31_55 OZONE GENERATING EQUIPMENT 46_31_57 OZONE DESTRUCTION EQUIPMENT 46_31_58 CLEANING FOR OXYGEN AND OZONE SERVICE 46_31_59 OZONE SYSTEM TESTING

DRAWINGS 9492-G-002 GENERAL LEGEND, SYMBOLS, AND ABBREVIATIONS FOR P&ID

DRAWINGS 9492-G-003 SYMBOLS FOR P&ID DRAWINGS VALVES, FITTINGS AND

MISCELLANEOUS SYMBOLS 9492-G-004 SYMBOLS FOR P&ID DRAWINGS SENSING ELEMENTS 9492-G-005 SYMBOLS FOR P&ID DRAWINGS EQUIPMENT 9492-G-006 EQUIPMENT TAG NUMBER CODES AND COLORS 9492-G-007 EQUIPMENT TAG NUMBER CODES AND COLORS

February 2016 iv RFQ 1618

503-J-055.01 USL WTP CONTROL SYSTEM BLOCK DIAGRAM 503-J-057 USL WTP SUPPLEMENTAL NITROGEN SYSTEM P&ID 503-J-058.01 USL WTP OZONE GENERATOR NO. 1 P&ID 503-J-058.02 USL WTP OZONE GENERATOR NO. 2 P&ID 503-J-058.03 USL WTP OZONE GENERATOR NO. 3 P&ID 503-J-059 USL WTP CLOSED LOOP COOLING WATER PUMPS P&ID 503-J-062.01 USL WTP OZONE DESTRUCTION SYSTEM - 1 P&ID 503-J-062.02 USL WTP OZONE DESTRUCTION SYSTEM - 2 P&ID 503-J-062.03 USL WTP OZONE DESTRUCTION SYSTEM - 3 P&ID

505-J-043.01 SOBRANTE WTP CONTROL SYSTEM BLOCK DIAGRAM 505-J-045 SOBRANTE WTP SUPPLEMENTAL NITROGEN SYSTEM P&ID 505-J-046.01 SOBRANTE WTP OZONE GENERATOR NO. 1 P&ID 505-J-046.02 SOBRANTE WTP OZONE GENERATOR NO. 2 P&ID 505-J-046.03 SOBRANTE WTP OZONE GENERATOR NO. 3 P&ID 505-J-047 SOBRANTE WTP CLOSED LOOP COOLING WATER PUMPS P&ID 505-J-050.01 SOBRANTE WTP OZONE DESTRUCTION SYSTEM - 1 P&ID 505-J-050.02 SOBRANTE WTP OZONE DESTRUCTION SYSTEM - 2 P&ID 505-J-050.03 SOBRANTE WTP OZONE DESTRUCTION SYSTEM - 3 P&ID 505-E-002 SOBRANTE WTP SECONDARY UNIT SUBSTATION

February 2016 01_31_23.10-1 9905A10 pw://Carollo/Documents/Client/CA/EBMUD/9905A10/02 Pre-Purchase/Specifications/01_31_23.10 (FINAL)

SECTION 01 31 23.10

WEB-BASED CONSTRUCTION DOCUMENT MANAGEMENT

PART 1 GENERAL

1.01 SUMMARY

A. The Ozone System Supplier (OSS), and its subcontractors and suppliers shall utilize EADOC (EADOC is a registered trademark of EADOC LLC.) for submission of all data and documents (unless specified otherwise herein and in this Section) throughout the duration of the Contract. “Copy” or Copies” shall refer to electronic copies unless a hard copy is specified. Where a hard copy is specified, both electronic and paper versions shall be submitted. 1. EADOC is a web-based construction management software hosted by EADOC

LLC. 2. EADOC is paid for by the District. 3. EADOC will be made available to all OSS’s personnel, subcontractor

personnel and suppliers working under the Contract. 4. The joint use of this system is to facilitate electronic exchange of information,

automation of key processes, and overall management of Contract Documentation.

5. EADOC shall be the primary means of project information submission and management.

B. Related Sections: 1. Section 01 33 00 Submittal Procedures.

1.02 USER ACCESS LIMITATIONS

A. The Engineer will establish the OSS’s access to EADOC by allowing access and assigning user profiles to accepted OSS personnel. User profiles will define levels of access into the system, and determine assigned function-based authorizations and user privileges to enter and access information in EADOC. Subcontractors and suppliers will be given access to EADOC by and through the OSS. Entry of information exchanged and transferred between the OSS and its subcontractors and suppliers on EADOC shall be the responsibility of the OSS.

1.03 OWNERSHIP OF DATA

A. Data entered in a collaborative mode (entered with the intent to share as determined by permissions and workflows within the EADOC system) by the Engineer and the OSS will be jointly owned.

1.04 AUTOMATED SYSTEM NOTIFICATION AND AUDIT LOG TRACKING

A. Review comments made (or lack thereof) by the District on OSS -submitted documentation shall not relieve the OSS from compliance with requirements of the Contract Documents. The OSS is responsible for managing, tracking, and documenting the Work to comply with the requirements of the Contract Documents. District’s acceptance via automated system notifications or audit logs extends only


to the face value of the submitted documentation and does not constitute validation of the OSS’s submitted information..

1.05 COMPUTER REQUIREMENTS

A. The OSS shall use PC based computer hardware and software that meets the requirements of EADOC system as recommended by EADOC LLC and as described herein to access and utilize EADOC. As recommendations are modified by EADOC, the OSS shall upgrade its system(s) to meet or exceed the recommendations. Upgrading of the OSS’s computer systems shall not be justification for a cost or time modification to the Contract.

B. The OSS shall ensure that connectivity to the EADOC system is accomplished through DSL, cable, T-1 or wireless communications systems. The minimum bandwidth requirement for using the system is 128 kb/s. It is recommended that a faster connection be used when uploading pictures and files into the system.

C. EADOC currently supports Mozilla's Firefox v9.0-14, Apple's Safari V4.0-5.0, Google Chrome V21-24, and Microsoft's Internet Explorer v7.0-9.0 web browsers for accessing the application.

D. The OSS shall use applications compatible with Adobe Acrobat Professional Version 7.0 to create Portable Document Format (PDF) files.

1.06 OSS RESPONSIBILITY

A. OSS shall be responsible for scanning or otherwise converting to electronic format all project submittals and OSS correspondence, drawings, sketches, etc., and uploading them to the EADOC web site.

B. The OSS shall be responsible for the validity of its information placed in EADOC.

C. Accepted users shall be knowledgeable in the use of computers, including Internet Browsers, email programs, CAD drawing applications, and Portable Document Format (PDF) document distribution program.

D. The OSS shall utilize the existing forms in EADOC to the maximum extent possible. If a required form does not exist in EADOC, the OSS shall include a form of its own or one provided by the Engineer (if available) as an attachment to a submittal. The District discourages the use of e-mails and other methods of submitting requests and documents. Unless approved in advance by the Engineer, requests and documents not submitted through EADOC will not be recognized as official correspondence.

E. PDF documents shall be created through electronic conversion rather than optically scanned whenever possible. If optically scanned, the document shall be converted through an OCR (Optical Character Reader) so that all documents are searchable. If the documents have multiple sections then the OSS shall provide a “bookmark” for each section. The OSS is responsible for the training of its personnel in the use of EADOC (outside what is provided by the District) and the other programs indicated above as needed. The OSS shall disable all security so that copying and pasting of information from the PDF document is enabled.


F. User Access Administration: 1. Provide a list of OSS’s key EADOC personnel for the Engineer’s acceptance.

OSS is responsible for informing the Engineer of additional personnel, subcontractors and suppliers to be added to the system, or of personnel, subcontractors and suppliers to be removed from the system. The Engineer reserves the right to perform a background check on all potential users.

1.07 CONNECTIVITY LIMITATIONS

A. EADOC is a web-based environment and therefore, subject to the inherent speed and connectivity limitations of the Internet. The OSS is responsible for its own connectivity to the Internet. EADOC response time is dependent on the OSS’s equipment, including processor speed, Internet access speed, etc. and current traffic on the Internet. The District will not be liable for any delays associated from the usage of EADOC including, but not limited to: slow response time, down time periods, connectivity problems, or loss of information. The OSS shall ensure connectivity to the EADOC system (whether at the home office or job site). Under no circumstances will usage of EADOC be grounds for a time extension or cost adjustment to the Contract.

PART 2 PRODUCTS

2.01 DESCRIPTION

A. EADOC project management application (no substitutions) provided by EADOC LLC www.EADOCsoftware.com.

PART 3 EXECUTION

3.01 EADOC UTILIZATION

A. EADOC shall be utilized in connection with all document and information management required by these Contract Documents. Documents and information to be submitted electronically include, but are not limited to, the documents described below: 1. Submittals:

a. Shop Drawings: 1) Shop drawings and design data documents shall be submitted as

MicroStation or AutoCAD format files and PDF attachments to the EADOC submittal work flow process and form. Examples include, but are not limited to: a) Standard manufacturer installation drawings. b) Drawings prepared to illustrate portions of the work designed or

developed by the OSS. c) Steel fabrication, piece, and erection drawings. d) Electrical interconnection drawings.

b. Product Data: 1) Product data and manufacturer's instructions shall be submitted as

PDF attachments to the EADOC submittal work flow process and form. Examples include, but are not limited to: a) Manufacturer’s printed literature.

http://www.eadocsoftware.com/


b) Preprinted product specification data and installation instructions.

c. Samples: 1) Sample submittals shall be physically submitted as specified in

Section 01 33 00 - Submittal Procedures; additionally, OSS shall enter submittal data information into EADOC with a copy of the submittal form(s) attached to the actual sample. Examples include, but are not limited to: a) Product finishes and color selection samples. b) Product finishes and color verification samples. c) Finish/color boards. d) Physical samples of materials.

d. Administrative Submittals: 1) All correspondence and pre-construction submittals shall be

submitted using EADOC. Examples include, but are not limited to: a) List of project personnel. b) Requests for Information (RFI). c) Certified payrolls. d) Plant Inspection Requests e) Requests for Meetings

2) All schedules and associated reports and updates shall be submitted as specified in these Contract Documents and as a native backed-up file of the scheduling program being used. The schedule shall be posted as a PDF file in the format specified in these Contract Documents and as backed-up file.

3) Plans for safety, demolition, environmental protection, and similar activities.

4) Outage Plans. 5) Meeting minutes for weekly construction meetings, progress

meetings, pre-installation meetings, etc. 6) Any general correspondence submitted.

e. Compliance Submittals: 1) Test reports, certificates, and manufacture field report submittals

shall be submitted on EADOC as PDF attachments. Examples include, but are not limited to: a) Field test reports. b) Quality Control certifications. c) Manufacturers documentation and certifications for quality of

products and materials provided. f. Record and Closeout Submittals:

1) Operation and maintenance data closeout submittals shall be submitted on EADOC as PDF documents during the approval and review stage as specified, with actual hardcopy set of documents submitted for final (in addition to the final being submitted via EADOC). Examples include, but are not limited to: a) Operation and Maintenance Manuals: Final documents shall be

submitted as specified. b) Extra Materials, Spare Stock, etc.: Submittal forms shall indicate

when and where actual materials are submitted. g. Financial Submittals:

1) Schedule of Costs, Pay Estimates, Daily Extra Work Reports, and Change Order Requests shall be submitted on EADOC. Supporting


material for Pay Estimates and Change Order Requests shall be submitted on EADOC as PDF attachments. Examples include, but are not limited to: a) OSS’s Schedule of Costs utilizing both the EADOC Schedule of

Costs format and as required by the Contract Documents in both PDF and Microsoft Excel.

b) OSS’s Monthly Progress Payment Requests utilizing EADOC. c) Contract Change proposals requested by the District.

2) The OSS shall provide the craft, material, and equipment data via EADOC, which will be utilized for Daily Extra Work Reports and Change Order Requests.

END OF SECTION


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February 2016 01_33_00-1 9905A10 pw://Carollo/Documents/Client/CA/EBMUD/9905A10/02 Pre-Purchase/Specifications/01_33_00 (FINAL)

SECTION 01_33_00

SUBMITTAL PROCEDURES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Requirements and procedures for submittals by the Ozone System OSS (OSS).

B. Related sections: 1. The Contract Documents are complementary; what is called for by one is as

binding as if called for by all. 2. It is the OSS’s responsibility for scheduling and coordinating the Work of

Supplier, subcontractors, other OSS s, and other individuals or entities performing or furnishing any of OSS’s Work.

3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the OSS to see that the completed Work complies accurately with the Contract Documents: a. Section 01_31_23.10- Web Based Construction Document Management. b. Section 26_05_83 - Low Voltage Motors.

1.02 REFERENCES

A. NSF International: 1. NSF 61 – Drinking Water System Components – Health Effects.

1.03 DEFINITIONS

A. Certificates: Describe certificates that document affirmations by the OSS or other entity that the work is in accordance with the Contract Documents.

B. Extra stock materials: Describe extra stock materials to be provided for the Owner's use in facility operation and maintenance.

C. Maintenance material submittals: Use this article to categorize maintenance materials submittals requiring no Engineer action other than confirmation of receipt under an explanatory heading.

D. Manufacturer's instructions: Instructions, stipulations, directions, and recommendations issued in printed form by the manufacturer of a product addressing handling, installation, erection, and application of the product; manufacturer's instructions are not prepared especially for the Work.

E. Product data: Product data usually consists of manufacturers' printed data sheets or catalog pages illustrating the products to be incorporated into the project.


F. Spare parts: Describe spare parts necessary for the Owner's use in facility operation and maintenance; identify the type and quantity here, but include the actual characteristics of the spare parts in Product as part of the specification of the product.

G. Shop drawings: Shop drawings are prepared specifically for the project to illustrate details, dimensions, and other data necessary for satisfactory fabrication or construction that are not shown in the contract documents. Shop drawings could include graphic line-type drawings, single-line diagrams, or schedules and lists of products and their application.

H. Submittals: Submittals are samples, product data, shop drawings, and others that demonstrate how OSS intends to conform with the Contract Documents.

I. Tools: Tools are generally defined as items such as special wrenches, gauges, circuit setters, and other similar devices required for the proper operation or maintenance of a system that would not normally be in the Owner's tool kit.

1.04 GENERAL INSTRUCTIONS

A. Provide submittals that are specified or reasonably required for construction, operation, and maintenance of the Work.

B. Provide submittal information from only 1 manufacturer for a specified product. Submittals with multiple manufacturers for 1 product will be rejected without review.

C. Where multiple submittals are required, provide a separate submittal for each specification section: 1. In order to expedite construction, the OSS may make more than 1 submittal

per specification section, but a single submittal may not cover more than 1 specification section.

2. The only exception to this requirement is when 1 specification section covers the requirements for a component of equipment specified in another section.

D. For example, circuit breakers are a component of switchgear. The switchgear submittal must also contain data for the associated circuit breakers, even though they are covered in a different specification section.

E. Edit all submittals so that the submittal specifically applies to only the equipment furnished. Neatly cross out all extraneous text, options, models, etc. that do not apply to the equipment being furnished, so that the information remaining is only applicable to the equipment being furnished.

F. Prepare submittals in the English language. Do not include information in other languages.

G. Present measurements in customary American units (feet, inches, pounds, etc.).

H. Show dimensions, construction details, wiring diagrams, controls, manufacturers, catalog numbers, and all other pertinent details.


I. Indicate project designated equipment tag numbers from P&IDs for submittal of devices, equipment, and assemblies: 1. Must be clear and legible, and of sufficient size for presentation of information:

a. Minimum page size will be 8 1/2 inches by 11 inches. b. Maximum page size will be 11 inches by 17 inches.

1.05 SUBMITTAL ORGANIZATION

A. Fully indexed with a tabbed divider for every component.

B. Sequentially number pages within the tabbed sections: 1. Submittals that are not fully indexed and tabbed with sequentially numbered

pages, or are otherwise unacceptable, will be returned without review.

C. Organize submittals in exactly the same order as the items are referenced, listed, and/or organized in the specification section.

D. For submittals that cover multiple devices used in different areas under the same specification section, the submittal for the individual devices must list the area where the device is used.

E. Consolidate electronic format submittals with multiples pages into a single file.

F. Refer to Section 01_31_23.10 for additional requirements for electronic submittals.

1.06 SUBMITTAL COVER SHEETS

A. Submittal Transmittal Form is provided in Appendix A of this Section: 1. Substitute forms require Engineer approval based on forms providing the

same information, statements, and certifications. 2. Submittal Number Field: Required submittal numbering format: Section

number-sequential number-resubmittal number: a. Example: 03_21_17-002-1:

1) “03_21_17” indicates the affected specification is Section 03_21_17. 2) “002” indicates the second submittal under this Section. 3) “1” indicates the first resubmittal of the Submittal.

b. Supplier may add a separate numbering scheme for Supplier's internal use. However, all correspondence with Engineer must include the required submittal numbering.

3. “From” Field: Provide name and address of company responsible for preparation of submittal. This could be OSS, subcontractor, other OSS, manufacturer, etc.

4. “Ozone System Supplier Reviewer” Field: Verify that the OSS has reviewed the submittal by signature.

B. OSS sign and date submittals indicating review and approval: 1. Signature indicates OSS certifies that they have satisfied submittal review

responsibilities and constitutes OSS's written approval of submittal. 2. Submittals without OSS's signature will be returned to the OSS unreviewed.

Subsequent submittal of this information will be counted as the first resubmittal.


C. Attachments: 1. Specification section: Include with each submittal a copy of the relevant

specification section: a. Indicate in the left margin, next to each pertinent paragraph, either

compliance with a check (√) or deviation with a consecutive number (1, 2, and 3).

b. Provide a list of all numbered deviations with a clear explanation and reason for the deviation.

2. Drawings: Include with each submittal a copy of the relevant Drawing, including relevant addendum updates: a. Indicate either compliance with a check (√) or deviation with a consecutive

number (1, 2, and 3). b. Provide a list of all numbered deviations with a clear explanation and

reason for the deviation. c. Provide field dimensions and relationship to adjacent or critical features of

the Work or materials.

D. OSS: Prepare submittal information in sufficient detail to show compliance with specified requirements: 1. Determine and verify quantities, field dimensions, product dimensions,

specified design and performance criteria, materials, catalog numbers, and similar data.

2. Coordinate submittal with other submittals and with the requirements of the Contract Documents.

3. Check, verify, and revise submittals as necessary to bring them into conformance with Contract Documents and actual field conditions.

1.07 SUBMITTAL CONTENT

A. Shop Drawings: 1. Details:

a. Fabrication drawings: drawn to scale and dimensioned. b. Front, side, and, rear elevations, and top and bottom views, showing all

dimensions. c. Locations of conduit entrances and access plates. d. Component layout and identification. e. Weight. f. Finish. g. Temperature limitations, as applicable. h. Nameplate information.

B. Product Information: 1. Product Data:

a. Details: 1) OSS name and address. 2) Subcontractor name and address.

b. Include: 1) Catalog cuts. 2) Bulletins. 3) Brochures.


4) Manufacturer’s Certificate of Compliance: signed by product manufacturer along with supporting reference data, affidavits, and tests, as appropriate.

5) Manufacturer’s printed recommendations for installation of equipment.

6) Quality photocopies of applicable pages from manufacturer’s documents.

2. Completely fill out a Motor Data Sheet, as specified in Section 26_05_83, for every motor furnished: a. Submit one copy of the Motor Data Sheet to the Engineer for review as

part of the associated equipment submittal. 3. Minor or incidental products and equipment schedules:

a. Details: 1) Shop Drawings of minor or incidental fabricated products will not be

required, unless requested. 2) Submit tabulated lists of minor or incidental products showing the

names of the manufacturers and catalog numbers, with Product Data as required to determine acceptability.

C. Design calculations: 1. Details:

a. Defined in technical sections. b. Unless noted otherwise, calculations must bear the original seal and

signature of a Professional Engineer licensed in the state where the project is located and who provided responsible charge for the design.

D. Qualifications Statements: 1. Details:

a. Defined in technical sections. b. Licensing documentation. c. Certification documentation. d. Education documentation.

E. Quality assurance/control submittals: 1. Test reports:

a. Details: 1) Include the following information:

a) A description of the test. b) List of equipment used. c) Name of the person conducting the test. d) Date and time the test was conducted. e) Ambient temperature and weather conditions. f) All raw data collected. g) Calculated results. h) Clear statement if the test passed or failed the requirements

stated in Contract Documents. i) Signature of the person responsible for the test.

2. Factory Acceptance Test: a. Details: Include complete test procedure and all forms to be used during

test. 3. Certificates:

a. Details: Defined in technical sections.


4. Manufacturers’ field reports: a. Details: Manufacturer’s Certificate of installation and functionality

compliance. 5. Test Plans:

a. Details: Defined in technical sections.

1.08 SUBMITTAL PROCEDURE

A. Ozone System Supplier: Send submittal to Engineer: 1. Delivery: Deliver submittals to Engineer using web based construction

document management system described in Section 01_31_23.10. 2. Timeliness: Schedule and make submissions in accordance with the

requirements of the individual specification sections and in such a sequence as to cause no delay in Work.

3. Supplier assumes risk of expense and delays when proceeding with work related to required submittals without review and approval.

B. Engineer: Review submittal and provide response: 1. Review description:

a. Engineer will be entitled to rely upon the accuracy or completeness of designs, calculations, or certifications made by licensed professionals accompanying a particular submittal whether or not a stamp or seal is required by Contract Documents or Laws and Regulations.

b. Engineer's review of submittals shall not release Supplier from their responsibility for performance of requirements of Contract Documents. Neither shall Engineer's review release from fulfilling purpose of installation nor from Supplier's liability to replace defective work.

c. Engineer's review of shop drawings, samples, or test procedures will be only for conformance with design concepts and for compliance with information given in Contract Documents.

d. Engineer's review does not extend to: 1) Accuracy of dimensions, quantities, or performance of equipment

and systems designed by Contractor. 2) Supplier's means, methods, techniques, sequences, or procedures

except when specified, indicated on the Drawings, or required by Contract Documents.

3) Safety precautions or programs related to safety which shall remain the sole responsibility of the Supplier.

e. Engineer can Approve or Not Approve any exception at their sole discretion.

2. Review timeframe: a. Except as may be provided in technical specifications, a submittal will be

returned within 30 days. b. When a submittal cannot be returned within the specified period, Engineer

will, within a reasonable time after receipt of the submittal, give notice of the date by which that submittal will be returned.

c. Engineer’s acceptance of progress schedule containing submittal review times less than those specified or agreed to in writing by Engineer will not constitute Engineer’s acceptance of review times.

d. Critical submittals: 1) Supplier will notify Engineer in writing that timely review of a

submittal is critical to the progress of Work.


2) Engineer will provide decision on request: a) Written agreement by Engineer to reduce submittal review time

will be made only for unusual situations. b) Written rejection of request.

3. Schedule delays: a. No adjustment of Contract Times or Contract Price will be allowed due to

Engineer’s review of submittals, unless all of the following criteria are met: 1) Engineer has failed to review and return first submission within the

agreed upon time frame. 2) Supplier demonstrates that delay in progress of Work is directly

attributable to Engineer’s failure to return submittal within time indicated and accepted by Engineer.

4. Review responses: 1 copy of submittal will be returned to Supplier with one of the following reviewer’s response: a. Approved:

1) No Exceptions: a) There are no notations or comments on the submittal and the

Supplier may release the equipment for production. 2) Make Corrections Noted - See Comments:

a) The Supplier may proceed with the work, however, all notations and comments must be incorporated into the final product.

b) Resubmittal not required. 3) Make Corrections Noted - Confirm:

a) The Supplier may proceed with the work, however, all notations and comments must be incorporated into the final product.

b) Submit confirmation specifically addressing each notation or comment to the Engineer within 15 calendar days of the date of the Engineer’s transmittal requiring the confirmation.

b. Not approved: 1) Correct and Resubmit:

a) Supplier may not proceed with the work described in the submittal.

b) Supplier assumes responsibility for proceeding without approval. c) Resubmittal of complete submittal package is required within 30

calendar days of the date of the Engineer’s submittal review response.

2) Rejected - See Remarks: a) Supplier may not proceed with the work described in the

submittal. b) The submittal does not meet the intent of the Contract

Documents. Resubmittal of complete submittal package is required with materials, equipment, methods, etc. that meet the requirements of the Contract Documents.

c. Receipt Acknowledged: Filed for Record: 1) This is used in acknowledging receipt of informational submittals that

address means and methods of construction such as schedules and work plans, conformance test reports, health and safety plans, etc.


C. Supplier: Prepare resubmittal, if applicable: 1. Clearly identify each correction or change made. 2. Include a response in writing to each of the Engineer’s comments or questions

for submittal packages that are resubmitted in the order that the comments or questions were presented throughout the submittal: a. Acceptable responses to Engineer’s comments are listed below:

1) “Incorporated” Engineer’s comment or change is accepted and appropriate changes are made.

2) “Response” Engineer’s comment not incorporated. Explain why comment is not accepted or requested change is not made. Explain how requirement will be satisfied in lieu of comment or change requested by Engineer.

b. Reviews and re-submittals: 1) Supplier shall provide re-submittals which include responses to all

submittal review comments separately and at a level of detail commensurate with each comment.

2) Supplier responses shall indicate how the supplier resolved the issue pertaining to each review comment. Responses such as “acknowledged” or “noted” are not acceptable.

3) Re-submittals which do not comply with this requirement may be rejected and returned without review.

4) Supplier shall be allowed no extensions of any kind to any part of their contract due to the rejection of non-compliant submittals.

5) Submittal review comments not addressed by the Supplier in re-submittals shall continue to apply whether restated or not in subsequent reviews until adequately addressed by the OSS to the satisfaction of the reviewing and approving authority.

c. Any resubmittal that does not contain responses to the Engineer’s previous comments shall be returned for Revision and Resubmittal. No further review by the Engineer will be performed until a response for previous comments has been received.

3. Re-submittal timeframe: a. Supplier shall provide re-submittal within 15 days. b. When a re-submittal cannot be returned within the specified period,

Supplier shall notify Engineer in writing. 4. Review costs:

a. Costs incurred by Owner as a result of additional reviews of a particular submittal after the second time it has been reviewed shall be borne by Supplier.

b. Reimbursement to Owner will be made by deducting such costs from Contractor's subsequent progress payments.

PART 2 PRODUCTS Not Used.

PART 3 EXECUTION Not Used.

END OF SECTION


APPENDIX A

OSS SUBMITTAL TRANSMITTAL FORM


DOCUMENT 01_33_00 OSS SUBMITTAL TRANSMITTAL FORM

Owner: Date:

OSS : Project No.:

Project Name: Submittal Number: 000

Submittal Title:

To:

From:

Specification No. and Subject of Submittal / Equipment Supplier Spec ##:

Subject:

Authored By: Date Submitted:

Submittal Response

Check Either (A) or (B):

(A) We have verified that the equipment or material contained in this submittal meets all the requirements specified in the project manual or shown on the contract drawings with no exceptions.

(B) We have verified that the equipment or material contained in this submittal meets all the

requirements specified in the project manual or shown on the contract drawings except for the following deviations (list deviations):

Certification Statement: By this submittal, I hereby represent that I have determined and verified all field measurements, field construction criteria, materials, dimensions, catalog numbers and similar data, and I have checked and coordinated each item with other applicable approved shop drawings and all Contract requirements. Supplier's Reviewer’s Signature:

Printed Name: In the event, OSS believes the Submittal response does or will cause a change to the requirements of the Contract, OSS shall immediately give written notice stating that OSS considers the response to be a Change Order. Firm:

Signature: Date

Returned:

PM/CM Office Use

Date Received GC to PM/CM:

Date Received PM/CM to Reviewer:

Date Received Reviewer to PM/CM:

Date Sent PM/CM to GC:




SECTION 01_41_00

REGULATORY REQUIREMENTS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Regulatory authorities and codes.

1.02 AUTHORITIES HAVING JURISDICTION

A. Building Department: 1. Upper San Leandro WTP: City of Oakland, Ca. 2. Sobrante WTP: Contra Costa County, Ca.

B. Fire Department: 1. Upper San Leandro WTP: City of Oakland, Ca. 2. Sobrante WTP: Contra Costa County, Ca.

1.03 APPLICABLE CODES

A. International Code Council (ICC): 1. Electrical code:

a. National Electrical Code (NEC), 2014.

B. California Code of Regulations (CCR), California Building Standards Code, CCR Title 24: 1. Building code:

a. California Building Code (CBC), Title 24, Part 2 – 2013. 2. Existing building code:

a. California Existing Building Code (CEBC), Title 24, Part 10 – 2013. 3. Fire code:

a. California Fire Code (CFC), Title 24, Part 9 – 2013. 4. Mechanical code:

a. California Mechanical Code (CMC), Title 24, Part 4 – 2013. 5. Plumbing code:

a. California Plumbing Code (CPC), Title 24, Part 5 – 2013. 6. Energy code:

a. California Energy Code (CEC), Title 24, Part 6 – 2013.

PART 2 PRODUCTS

Not used.

PART 3 EXECUTION

Not used. END OF SECTION



SECTION 01_75_17

COMMISSIONING AND PROCESS START-UP

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Requirements for the Planning, Commissioning, and Process Start-up phases for the Project equipment/system and/or facility. The Ozone System Supplier (OSS) shall be responsible for providing services and participating in activities specified herein and coordinating with the District, Engineer, Contractor and other manufacturers working under the Contractor (e.g. LOX equipment) for the Project. The OSS shall include the cost for providing these services in their response to the RFQ. The Project Manager and start-up personnel for the OSS shall be the individuals who meet qualifications listed in the RFQ and, unless approved in writing by the District, whose resumes were submitted by the OSS in their response to the RFQ.

B. Related sections: 1. Section 01_33_00 - Submittal Procedures. 2. Section 01_78_23 - Operation and Maintenance Data. 3. Section 33_12_01 - Basic Mechanical Materials and Methods. 4. Section 40_05_00.09 - Piping Systems Testing. 5. Section 40_80_01 - Testing, Calibration, and Commissioning. 6. Section 46_05_94 - Mechanical Equipment Testing. 7. Section 46_31_59 - Ozone System Testing.

1.02 DEFINITIONS

A. Commissioning – The process of testing the installation for compliance with contract requirements and demonstrating, through documented verification, that the project has successfully met the Contractual requirements and the Project is ready for Process Start-up.

B. Component – A basic building block of equipment, subsystems, and systems that requires installation or functional testing but does not have an electrical connection or internal electronics. (Examples: filter effluent piping and manual isolation valves).

C. Device – A basic building block of equipment, subsystems, and systems that requires installation or functional testing and does have an electrical connection or internal electronics. (Examples: filter level transmitter or water pump pressure transmitter).

D. Engineer - As defined in Article 5 of the Supplier Agreement.

E. Equipment – An assembly of component(s) and devices(s) that requires installation or functional testing. (Examples: Pump, motor, VFD, Ozone Generator, UV Disinfection System, etc.).


F. Facility – A grouping of process areas, systems, subsystems, equipment, components, and devices (Example: Treatment Plant, Pump Station, etc.).

G. Functional Testing – Testing performed on a completed subsystem to demonstrate that equipment/system meets manufacturers’ calibration and adjustment requirements and other requirements as specified. Functional testing includes operating equipment/system manually in local, manually in remote (or remote manual), and automatically in remote (in remote auto).

H. Installation Testing – Testing to demonstrate that subsystem component (piping, power, networks, devices, etc.) is ready and meet the project requirements in advance of functional testing. Installation testing also includes manufacturers’ certification of installation and other requirements as specified to prepare equipment/system for Functional Testing. Also referred to as Field Acceptance Testing.

I. Instrumentation and Controls Performance Testing – Testing to prove the performance of the Instrumentation Process Control system by operating for an extended time period.

J. Manufacturer’s Certificate of Source Testing – When applicable, the form is used during Source Testing for the manufacturer to confirm that the applicable source tests have been performed and results conform to the Contract Documents. The form is provided at the end of this Section.

K. Manufacturer’s Certificate of Installation and Functionality Compliance – The form is used during Installation Testing and Functional Testing. It is submitted at the end of Functional Testing to confirm that the equipment/system is installed in conformance with the Contract Documents and that it meets the Functional Testing requirements defined in the Contract Documents. The form is provided at the end of this Section.

L. Ozone System Supplier (OSS) - The Supplier providing the ozone system equipment as specified in these Procurement Documents.

M. Ozone System Performance Testing Period - Testing to prove the production and efficiency performance of the ozone generators.

N. Phases – The work activities of testing, training, facility commissioning, and process start-up are grouped into the 3 distinct phases as defined in the table below:

Planning Phase

Commissioning Phase

Process Start-Up Phase

Owner Training Plan and Schedule

Source Testing Process Start-up

Commissioning and Process Start-up Schedule

Owner Training Process Operational Period

Subsystem Testing Plan Installation Testing Instrumentation and Controls Performance Testing

Draft O&M Manuals Functional Testing Ozone System Performance Testing Period

Closeout Documentation

Final training and completion of O&M Manuals


O. Process Operational Period – A period of time after completion of the Process Start-up set aside for final Operational Testing to verify facility performance meets the Contract Document requirements. This period may specifically limit other construction activities.

P. Product – A system, subsystem or component.

Q. Process Start-up – Activities conducted after commissioning that are necessary to place systems or process areas into operational service.

R. Source Testing – Quality control testing conducted at the source or point of assembly to demonstrate components, devices, equipment/systems, and software meets specified performance requirements prior to shipment. Also referred to as factory testing or factory acceptance testing (FAT).

S. Submittals - Documentation specified in this section for review and comment by the District and Engineer. All submittals shall be made in accordance with Section 01_33_00.

T. Subsystem – A building block of systems made up from a grouping of components, devices, and equipment that perform a definable function. (Examples: Filter No. 1 Backwash Subsystem, Sedimentation Basin No. 1 Hoseless Sludge Removal Subsystem).

U. System – A grouping of subsystems, equipment, components, and devices that perform a definable function. (Examples: Filter No. 1, Sedimentation Basin).

1.03 COMMISSIONING AND START-UP COORDINATOR (CSC)

A. District will designate and provide a CSC for this project after the installation contract is awarded. The approved Project Manager and start-up personnel of the OSS shall coordinate all Work specified in this Section through the CSC.

1.04 SERVICES OF OSS REPRESENTATIVES

A. Refer to RFQ for qualifications of OSS project manager, training, and start-up personnel.

B. No substitute representatives will be allowed unless approved in writing by Owner.

C. Completion of OSS on-site services: Engineer approval required.

D. OSS is responsible for determining the time required to perform the specified services: 1. Minimum times specified in the Contract Documents are estimates. 2. No additional costs associated with performing the required services will be

approved. 3. OSS required to schedule services in accordance with the Contractor’s project

schedule including making multiple trips to project site when there are separate milestones associated with installation of each occurrence of manufacturer’s equipment.


E. OSS on-site services as specified in the Contract Documents include the following: 1. Assistance during Commissioning and Process Start-up. OSS staff shall be

regularly engaged and experienced in all aspects of commissioning and process start-up of Project, equipment/systems of similar size, type, and capacity as this project.

2. Provide daily copies of manufacturers’ representatives field notes and data to Engineer.

3. Other requirements as specified in the Contract Documents. 4. Provide technical instruction for commissioning and process start-up. 5. Provide assistance in directing the actual facility operation during

Commissioning Phase and Process Start-up Phase. 6. Carefully review the additional testing requirements in the Contract Documents

and coordinate with requirements specified in this Section.

1.05 PLANNING PHASE

A. Owner training responsibilities by OSS: 1. Ozone System Supplier Training Coordinator.

a. The OSS shall assign an individual to serve as the Training Coordinator for all training provided by the OSS and their suppliers.

b. The responsibilities of the Training Coordinator shall include, but not be limited to: 1) Develop and submit a training schedule that is coordinated with all

project schedules, and is acceptable to the District. 2) Work with the CSC to identify and schedule training locations at

District facilities or other locations as needed. 3) Coordinate and supervise all facets of each training session. Provide

any necessary training materials including computers, projectors, screens, white boards, and flip charts.

4) Coordinate scheduling of manufacturer visits for training. 5) Coordinate professional video taping of all training sessions, and

participate in the editing of the final training videotapes before submittal to the District.

c. The Training Coordinator shall meet with the CSC a minimum of 120 days prior to initiation of the first training session to review training requirements including training schedules, lesson plans, learning objections, content outline, instructional delivery methods, and other details as determined by the CSC . This meeting shall be held at the District's Administration Building in Downtown Oakland or at another District facility. Subsequent meeting or teleconference may be required if all issues cannot be adequately addressed in the initial meeting. All OSS manufacturers' training representatives should be present at this meeting. If the OSS elects to act on the behalf of the manufacturer's representatives, then the OSS shall ensure that the various manufacturers' training representatives are available for teleconferencing during the meeting.

2. Training instruction format: a. The training for all District personnel shall be provided as one entity. b. Instructors shall apply adult education best practices, emphasizing learner

participation and activity. c. Training delivery may include problem solving, question/answer, hands-on

instruction, practice, evaluation/feedback tools, and lecture.


d. Visual aids and hands-on practice sessions shall support training objectives.

e. Lecturing should be less than 50 percent of class time. f. Conduct hands-on instruction according to the following descriptions:

1) Present hands-on demonstrations of at least the following tasks: a) Proper start-up, shutdown, and normal and alternative operating

strategies. b) Emergency shutdown procedures and system restart. c) Common corrective maintenance repairs for each group. d) Describe recommended procedures to check/test

equipment/system following a corrective maintenance repair. 2) Use tools and equipment provided by manufacturer to conduct the

demonstrations: a) Submit requests for supplemental assistance and facilities with

the Contractor’s proposed lesson plans. 3) OSS remains responsible for equipment disassembly or assembly

during hands-on training situations involving equipment disassembly or assembly by Owner’s personnel: a) Provide written certification of proper equipment/system

operation to Engineer after completion of hands-on training. 3. Class agenda:

a. Include the following information in the agenda: 1) Instructor name. 2) Listing of subjects to be discussed. 3) Time estimated for each subject. 4) Allocation of time for Owner staff to ask questions and discuss the

subject matter. 5) List of documentation to be used or provided to support training.

b. Owner may request that particular subjects be emphasized and the agenda be adjusted to accommodate these requests.

c. Distribute copies of the agenda to each student at the beginning of each training class.

4. Number of students: a. Estimated class size: 12 persons:

1) Owner will determine the actual number of students. 2) Engineer will provide an estimated headcount 1 week prior to the

class, so that the instructor can provide the correct number of training aids for participants.

3) Limit classes that include extensive hands-on activities to a maximum of 5 students per class.

5. Instructor qualifications: a. Refer to minimum qualifications specified in the RFQ.

6. Training aids: a. Instructors are encouraged to use audio-visual devices, P&IDs, models,

charts, and so forth, to increase the transfer of knowledge. b. Instructors shall provide such equipment (televisions, video

recorder/player, computer, projectors, screens, easels, etc.), models, charts, and so forth for each class.

c. Instructor is responsible for confirming with Engineer and Owner in advance of each class that the classroom will be appropriate for the types of audiovisual equipment to be employed.


7. Classroom documentation: a. Trainees will keep training materials and documentation after the session. b. Operations and maintenance manuals, as specified in technical sections:

1) Provide a minimum of 2 copies of final draft operations and maintenance manuals as specified in Section 01_78_23 for use during the classroom instruction. Final draft O&M Manuals shall have been reviewed and conditionally approved by the Engineer. O&M Manuals shall be finalized after training and record drawings are complete. Refer to Milestones in the Supplier Agreement.

2) Owner reserves the right to delay training for a particular equipment item if the operations and maintenance manuals for that equipment are incomplete, inaccurate, or otherwise unsuitable for use by the Owner’s staff.

3) No contract extensions or extra costs will be allowed for training delays due to operations and maintenance manual submittal delays.

c. Provide supplemental documentation handouts to support instruction. d. Digitally record audio and video of each training class:

1) Include classroom and field instruction with question and answering periods.

2) Record in digital format and recording shall become property of the Owner: a) Provide audio quality that is not degraded during the recording

of the field sessions due to background noise, space, distance or other factors.

3) Video files shall be file format and delivery medium as directed and approved by Owner.

4) Provide 2 complete sets of video materials fully indexed and cataloged with printed labels stating session content and dates recorded.

5) The OSS shall provide a written release from all claims to the recorded training material produced, if required.

e. Training modules: 1) Provide a training module for each equipment category. 2) Divide each training module’s instructional content into discrete

lesson plans. f. Lesson plans:

1) Provide performance based learning objectives. 2) State learning objectives in terms of what the trainees will be able to

do at the end of the lesson. 3) Define student conditions of performance and criteria for evaluating

instructional success: a) Provide the following information.

4) Instruction lesson plan outlines for each craft. a) Provide specific components and procedures.

5) Minimum requirements: a) Hands-on demonstrations planned for the instructions. b) Cross-reference training aids. c) Planned training strategies such as whiteboard work, instructor

questions, and discussion points or other planned classroom or field strategies.

d) Attach handouts cross-referenced by section or topic in the lesson plan.


e) Indicate duration of outlined training segments. 6) Provide maintenance instruction lesson plans including mechanical,

instrumentation, and electrical aspects: a) Equipment operation:

(1) Describe equipment’s operating (process) function and system theory.

(2) Describe equipment’s fundamental operating principles and dynamics.

(3) Identify equipment’s mechanical, electrical, and electronic components and features.

(4) Identify support equipment associated with the operation of subject equipment.

(5) Detail the relationship of each piece of equipment or component to the subsystems, systems, and process.

(6) Cite hazards associated with the operations, exposure to chemicals associated with the component, or the waste stream handled by the component.

(7) Specify appropriate safety precautions, equipment, and procedures to eliminate, reduce, or overcome hazards.

b) Detailed component description: (1) Identify and describe Preventative Maintenance (PM)

inspection procedures required for all equipment provided , spot potential trouble symptoms (anticipate breakdowns), and forecast maintenance requirements (predictive maintenance): (a) Review preventive maintenance frequency and task

analysis table. (2) Identify each component function and describe in detail. (3) Where applicable, group relative components into

subsystems. (4) Identify and describe in detail equipment safety features,

permissive and controls interlocks. 7) Provide the following information in equipment troubleshooting

lesson plans: a) Define recommended systematic troubleshooting procedures as

they relate to specific craft problems. b) Provide component specific troubleshooting checklists as they

relate to specific craft problems. 8) Provide the following information in equipment Corrective

Maintenance (CM) troubleshooting lesson: a) Describe recommended equipment preparation requirements as

they relate to specific craft problems. b) Identify and describe the use of any special tools required for

maintenance of the equipment as they relate to specific craft problems.

c) Describe component removal/installation and disassembly/assembly procedures for specific craft repairs.

d) Perform at least 2 hands-on demonstrations of common corrective maintenance repairs: (1) Additional demonstrations may be required by the Owner.


e) Describe recommended measuring instruments and procedures, and provide instruction on interpreting alignment measurements, as appropriate.

8. Class logistics: a. Delivery time minimum: 3 hours. b. Delivery time maximum: 4 hours:

1) Longer time requires Engineer approval. If class duration is longer than 4 hours, then the class shall be scheduled on multiple days in 4-hour or less increments.

c. Class agenda: 1) Refreshment break: One 10-minute.

a) Provide refreshments for each training session including coffee, tea, juice, cold soft drinks, a selection of bakery items, and fresh fruit.

2) Meal break: One 45-minute, unless otherwise specified, if training extends into the District's lunch period. The meal break does not count in the training delivery time.

3) Schedule refreshment breaks and meal breaks to meet the class needs and Owner work rules.

d. Schedule specific sessions: 1) Minimum of 30 days in advance to allow Owner staffing

arrangements to take place. 2) At the times requested by the Owner, within the period 7 a.m. to 7

p.m. Tuesday through Thursday: a) Times scheduled will be at Owner’s discretion.

3) Owner approval and confirmation required for session schedules. 4) Provide minimum of 2 sessions for each class unless otherwise

noted: a) The purpose of having multiple sessions on each class is to

accommodate the attendance of as many Owner personnel working different shifts as possible.

b) A maximum of 1 session per day for each class. e. Training locations: All classroom training shall be at District facilities or

other locations with the San Francisco Bay Area as determined by the District unless otherwise specified. Coordinate the exact locations for training sessions with the District.

9. Training Evaluation Form a. Training Evaluation Form is included at the end of this Section shall be

distributed following each training session. b. Return completed Training Evaluation Forms to Owner’s designated

training coordinator immediately after session is completed. c. Revise training sessions judged “Unsatisfactory” by a majority of

attendees: 1) Conduct training sessions again until a satisfactory rating is achieved

at no additional cost to Owner. The OSS shall be responsible for all costs associated repeated training sessions including all costs for District trainee time.

10. Submittals: a. Prior to the first training session:

1) Comprehensive training schedule identifying all training by specification section and paragraph number: 90 calendar days prior to initial training session.


2) Training course materials: 14 calendar days prior to initial training session: a) Training agenda, lesson plan, presentation, and handouts. b) Other audio-visual aids utilized during each training course. c) Format: 2 electronic copies and 3 hard copies organized in

notebooks. d) Final Draft O&M Manuals

b. Post training session: 1) Training course materials: Due 14 calendar days after class

completion: a) Video recordings. b) Class attendance sheets. c) Training agendas, final lesson plans, presentation, and

handouts. d) Other audio-visual aids utilized during each training course. e) Provide materials for all sessions of the classes in a single

transmittal. f) Format: 2 electronic copies and 3 hard copies organized in

notebooks. 11. The following table summarizes the equipment/systems where training is

required. Additional training shall be provided if specified in a section not included in the table.

Specification Section and Paragraph Equipment/system Name

40_61_00, Article 3.07 Common Work Results for Process Controls 40_61_05, Article 3.10 Packaged Control System 46_31_52, Article 3.07 Ozone Systems: General 46_31_54, Article 3.03 Supplemental Nitrogen Equipment 46_31_58, Article 3.08 Cleaning for Oxygen and Ozone Service

B. Commissioning and Process Start-up schedule and responsibilities for the OSS: 1. Commissioning overview:

a. Comply with Commissioning and Process Start-up Roles and Responsibilities Matrix specified at the end of this Section.

2. Submittal due date: a. Submit Commissioning and Process Start-up schedule not less than 240

calendar days prior to planned initial commissioning of each subsystem or system.

3. Schedule requirements: a. Schedule durations and float for commissioning and process start-up

activities to ensure Work does not fall behind schedule due to complications or delays during Commissioning and Process Start-up.

b. Time-scaled network diagram detailing the work to take place in the period between 210 calendar days prior to planned initial commissioning and process start-up of equipment and systems together with supporting narrative.

c. Provide detailed schedule of Commissioning and Process Start-up activities including durations and sequencing requirements: 1) Identify the following activities:

a) Commissioning Phase: (1) Source Testing.


(2) Owner Training. (3) Installation Testing. (4) Functional Testing. (5) Closeout Documentation.

b) Process Start-up Phase: (1) Process Start-up. (2) Process Operational Period. (3) Instrumentation and Controls Performance Testing.

d. Schedule manufacturer’s services to avoid conflict with other on-site testing or other manufacturers’ on-site services.

e. Verify that conditions necessary to allow successful testing have been met before scheduling services.

f. OSS shall address all Engineer and CSC comments on the submitted schedule, make resubmittals as needed, and obtain final approval no later than 90 days prior to start of any testing, including source testing.

C. Subsystem testing plans responsibilities of the OSS: 1. Submit separate plans for on-site testing of each individual subsystem and

system to include the following: a. Approach to testing including procedures, schedule, and details of

support to be provided by the District. b. Test objective: Demonstrate subsystem meets the design requirements as

specified in the technical sections. c. Test descriptions, forms, temporary systems (pumps, piping, etc.),

shutdown requirements for existing systems, test forms, test logs, witness forms, and checklists to be used to control and document the required tests including details for conducting pre-testing activities including: 1) Removal of rust preventatives and oils applied to protect equipment

during construction. 2) Flushing lubrication systems and disposing of flushing oils:

a) Recharging of lubrication systems with lubricant recommended by manufacturer.

3) Flushing fuel systems and providing fuel for testing and art-up. 4) Installing and adjusting packing, mechanical seals, O-rings, and

other seals. Replace defective seals. 5) Removing temporary supports, bracing, or other foreign objects

installed to prevent damage during shipment, storage, and erection. 6) Checking rotating machinery for correct direction of rotation and for

freedom of moving parts before connecting driver. 7) Performing cold alignment and hot alignment to manufacturer's

tolerances. 8) Adjusting V-belt tension and variable pitch sheaves. 9) Inspecting hand and motorized valves for proper adjustment:

a) Tightening packing glands to insure no leakage, but permit valve stems to rotate without galling.

b) Verifying valve seats are positioned for proper flow direction. 10) Tightening leaking flanges or replace flange gasket:

a) Inspecting screwed joints for leakage. d. Test forms: Include, but not limited to, the following information:

1) Tag and name of equipment/system to be tested. 2) Test date. 3) Names of persons conducting the test.


4) Names of persons witnessing the test, where applicable. 5) Test data. 6) Applicable project requirements. 7) Check offs for each completed test or test step. 8) Place for signature of person conducting tests and for the witnessing

person, as applicable. e. Manufacturer’s Certificate of Installation and Functionality Compliance test

forms which certify the equipment meets the following requirements. An example certification form is included at the end of this Section. 1) Has been properly installed, adjusted, aligned, and lubricated. 2) Is free of any stresses imposed by connecting piping or anchor bolts. 3) Is able to be operated as necessary for Functional Testing. 4) Is suitable for satisfactory full-time operation under full load

conditions. 5) Operates within the allowable limits for vibration and noise.

f. Submit electrical equipment, instrumentation, and control panel test plans and certification forms that document all components are: 1) Properly installed, calibrated, and functioning. 2) Electrical Installation Testing is complete and test results have been

approved by the Engineer: 3) Noted deficiencies have been corrected. 4) Relays, circuit breakers, and other protective devices are set. 5) Control logic for start-up, shutdown, sequencing, interlocks, control,

and emergency shutdown have been tested and are properly functioning.

6) Motor control is calibrated and tested. 7) Demonstrate proper operation of each control loop function including

mechanical, electrical, alarms, local and remote controls, instrumentation, and other equipment/system functions: a) Generate signals with test equipment/system to simulate

operating conditions in each control mode. g. Test plans shall identify Functional Testing durations for each subsystem:

1) Durations will vary depending on the availability of water for testing. 2) Target minimum Functional Test duration: 8 hours continuous

successful operation. Multiple subsystems may be tested simultaneously if they are linked from a process standpoint.

3) Identify equipment/system that cannot be tested for a minimum of 8 hours as specified in technical sections.

h. Source Test Plans: 1) As specified in this Section and other technical sections. 2) Source Testing requirements as specified in technical sections:

a) Non-witnessed: Provide Manufacturer’s Certificate of Source Testing.

b) Witnessed: 3 Owner's representatives present during testing unless otherwise specified and provide Manufacturer’s Certificate of Source Testing.

3) Prepared by Contractor as a result of discussions and planning emerging from regularly conducted commissioning and process start-up meetings for source tests as specified in the Contract Documents.

4) Provide the following items for each Source Test: a) Purpose and goals of the test.


b) Identification of each item of equipment/system, including system designation, location, tag number, control loop identifier, etc.

c) Description of the pass/fail criteria that will be used. d) Listing of pertinent reference documents (Contract Documents

and industry standards or specifications applicable to the testing).

e) Complete description, including drawings or photographs, of test stands and/or test apparatus.

f) Credentials of test personnel. g) Descriptions of test equipment to be used, product information

and all appropriate calibration records for the test equipment. h) Test set-up procedures. i) Detailed, step-by-step test procedures:

(1) The level of detail shall be sufficient for any witness with a rudimentary technical aptitude to be able to follow the steps and develop confidence that the tests were being performed as planned.

(2) All steps are significant and all steps shall be included in the procedures.

j) Sample data logs and data recording forms. Sample computations or analyses with the results in the same format as the final report to demonstrate how data collected will be used to generate final results: (1) Complete disclosure of the calculation methodologies. (2) Include a sample for each type of computation required for

the test and analysis of the results. k) Detailed outline of the Source Test report. l) Sample test reports.

D. Process Start-up Plan 1. The CSC and OSS shall develop and submit a Process Start-up Plan to verify

that all systems associated with the Project meets the Contract Document requirements. The plan shall include: a. Pre-start-up activities:

1) Commissioning Documentation and Data Review. 2) Complete Final Process Start-up Forms and Documentations. 3) Control loop tuning:

a) Perform control loop tuning during system testing with water to the extent possible.

b. Process area start-ups: 1) Process start-up individual process areas comprised of multiple

interdependent systems where possible and beneficial to reduce complexity and risk of complete facility testing.

2) Process area test flows may be limited by upstream and downstream process constraints (i.e., tank and basin volumes) and/or localized recirculation capabilities.

c. Facility-wide process start-up: d. Process control systems testing:

1) Complete system instrumentation, controls and PLC, HMI, and LOI programming for the facility.


e. Remaining equipment/system tests

E. Process Operational Period Start-up Plan 1. CSC and OSS shall develop and submit a testing plan for the Process

Operational Period: a. Plan shall demonstrate conformance with treatment standards is required

prior to Operational Testing. b. Target duration of Process Operational Start-up: 7 calendar days

continuous operation 24 hours per day.

F. Ozone System Performance Testing Plan 1. The CSC and OSS shall develop and submit a ozone system performance

testing plan to demonstrate performance requirements specified in Section 46_31_59.

2. Ozone system performance testing may extend beyond completion of the Process Operational Period but shall be completed within the constraints of Section 46_31_59.

G. Submittals: 1. OSS is responsible for submitting and obtaining approval of all the above test

plans within the timeframes specified below: a. Provide initial submittals for test plans for start-up, commissioning, and

source testing of all equipment not less than 90 calendar days prior to any planned testing of subsystem or system.

b. Revise and update test plans based on review comments, actual progress, or to accommodate changes in the sequence of activities.

c. OSS shall address all Engineer comments on the test plans, make resubmittals as needed, and obtain final approval no later than 60 days prior to start of any testing, including source testing.

1.06 COMMISSIONING PHASE

A. Overview of Commissioning Phase: 1. General:

a. Includes specified Source Testing, Owner Training, Installation Testing, Functional Testing, and Closeout Documentation required by this Section and the technical sections.

2. OSS responsibilities: a. Furnish labor, tools, equipment, instruments, and services required for

and incidental to completing commissioning and process start-up activities in accordance with the approved Commissioning and Process Start-up Plans submitted during the Planning Phase.

b. Prior to testing, verify equipment protective devices and safety devices have been installed, calibrated, and tested.

c. Acceptable tests: Demonstrates that the equipment/system performance meets the requirements described in the approved test plans. 1) When the equipment/system fails to meet the specified requirements,

perform additional, more detailed, testing to determine the cause, correct, repair, or replace the causative components and repeat the testing that revealed the deficiency.


B. Source Testing Responsibilities by the OSS: 1. Also referred to as factory testing or factory acceptance testing (FAT). 2. Test components, devices, and equipment/system for proper performance at

point of manufacture or assembly as described in the approved Source Test plan.

3. Notify the Engineer in writing when the equipment/system is ready for source inspection and testing.

4. Test results: a. Prepare and submit test results using the approved Source Test forms.

5. OSS is responsible for costs associated with three (3) Owner's representatives witnessing Source Tests: a. Include costs for at least the following:

1) Transportation, if to be performed at a location more than 200 miles one way from Oakland, CA: a) Travel 1 day on commercial airline to site including air flight

costs. b) Travel 1 day on commercial airline from site including air flight

costs. c) Mid-size rental car or taxi services from hotel to and from the

test site plus fuel, tolls, and airport parking at the departing airport.

d) International travel: Per diem rates as established by the US Department of State for the specific location and dates of travel. Travel expenses may include the direct cost of securing passports, visas, language interpreters, document translators, communications and internet access.

2) Hotel costs, if to be performed at a location more than 125 miles one way from Oakland, CA, at a facility with an American Automobile Association 3 diamond or better rating or equivalent for single occupancy room per person per day.

3) Meal allowance of $61 per person per day. 4) On-site time: 1 day at the site, unless specified otherwise.

b. If Source Test is not ready when the witnesses arrive or if the Source Test fails, the witnesses will return home with OSS responsible for costs associated with the trip including costs described above. OSS is responsible for rescheduling the Source Test and witnesses’ costs associated with the second trip including costs described above.

c. All fees incurred such as airline reservation change fees, loss of fare due to purchase of nonrefundable tickets, hotel cancellation/rebooking fees, and similar expenses incurred as a result of OSS-requested changes to the inspection schedule after the initial notification shall be borne by the OSS.

d. OSS is responsible for witnesses’ costs associated with retests including costs described above.

6. OSS is responsible for providing fuel, chemicals, and other consumables needed for Source Testing.

C. Owner training responsibilities by OSS: 1. Complete training during the Commissioning Phase in accordance with the

schedule and training plans approved during the Planning Phase.


D. Installation Testing Responsibilities by OSS: 1. Perform subsystem testing according to approved Subsystem Testing Plans. 2. Obtain the Manufacturer’s Certificate of Installation and Functionality

Compliance for all equipment using the approved form. a. Form shall be submitted after completion of Functional Testing, as

specified in this Section. 3. Perform mechanical equipment Installation Testing: As specified in the

approved test plan. 4. Instrumentation devices and subsystems Installation Testing: As described in

the approved test plans.

E. Functional Testing Responsibilities: 1. Perform subsystem testing according to approved Subsystem Testing Plans

and schedule. 2. Notify the Engineer no later than 5 days prior to when the Work is ready for

Functional Testing: 3. Perform testing in the presence of the Engineer.

a. Repair or replace parts that operate improperly and retest. b. Submit testing results using the approved forms.

4. Provide completed Manufacturer’s Certificate of Installation and Functionality Compliance using the approved forms for all equipment: a. Submit preliminary test reports for each phase of testing including Source

Testing for each equipment/system within 1 day of completing test. Submit final test report for each system within 14 days of completing test. 1) Engineer approval of preceding test reports is required prior to start

of next test. 2) Tests will be rescheduled if test report is not approved by the

required deadline.

1.07 PROCESS START-UP PHASE

A. Process Start-up Responsibilities by OSS: 1. Perform process start-up in accordance with the approved test plan in the

presence of the Engineer. 2. Perform Pre-start-up activities in accordance with the approved plan. 3. Conduct Process area start-ups in accordance with the approved plan. 4. Conduct Facility-wide process start-up in accordance with the approved plan

B. Process Operational Period Responsibilities by OSS: 1. Prior to beginning the Process Operational Period:

a. Conformance with treatment standards is required prior to Operational Testing.

b. Correct any outstanding punchlist items prior to the Operational Testing. 2. Engineer will be present for process operational period unless such presence

is expressly waived in writing. 3. The OSS shall provide:

a. Specified start-up materials and operating supplies. b. Necessary labor assistance, in the event of an emergency equipment

failure requiring immediate attention (emergency is defined as a failure of function which precludes the further operation of a critical segment of or the whole of the work) with a response time of not more than 4 hours from the time of notification.


c. Manufacturer’s authorized representative to supervise placing equipment/systems in operation and provide guidance during Operational Testing per applicable section.

d. Necessary manufacturer’s representatives and operating supplies for retesting systems that fail to pass the initial Operational Testing due to deficiencies in products of workmanship at no additional cost to the Owner.

4. Owner will provide: a. Operations personnel for duration of test to operate the treatment plant

and coordinate with the OSS for operation of the ozone systems. 5. The Contractor’s CSC will oversee Process Operational Period:

a. OSS will operate the completed system. b. Entire system shall continuously meet performance requirements and

shall operate without fault, failure, or defect for a continuous period. c. Individual equipment/system failures that are corrected within 4 hours and

do not prevent the entire project from continuously satisfying the established operational requirements shall not require the consecutive day test to be re-started unless the failure recurs. Operating redundant equipment during a failure will not be considered a correction to a failure.

d. Restart the consecutive test period for any of the following conditions: 1) Any failure of the complete Project construction to meet operational

requirements. 2) When malfunctions or deficiencies cause shutdown or partial

operation of the facility or results in failure of the complete Project construction to meet operational requirements.

3) Any individual equipment/system failure that meets any of the following conditions: a) Requires more than 4 hours to correct, unless otherwise

specified in Section 40_80_01. b) Recurs within the 24 hour correction period requiring further

correction. 4) Immediately correct defects in material, workmanship, or

equipment/system which became evident during Operational Testing. 6. Instrumentation and Controls Performance Testing: 7. After the Process Operational Period, test PCIS system for additional 60 days

as specified in Section 40_80_01 to identify issues and make corrections, as needed. a. OSS shall provide 24 hours of programming support during

Instrumentation and Controls Performance Testing. The cost for this programming effort shall be included in the bid price.

C. Ozone System Performance Testing: 1. Conduct ozone system performance testing in accordance with the approved

plan. 2. Ozone system performance testing may extend beyond completion of the

Process Operational Period but shall be completed within the constraints of Section 46_31_59.


1.08 CLOSEOUT DOCUMENTATION RESPONSIBILITIES BY OSS:

A. Submittals: 1. Provide approved final records generated during commissioning and process

start-up phase of Project: a. Required documents include but are not limited to:

1) Training documentation. 2) Manufacturer’s Certificates of Source Testing. 3) Manufacturer’s Certificates of Installation and Functionality

Compliance. 4) Daily logs of equipment/system testing identifying tests conducted

and outcome. 5) Test forms and documentation. 6) Functional Testing results. 7) Logs of time spent by manufacturer's representatives performing

services on the job site. 8) Electrical phase, voltage, and amperage measurements. 9) Insulation resistance measurements.

b. Data sheets of control loop testing including testing and calibration of instrumentation devices and setpoints. Format: 2 electronic copies and 3 hard copies organized in notebooks.

c. Due date: Within 14 calendar days of Substantial Completion. 2. Provide Instrumentation and Control Performance Testing reports:

B. Format: 2 electronic copies and 3 hard copies organized in notebooks. a. Due date: Within 7 calendar days of completing Instrumentation and

Controls Performance testing completion. 2. Refer to Section 46_31_52 for additional requirements.



END OF SECTION


MANUFACTURER’S CERTIFICATE OF SOURCE TESTING OWNER EQPT/SYSTEM PROJECT NAME EQPT TAG NO. PROJECT NO. EQPT SERIAL NO. SPECIFICATION NO. SPECIFICATION TITLE.

Comments:

I hereby certify Source Testing has been performed on the above-referenced equipment/system as defined in the Contract Documents and results conform to the Contract Document requirements. Testing data is attached.

Date of Execution: , 20

Manufacturer.

Manufacturer’s Authorized Representative Name (print):

(Authorized Signature)

If applicable, Witness Name (print):

(Witness Signature)


MANUFACTURER’S CERTIFICATE OF INSTALLATION AND FUNCTIONALITY COMPLIANCE

OWNER EQPT/SYSTEM PROJECT NAME EQPT TAG NO. PROJECT NO. EQPT SERIAL NO. SPECIFICATION NO. SPECIFICATION TITLE. I hereby certify that the above-referenced equipment/system has been: (Check Applicable) Installed in accordance with manufacturer’s recommendations.

Inspected, checked, and adjusted.

Serviced with proper initial lubricants.

Electrical/Instrumentation and mechanical connections meet quality and safety standards.

All applicable safety equipment has been properly installed.

Functionally tested.

System has been performance tested, and meets or exceeds specified performance requirements.

NOTES: Attach test results with collected data and test report. Attach written certification report prepared by and signed by the electrical and/or instrumentation subcontractor.

Comments:

I, the undersigned manufacturer’s representative, hereby certify that I am (i) a duly authorized representative of the manufacturer, (ii) empowered by the manufacturer to inspect, approve, and operate this equipment/system and (iii) authorized to make recommendations required to assure that the equipment/system furnished by the manufacturer is complete and operational, except as may be otherwise indicated herein. I further certify that all information contained herein is true and accurate.

Date: , 20 Manufacturer: Manufacturer’s Authorized Representative Name (print): By Manufacturer’s Authorized Representative: (Authorized Signature)


COMMISSIONING AND PROCESS START-UP

TRAINING EVALUATION FORM EQUIPMENT/SYSTEM ITEM:

VENDOR/MANUFACTURER:

DATE: NAME OF REPRESENTATIVE:

1. Was representative prepared? Acceptable Unacceptable or N/A 2. Was an overview description presented? Acceptable Unacceptable or N/A 3. Were specific detail presented for system Acceptable Unacceptable or N/A

components? 4. Were alarm and shutdown conditions Acceptable Unacceptable or N/A

clearly presented? 5. Were step-by-step procedures for starting, Acceptable Unacceptable or N/A

stopping, and trouble-shooting presented? 6. Were routine/preventative maintenance Acceptable Unacceptable or N/A

items clearly identified? 7. Was the lubrication schedule (if any) Acceptable Unacceptable or N/A

discussed? 8. Was the representative able to answer all Acceptable Unacceptable or N/A

questions? 9. Did the representative agree to research Acceptable Unacceptable or N/A

and answer unanswered questions? 10. Comments:

11. Overall Rating: Satisfactory Unsatisfactory Notes:

Sessions judged “Unsatisfactory” by a majority of attendees shall be revised and conducted again until a satisfactory rating is achieved.

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9905A10 pw://Carollo/Documents/Client/CA/EBM

UD/9905A10/02 Pre-Purchase/Specifications/01_75_17 (FINAL)

COMMISSIONING AND PROCESS START-UP ROLES AND RESPONSIBILITIES MATRIX

NO. TASK OWNER CONTRACTOR ENGINEER OSS CSC

Planning Phase

Owner Training Plan and Schedule

1 Owner Training Plan and Schedule Support Lead Review Support SWR

2 Training Support Support Witness Lead SWR

Commissioning and Process Start-up Schedule

3 Commissioning and Process Start-up Schedule Support Lead Review Support SWR

Subsystem Testing Plan

4 Subsystem Testing Plan Support Lead Review Support SWR

Commissioning Phase

Source Testing

5 Source Testing Witness Support Witness, Review

Lead SWR

Installation Testing

6 Electrical Conductor Testing Witness Support Witness Lead SWR

7 Electrical Field Acceptance Tests Witness Support Witness Lead SWR

8 Instrument Field Calibration Witness Support Witness Lead SWR

9 Network Installation Testing Witness Support Witness Lead SWR

10 Loop Testing Witness Support Witness Lead SWR

11 Pressure Testing Witness Support Witness Lead SWR

12 Leak Testing Witness Support Witness Lead SWR

Functional Testing

13 Network Operational Testing Witness Support Review Lead SWR

February 2016 01_75_17-22





14 Preliminary Run Testing Local /Manual Control Witness Support Review Lead SWR

15 PCIS Functional Demonstration Testing

- Local/Auto Control Testing

- Remote/Manual Contact Testing

- Alarm Testing

- Control Loop Testing

Witness Support Review Lead SWR

16 Subsystem Start-up and Testing Witness Support Review Lead SWR

17 Equipment/System Start-up and Testing Witness Support Review Lead SWR

18 Manufacturer’s Certificate of Installation and Functionality Compliance

Witness Support Witness, Review

Lead SWR

Process Start-up Phase

Process Start-up

19 Commissioning Documentation and Data Review

Review Support Lead Support SWR

20 Start-up Sequence Review Support Support Review Lead SWR

21 Temporary Testing Arrangement Finalization Support Support Support Lead SWR

22 Start-up Forms Finalization Support Support Support Lead SWR

23 Operation Testing Plan Finalization Review Support Lead Lead SWR

24 System Testing Support Support Witness Lead SWR

25 Control Loop Tuning and Optimization Support Support Witness Lead SWR

26 Process Area Start-ups Support Support Witness Lead SWR

27 Facility Wide Start-up Support Support Witness Lead SWR

28 Process Control Systems Testing Support Support Witness Lead SWR

February 2016 01_75_17-23





Process Operational Period

29 Operational Testing Support Support Witness, Review

Lead SWR

30 Final Testing Reports Support Support Review Lead SWR

Instrumentation and Control Performance Testing

31 PCIS Performance Testing Support Support Review Lead SWR

Ozone System Performance Testing Period

32 Ozone System Performance Testing Support Support Witness, Review

Lead SWR

Legend: Lead: Primarily responsible for organization, coordination, and execution of task work product or result. Support: Assist the lead with organization, coordination, and execution of task work product or result. Witness: Observe and document completion of task work product or result. Review: As necessary to accept task work product result. SWR: Support, Witness, and Review

February 2016 01_75_17-24




SECTION 01_78_23

OPERATION AND MAINTENANCE DATA

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Preparation and submittal of Operation and Maintenance (O&M) Manuals by the OSS and the O&M Manual Review Checklist and Maintenance Summary Forms in Attachment A of this Section.

1.02 SUBMITTALS

A. Submit Operation and Maintenance Manuals before field quality control testing and before training of each piece of equipment or system. Submit the O&M Manual Review Checklist and Maintenance Summary Forms with each O&M manual submitted.

B. Submit eight (8) Draft Manuals for each piece of equipment or system - four (4) manuals for the Sobrante WTP and FOUR (4) manuals for the USL WTP. Manuals shall be specific for each WTP if there are any differences in the equipment supplied to each WTP.

C. Submit eight (8) Final Manuals for each piece of equipment or system - four (4) manuals for each WTP. Prepare Final Manuals based on comments from the District and Engineer. Submit Finals Manuals prior to Contract Completion.

D. Make manuals available at each project site for use by construction personnel and Owner.

E. Make additions and revisions to the Manuals in accordance with Owner's review comments.

1.03 OPERATION AND MAINTENANCE MANUALS

A. Preparation: 1. Hardcopy manuals:

a. Provide Operations and Maintenance Manuals in 3-ring binders with rigid covers. Utilize numbered tab sheets to organize information.

b. Provide original and clear text on reproducible non-colored paper. c. Provide all dimensions and units in English units. d. Provide manual entirely in the English language. e. Provide 4 copies of each WTP O&M Manual

2. Electronic O&M manuals: a. After preparation of the Final O&M Manual, an electronic version shall be

supplied in addition to the required number of hard copies. b. Electronic files shall be created in both pdf and Microsoft Word (2007 or later)

versions. The security features of all submitted files shall be disabled so that the District can perform future editing. Custom-developed drawings included in the O&M Manual, such as loop diagrams, system interconnection diagrams, and P&IDs, shall also be submitted electronically in both pdf and the native CAD file format for future editing of the drawings by the District. For AutoCAD files, the


associated pdf files shall be saved such that all AutoCAD layering is preserved in the pdf file.

c. Electronic versions shall match the hard copy page for page with blank pages deleted. Electronic files shall be converted to pdf directly rather than using optical scanning. For any document not already in electronic format, the documents shall be scanned using optical character recognition to provide searching capability in the document.

d. All electronic files shall be supplied to the Engineer on CD+/-R 700 MB CD or DVD+/-R 4.7 GB DVD if the file is larger 700 MB along with the approved O&M Manuals.

B. Contents of Operation and Maintenance Manuals: As specified in Section 46_31_52.

C. Maintenance Summary Forms: 1. Furnish completed Maintenance Summary Forms (see Appendix A for typical format)

for each piece of equipment that requires maintenance as part of the O&M Manual. Include all typical, routine, or preventive maintenance required to ensure satisfactory performance during warranty period and longevity of the equipment. Manufacturer’s representative shall sign and date the forms certifying accuracy of the information.

2. Briefly summarize each maintenance activity on the forms. Specific references to more detailed maintenance information located elsewhere in the O&M manual may be placed in the “Comments” column. However, simply referencing other sections in the O&M manual without a brief description of the maintenance activity is not acceptable.

3. Information on the forms shall be word-processed, or typewritten. 4. Maintenance Summary Forms shall be on 8-1/2 inch by 11-inch paper and may be as

many pages as required to completely summarize the required maintenance. However, the order and format must be in accordance with the supplied forms. A blank Maintenance Summary Form will be provided by the District in electronic format (MS Word) upon request.



END OF SECTION


ATTACHMENT A

O&M MANUAL REVIEW CHECKLIST AND MAINTENANCE SUMMARY FORM


O&M MANUAL REVIEW CHECKLIST (Manufacturer’s Representative to complete one form per submittal)

SPEC. SECTION TITLE & NO:

MFR Name, Address, Phone:

Local Rep Name, Address, Phone:

GENERAL FORMAT (See Section 01 33 00 for additional details)

DESCRIPTION PROVIDED?

COMMENTS YES NO

Specified copies provided

Binder cover clearly labeled

Spine Label

System/Equipment type clearly identified

District facility or facilities name(s) identified

Specification number & title shown

Title page provided

Equipment tag numbers correctly shown

Ozone System Supplier’s name, address, phone number provided

Local Representative’s name, address, phone number provided

Table of contents provided

Heavy section dividers w/ numbered or lettered plastic tabs provided

Pages punched for 3-ring binder

Info larger than 8-1/2 x 11 folded showing title block

Original quality copies provided

TECHNICAL CONTENT (See Section 01 33 00 for details)

DESCRIPTION LOCATION IN O&M

COMMENTS TAB# PAGES N/A

Equipment Descriptions

• Equipment names, model numbers & tag numbers

• Equipment & major component functions

• Drawings, diagrams & illustrations

• Equipment Specification

• Bill of materials

• Legend, Abbreviation, and Acronym List

Performance Information

• Nameplate data





Installation Instructions

• Installation procedures & drawings

• Equipment tolerances

• Adjustment procedures

Operating Instructions

• Startup procedures

• Normal & routine operations

• Control functions

• Alarms description and settings

• Shutdown procedures

• Emergency operations

Electrical Information

• Nameplate data

• Relay, control, alarm contact settings

• Motor test data

Electrical Drawings

• Single-line diagrams, three-line diagrams

• Interconnection wiring diagram

• Schematic and elementary diagrams

• Panel layout drawings

Instrumentation & Control

• Control diagrams

• Panel layout drawings

• Instrument data sheets (specification forms)

• Calibration Procedures

• Final settings for adjustable control devices

• Block diagrams and riser diagrams

• Loop diagrams

• Pneumatic/Hydraulic piping drawings

• Hard copy printouts of control programs

• Field calibration data sheets

• Programming software (licensed to EBMUD) with user manuals

Shipping and Storage Instructions

Testing

• Factory Test Report (procedures and results)

• Field Test Procedures

• Manufacturer’s Certificate of Proper Installation (where specified)

• Field Test Results

Troubleshooting guide





Safety

• Safety procedures/Lockout discussion

• CAUTION, WARNING, DANGER text

• Material Safety Data Sheets (MSDS)

• Special safety equipment

Preventive Maintenance

Maintenance Summary Forms

Spare Parts for Equipment & Components

• Predicted life of parts subject to wear or aging

• Recommended spare parts list w/ part numbers

• Complete instructions for obtaining parts

• Long-term storage requirements

• Special tools

Long-term Shutdown Instructions

Warranty/Guarantee


TYPICAL MAINTENANCE SUMMARY FORM (Use as many pages as necessary. This form is available in MS Word format upon request)

1. Equipment Name: 2. Manufacturer:

3. Identification Numbers:

Tag:

Model:

Serial: 4. Nameplate Data (HP, voltage, speed, flow rate, head, etc.):

5. Manufacturer’s Local Representative:

Name:

Telephone:

Address: 6. LUBRICANT LIST

Reference Symbol Lubricant Description List symbols used in Item 8 below

List equivalent lubricants: brand name(s), type, grade, viscosity, etc.

7. SPARE PARTS (Recommendation spare parts with part numbers; if any.) OEM Part# Part Name-Description

8. Equipment Replacement Cost [$] ____________________________________


9. MAINTENANCE REQUIREMENTS

Maintenance Task Briefly list each required preventive maintenance activity

Frequency (daily, weekly, monthly, Annual, etc)

Task Duration Time needed to complete each task (with units: hours, days, weeks, etc)

Lubricant Refer by symbol in lubricant list (Item 6)

Task Details Location List O&M Manual Tab and page number which provides details on the activity

I, certify that the information on this form is an accurate and complete summary of all typical, routine, and preventive maintenance tasks required to ensure satisfactory performance during warranty period and the overall longevity of the equipment or systems.

(Manufacturer’s Representatives Signature) (Date)


SECTION 01_81_01

PROJECT DESIGN CRITERIA

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Project design criteria such as temperature and site elevation.

1.02 PROJECT DESIGN CRITERIA

A. All equipment and materials for the project are to be suitable for performance in domestic water treatment plant environment and under following conditions: 1. Design temperatures are:

a. Outdoor temperatures: 1) Sobrante WTP: 21 to 97 degrees Fahrenheit. 2) USL WTP: 28 to 89 degrees Fahrenheit.

b. Indoor temperatures for the following areas at both WTPs: 1) Process areas: 45 to 100 degrees Fahrenheit. 2) Electrical rooms: 45 to 80 degrees Fahrenheit.

2. Moisture conditions: Defined in individual equipment sections. 3. Site elevation:

a. Sobrante WTP: Approximately 260 feet above mean sea level. b. USL WTP: Approximately 400 feet above mean sea level.

4. Raw water temperature and quality: a. The raw water temperature will range between 45 and 80 degrees F.

Design the Ozone Systems in accordance with a maximum heat exchanger closed loop outlet cooling water temperature of 80 degrees Fahrenheit.

b. Average raw water quality conditions at Sobrante WTP: 1) pH = 7.6. 2) Turbidity = 5.2 NTU. 3) Alkalinity = 71 mg/L as CaCO3. 4) Hardness = 76 mg/L as CaCO3.

c. Average raw water quality conditions at USL WTP: 1) pH = 7.8. 2) Turbidity = 1.6 NTU. 3) Alkalinity = 110 mg/L as CaCO3. 4) Hardness = 119 mg/L as CaCO3.

5. Treated water (potable) chemistry: Unless otherwise noted, materials that contact water covered by ozone equipment specifications will be subjected to water that promotes galvanic corrosion. Materials and coatings shall be suitable for use with treated water with the following characteristics: The presence of chloramines in the water shall not have any effect on the manufacturer's warranty. a. Average treated water quality conditions at Sobrante WTP:

1) pH = 8.2 to 9.4. 2) Turbidity = 0.03 to 0.08 NTU. 3) Alkalinity = 71 mg/L bicarbonate as CaCO3. 4) Hardness = 65 to 85 mg/L as CaCO3.


5) Total Dissolved Solids = 120 to 230 mg/l. 6) Chloramine = 0.05 to 3.8 mg/l as free chlorine.

b. Average treated water quality conditions at USL WTP: 1) pH = 8.2 to 9.6. 2) Turbidity = 0.03 to 0.10 NTU. 3) Alkalinity = 130 mg/L bicarbonate as CaCO3. 4) Hardness = 85 to 154 mg/L as CaCO₃. 5) Total Dissolved Solids = 190 to 290 mg/l 6) Chloramine = 0.05 to 3.8 mg/l as free chlorine.

6. Treated Water Production Capacity = 60 million gallons per day (each WTP): a. Ozone system capacity: As defined in individual equipment specification

sections.


PART 3 EXECUTION

Not Used.

END OF SECTION

February 2016 01_81_02-1 9905A10 pw://Carollo/Documents/Client/CA/EBMUD/9905A10/02 Pre-Purchase/Specifications/01_81_02 (IDS95)

SECTION 01_81_02

SEISMIC DESIGN CRITERIA

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Seismic design criteria for the following: 1. Anchorage of mechanical and electrical equipment. 2. Other items as specified or indicated in the Specifications.


binding as if called for by all. 2. It is the Ozone System Supplier's responsibility for scheduling and

coordinating the Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of Ozone System Supplier's Work. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Ozone System Supplier to see that the completed Work complies accurately with the Contract Documents: a. Section 01_41_00 - Regulatory Requirements. b. Section 03_21_17 - Adhesive-Bonded Reinforcing Bars and All Thread

Rods. c. Section 05_05_24 - Mechanical Anchoring and Fastening to Concrete and

Masonry.

1.02 REFERENCES

A. American Society of Civil Engineers (ASCE): 1. 7-10 - Minimum Design Loads for Buildings and Other Structures.

B. Institute of Electrical and Electronics Engineers (IEEE) 1. 693, Recommended Practice for Seismic Design of Substations

1.03 SYSTEM DESCRIPTION

A. Design in accordance with the requirements of the applicable codes as specified in Section 01_41_00 as modified by this Section.

B. Design Requirements for Sobrante Water Treatment Plant: 1. Risk Category: IV. 2. Design spectral acceleration at short periods, SDS = 1.274. 3. Design spectral acceleration at 1 sec periods, SD1 = 0.771.

C. Design Requirements for Upper San Leandro Water Treatment Plant: 1. Risk Category: IV. 2. Design spectral acceleration at short periods, SDS = 1.653. 3. Design spectral acceleration at 1 sec periods, SD1 = 1.031.


D. General Design Requirements: 1. Component importance factor, IP = 1.5. 2. Component amplification factor, aP : In accordance with ASCE 7-10,

Table 13.6-1. 3. Component response modification factor, RP : In accordance with ASCE 7-10,

Table 13.6-1. 4. Do not use friction to resist sliding due to seismic forces. 5. The effects of the vertical seismic loads shall be considered in the design of

the anchors. 6. Resist seismic forces through direct bearing on anchors and fasteners. Do not

design or provide connections that use friction to resist seismic forces. 7. Anchoring and fastening to concrete:

a. The Contractor will provide anchors as specified in Section 05_05_24 or Section 03_21_17 in accordance with the design provided by the Ozone System Supplier.

b. Design anchor bolts, bolts, or welded studs for anchors for resisting seismic forces. Anchor bolts used to resist seismic forces shall have a standard hex bolt head. Do not design anchor bolts fabricated from rod stock with an L or J-shape.

1.04 SEISMIC QUALIFICATION AND CERTIFICATION

A. The electrical equipment and all components provided by the OSS, shall be designed and anchored to resist Code prescribed seismic forces and shall not undergo loss of their intended function after application of these forces. Certification that the equipment is seismically qualified for the above requirements shall be demonstrated as prescribed in Section 13.2 of ASCE 7-05. For equipment covered by IEEE 693, an acceptable certification is a seismic report prepared by the equipment manufacturer in accordance with IEEE 693. This report shall certify that the equipment meets or exceeds IEEE 693 high seismic qualification level requirements.

1.05 PROOF OF COMPLIANCE

A. Structural integrity and anchorage. 1. Structural integrity and anchorage shall be certified by an approved calculation

that demonstrates the adequacy of the anchorage system for seismic forces. This calculation may be based on principles of structural analysis and engineering mechanics, or based on similarity to approved shake table tests.

1.06 SUBMITTALS

A. Shop drawings and calculations: Complete shop drawings, test data, and seismic calculations.

B. Calculations shall be signed and stamped by a civil or structural engineer licensed in the State of California.




END OF SECTION



SECTION 03_21_17

ADHESIVE-BONDED REINFORCING BARS AND ALL THREAD RODS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Bonding reinforcing bars and all thread rods in concrete using adhesives as specified.

B. The Ozone System Supplier shall design the anchorage for the equipment supplied based on the materials and installation methods specified in this Section or Section 05_05_24. The Contractor will provide the materials and labor associated with Work described in this Section.

C. Related sections: 1. The Contract Documents are complementary; what is called for by one is as

binding as if called for by all. 2. It is the Contractor’s responsibility for scheduling and coordinating the Work of

subcontractors, suppliers, and other individuals or entities performing or furnishing any of Contractor’s Work.

3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_41_00 - Regulatory Requirements. b. Section 01_81_02 - Seismic Design Criteria. c. Section 05_05_24 - Mechanical Anchoring and Fastening to Concrete.

1.02 REFERENCES

A. American National Standards Institute (ANSI): 1. Standard B212.15 - Carbide Tipped Masonry Drills and Blanks for Carbide

Tipped Masonry Drills.

B. ASTM international (ASTM): 1. C 881 - Standard Specification for Epoxy-Resin-Base Bonding Systems for

Concrete.

C. ICC Evaluation Service, Inc. (ICC-ES): 1. AC308 - Acceptance Criteria for Post-Installed Adhesive Anchors in Concrete

Elements.

D. Society for Protective Coatings (SSPC): 1. Surface Preparation Standards (SP):

a. SP-1 - Solvent Cleaning.


1.03 SUBMITTALS

A. Product Data: Furnish technical data for adhesives, including: 1. Manufacturer’s printed installation instructions (MPII). 2. Independent laboratory test results. 3. Handling and storage instructions.

B. Quality control submittals: 1. Adhesive manufacturer's past project experience data on at least 3 similar

projects supplied with proposed products within the last 3 years. 2. Special inspection: Provide detailed step-by-step instructions for the special

inspection procedure in accordance with the building code as specified in Section 01_41_00.

3. ICC Evaluation Service, Inc., Evaluation Services Report in compliance with the AC308-Acceptance Criteria for Post-Installed Adhesive Anchors in Concrete Elements.

1.04 QUALITY ASSURANCE

A. Qualifications: 1. Installer qualifications:

a. All individuals performing the work described in this Section shall be certified by a qualified organization to install adhesive anchors by following the MPII. Those organizations deemed to be qualified are: 1) ACI-CRSI Adhesive Anchor Installer Certification Program. 2) An adhesive anchor manufacturer’s certification program, subject to

acceptance by the Engineer.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Storage and protection: 1. Store adhesives and adhesive components on pallets or shelving in a covered-

storage area. 2. Control temperature above 60 degrees Fahrenheit and dispose of product if

shelf life has expired. 3. If stored at temperatures below 60 degrees Fahrenheit, test components prior

to use to determine if they still meet specified requirements.

1.06 PROJECT CONDITIONS

A. Refer to Section 01_81_02.

PART 2 PRODUCTS

2.01 GENERAL

A. Like items of materials: Use end products of one manufacturer in order to achieve structural compatibility and singular responsibility.


2.02 ADHESIVE FOR SELF-CONTAINED CARTRIDGE SYSTEM

A. Adhesive shall have a current ICC Evaluation Service report documenting acceptance under AC308 for use with cracked concrete and for the seismic design categories specified.

B. Materials: 1. In accordance with ASTM C 881, Type IV, Grade 3, Class B or C depending

on site conditions. 2. 2-component, 100 percent solids, insensitive to moisture. 3. Cure temperature, pot life, and workability: Compatible with intended use and

environmental conditions.

C. Packaging: 1. Furnished in side-by-side cartridges with resin and hardener components

isolated until mixing through manufacturer’s static mixing nozzle. Nozzle designed to thoroughly blend the components for injection from the nozzle directly into prepared hole.

2. Container markings: Include manufacturer's name, product name, batch number, mix ratio by volume, product expiration date, ANSI hazard classification, and appropriate ANSI handling precautions.

D. Manufacturers: One of the following or equal as approved by the Engineer: 1. Hilti, Inc., Tulsa, OK: RE 500-SD. 2. Simpson Strong-Tie Company, Inc., Pleasanton, CA: SET-XP.

2.03 ALL THREAD RODS

A. All thread rods: 1. Uncoated

a. In accordance with ASTM A36 unless otherwise indicated on the Drawings.

b. Nuts: ASTM A194. c. Washers: ASTM F436.

2. Galvanized: a. In accordance with ASTM A36 unless otherwise indicated on the

Drawings, and hot dip galvanized in accordance with ASTM A153. b. Nuts: ASTM A194, hot-dip galvanized in accordance with ASTM A153. c. Washers: ASTM F436, hot-dip galvanized in accordance with ASTM

A153. 3. Stainless steel:

a. Units descaled, pickled, and passivated as specified in “Fabrication” in this Section.

b. Threaded rods and nuts to be the products of a single manufacturer/fabricator to ensure proper fit without galling. Ship all thread rods with properly fitting nuts attached.

c. Type 304: 1) Rod: ASTM F593, Group 1, Condition CW, coarse threads. 2) Nuts: ASTM F594. Match alloy of rod (group and UNS designation). 3) Washers: Type 304 stainless steel.

d. Type 316: 1) Rod: ASTM F593, Group 2, Condition CW, coarse threads.


2) Nuts: ASTM F594. Match alloy of rod (group and UNS designation). 3) Washers: Type 316 stainless steel.

2.04 REINFORCING BARS

A. Reinforcing bars: 1. Reinforcing bars embedded in concrete:

a. In accordance with ASTM A615 or A706 Grade 60, deformed reinforcing bars.

2. Reinforcing bars that are required to be welded shall meet the following requirements: a. Low-alloy, Grade 60, deformed reinforcing bars in accordance with

ASTM A706. b. ASTM A615 Grade 60 may be used in lieu of ASTM A706 Grade 60 if

following requirements are satisfied. 1) Welding procedures in accordance with AWS D1.4 are submitted to

Engineer. 2) Specific location for proposed substitution is acceptable to Engineer.

3. Reinforcing bars that are required to resist earthquake-induced flexural and axial forces in concrete frame members and in concrete shear wall boundary members that meet following requirements: a. Low-alloy, Grade 60, deformed reinforcing bars in accordance with

ASTM A706. b. ASTM A615 Grade 60 may be used in lieu of ASTM A706 Grade 60 if

following requirements are satisfied: 1) Mill certificates demonstrating following are submitted to Engineer:

a) Actual yield strength based on mill tests does not exceed minimum yield strength specified in this Section by more than 18,000 pounds per square inch. Retests shall not exceed this value by more than an additional 3,000 pounds per square inch.

b) Ratio of ultimate tensile strength to actual tensile yield strength based on mill tests of reinforcing bars shall not be less than 1.25.

PART 3 EXECUTION

3.01 GENERAL

A. Execution of this work is restricted to those installers certified through a qualified certification program described under Quality Assurance and accepted by the Engineer.

B. The work shall be performed in strict accordance with the accepted MPII and the following instructions. Where the accepted MPII and the following instructions conflict, the MPII shall prevail.

C. Provide adhesive packaged as follows: 1. Disposable, self-contained cartridge system capable of dispensing multiple

adhesive components in the proper mixing ratio, and fit into a manually or pneumatically operated caulking gun.

2. Dispense components through a mixing nozzle that thoroughly mixes components.


3.02 HOLE SIZING AND INSTALLATION

A. Drilling holes: 1. Determine location of reinforcing bars or other obstructions with a

non-destructive indicator device, and mark locations with construction crayon on the surface of the concrete.

2. Do not damage or cut existing reinforcing bars, electrical conduits, or other items embedded in the existing concrete without acceptance by Engineer.

B. Hole drilling equipment: 1. Electric or pneumatic rotary impact type with medium or light impact. 2. Drill bits: Carbide-tipped in accordance with ANSI B212-15 unless otherwise

recommended by the manufacturer or required as a “condition of use” in the ICC Evaluation Report submitted.

3. Hollow drill bits with flushing air systems are preferred. Air supplied to hollow drill bits shall be free of oil, water, or other contaminants that will reduce bond.

4. Where edge distances are less than 2 inches, use lighter impact equipment to prevent microcracking and concrete spalling during drilling process.

C. Hole diameter: Reinforcing bar diameter or all thread rod diameter plus 1/8 inch.

D. Obstructions in drill path: 1. If an existing reinforcing bar or other obstruction is hit while drilling hole, stop

drilling hole and fill the hole with drypack mortar. Relocate the hole to miss the obstruction and drill another hole. Repeat the above until the hole has been drilled to the required depth.

2. Avoid drilling an excessive number of holes in an area of a structural member, which would excessively weaken the structural member and endanger the stability of the structure. Drypack holes which hit obstructions and allow drypack to reach strength equal to the existing concrete before drilling adjacent holes. Epoxy grout may be substituted for drypack when acceptable to Engineer.

3. When existing reinforcing steel is encountered during drilling and when acceptable to Engineer, enlarge the hole by 1/8 inch, core through the existing reinforcing steel at the larger diameter, and resume drilling at original hole diameter.

4. Bent bar reinforcing bars: Where edge distances are critical, and striking reinforcing steel is likely, and if acceptable to Engineer, drill hole at 10 degree angle or less from axis of reinforcing bar or all thread rod being installed.

E. Install reinforcing bars and all thread rods to depth, spacings, and locations as indicated on the Drawings: 1. Do not install adhesive-bonded all-thread rods or reinforcing bars in overhead

applications.

F. Cleaning holes: 1. Insert long air nozzle into hole and blow out loose dust. Use compressed air

that is free of oil, water, or other contaminants that will reduce bond. 2. Use a stiff bristle brush to vigorously brush hole to dislodge compacted drilling

dust.


3. Repeat step 1. 4. Repeat above steps as required to remove drilling dust or other material that

will reduce bond. The hole shall be clean and dry.

G. Cleaning reinforcing bars and all thread rods: 1. Clean reinforcing bars and all thread rods over embedment length to bare

metal, free of oil, grease, paint, dirt, mill scale, rust, or other coatings that will reduce bond.

2. Solvent clean reinforcing bar and all thread rods over the embedment length in accordance with SSPC SP-1 Solvent Cleaning. Provide an oil and grease free surface to promote bonding of adhesive to steel.

H. Filling hole with adhesive: 1. Fill hole with adhesive before inserting the reinforcing bar or all thread rod. Fill

hole with adhesive starting from bottom of hole. Fill hole without creating air voids.

2. Fill hole with sufficient adhesive so that excess adhesive is extruded out of the hole when the reinforcing bar or all thread rod is inserted into the hole.

END OF SECTION


SECTION 05_05_24

MECHANICAL ANCHORING AND FASTENING TO CONCRETE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Cast-in anchors and fasteners:

a. Anchor bolts. b. Anchor rods. c. Concrete inserts. d. Deformed bar anchors. e. Welded studs.

2. Post-installed steel anchors and fasteners: a. Concrete anchors. b. Sleeve anchors. c. Screw anchors. d. Undercut concrete anchors.

3. Appurtenances for anchoring and fastening: a. Anchor bolt sleeves. b. Isolating sleeves and washers. c. Thread coating for threaded stainless steel fasteners.

B. The Ozone System Supplier shall design the anchorage for the equipment supplied based on the materials and installation methods specified in this Section or Section 03_21_17. The Contractor will provide the materials and labor associated with Work described in this Section.




3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittals. b. Section 01_41_00 - Regulatory Requirements. c. Section 01_81_01 - Project Design Criteria. d. Section 01_81_02 - Seismic Design Criteria e. Section 03_21_17 - Adhesive-Bonded Reinforcing Bars and All Thread

Rods.


1.02 REFERENCES

A. American Concrete Institute (ACI): 1. 355.2 - Qualification of Post-Installed Mechanical Anchors in Concrete &

Commentary.

B. American National Standards Institute (ANSI): 1. B212.15 - Cutting Tools - Carbide-tipped Masonry Drills and Blanks for

Carbide-tipped Masonry Drills.

C. American Welding Society (AWS): 1. D1.1 - Structural Welding Code - Steel. 2. D1.6 - Structural Welding Code - Stainless Steel.

D. ASTM International (ASTM): 1. A 29 - Standard Specification for Steel Bars, Carbon and Alloy, Hot-Wrought,

General Requirements for. 2. A 36 - Standard Specification for Carbon Structural Steel. 3. A 53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded and Seamless. 4. A 108 - Standard Specification for Steel Bars, Carbon and Alloy, Cold

Finished. 5. A 123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron

and Steel Products. 6. A 153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware. 7. A 240 - Standard Specification for Chromium and Chromium Nickel Stainless

Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications.

8. A 308 - Standard Specification for Steel Sheet, Terne (Lead-Tin Alloy) Coated by the Hot-Dip Process.

9. A 496 - Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement.

10. A 563 - Standard Specification for Carbon and Alloy Steel Nuts. 11. B 633 - Standard Specification for Electrodeposited Coatings of Zinc on Iron

and Steel. 12. B 695 - Standard Specification for Coatings of Zinc Mechanically Deposited on

Iron and Steel. 13. E 488 - Standard Test Methods for Strength of Anchors in Concrete Elements. 14. F 436 - Standard Specification for Hardened Steel Washers. 15. F 593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws and

Studs. 16. F 594 - Standard Specification for Stainless Steel Nuts. 17. F 1554 - Standard Specification for Anchor Bolts, Steel, 36, 55 and 105-ksi

Yield Strength. 18. F 2329 - Standard Specification for Zinc Coating, Hot-Dip, Requirements for

Application to Carbon and Alloy Steel Bolts, Screws, Washers, Nuts, and Special Threaded Fasteners.


E. International Code Council Evaluation Service, Inc. (ICC-ES): 1. AC01 - Acceptance Criteria for Expansion Anchors in Masonry Elements. 2. AC106 - Acceptance Criteria for Predrilled Fasteners (Screw Anchors) in

Masonry. 3. AC193 - Acceptance Criteria for Mechanical Anchors in Concrete Elements.

1.03 DEFINITIONS

A. Built-in anchor: Headed bolt or assembly installed in position before filling surrounding masonry units with grout.

B. Cast-in anchor: Headed bolt or assembly installed in position before placing plastic concrete around.

C. Overhead installations: Fasteners installed on overhead surfaces where the longitudinal axis of the fastener is more than 60-degrees above a horizontal line so that the fastener resists sustained tension loads.

D. Passivation: Chemical treatment of stainless steel with a mild oxidant for the purpose of enhancing the spontaneous formation of the steel’s protective passive film.

E. Post-installed anchor: Fastener or assembly installed in hardened concrete or finished masonry construction, typically by drilling into the structure and inserting a steel anchor assembly.

F. Terms relating to structures or building environments as used with reference to anchors and fasteners: 1. Corrosive locations: Describes interior and exterior locations as follows:

a. Locations used for delivery, storage, transfer, or containment (including spill containment) of chemicals used for plant treatment processes.

b. Exterior and interior locations at the following treatment structures: 1) Ozone Contactors.

2. Wet and moist locations: Describes locations, other than “corrosive locations,” that are submerged, are immediately above liquid containment structures, or are subject to frequent wetting, splashing, or wash down. Includes: a. Exterior portions of buildings and structures. b. Liquid-containing structures:

1) Locations at and below the maximum operating liquid surface elevation.

2) Locations above the maximum operating liquid surface elevation and: a) Below the top of the walls containing the liquid. b) At the inside faces and underside surfaces of a structure

enclosing or spanning over the liquid (including walls, roofs, slabs, beams or walkways enclosing the open top of the structure).

c. Liquid handling equipment: 1) Bases of pumps and other equipment that handles liquids.

d. Indoor locations exposed to moisture, splashing or routine wash down during normal operations, including floors with slopes toward drains or gutters.

e. Other locations indicated on the Drawings.


3. Other locations: a. Interior dry areas where the surfaces are not exposed to moisture or

humidity in excess of typical local environmental conditions.

1.04 SUBMITTALS

A. General: 1. Submit as specified in Section 01_33_00. 2. Submit information listed for each type of anchor or fastener to be used.

B. Action submittals: 1. Product data:

a. Cast-in anchors: 1) Manufacturer’s data including catalog cuts showing anchor sizes and

configuration, materials, and finishes. b. Post-installed anchors:

1) For each anchor type, manufacturer’s data including catalog cuts showing anchor sizes and construction, materials and finishes, and load ratings.

2. Samples: a. Samples of each type of anchor, including representative diameters and

lengths, if requested by the Engineer. 3. Certificates:

a. Cast-in anchors: 1) Mill certificates for steel anchors that will be supplied to the site.

b. Post-installed anchors: 1) Manufacturer’s statement or certified test reports demonstrating that

anchors that will be supplied to the site comply with the materials properties specified.

4. Test reports: a. Post-installed anchors: For each anchor type used for the Work:

1) Current ICC-ES Report (ESR), or equivalent acceptable to the Engineer and the authority having jurisdiction, demonstrating: a) Acceptance of that anchor for use under the building code

specified in Section 01_41_00. b) That testing of the concrete anchor included the simulated

seismic tension and shear tests of AC193, and that the anchor is accepted for use in Seismic Design Categories C, D, E, or F and with cracked concrete.

b. Concrete anchor pre-installation test report. 5. Manufacturer’s instructions.

a. Requirements for storage and handling. b. Recommended installation procedures including details on drilling, hole

size (diameter and depth), hole cleaning and preparation procedures, anchor insertion, and anchor tightening.

c. Requirements for inspection or observation during installation. 6. Qualification statements:

a. Post-installed anchors: Installer qualifications: 1) Submit list of personnel performing installations and include date of

manufacturer’s training for each.



A. Qualifications: 1. Post installed anchors shall be in accordance with building code specified in

Section 01_41_00. 2. Installers: Post-installed mechanical anchors:

a. Conduct a training session with the manufacturer’s authorized technical representative for the project on-site: 1) Training shall cover the complete installation process for each type of

anchor to be used and shall include, but not be limited to hole drilling procedures and techniques; hole preparation and cleaning; bolt installation; and bolt proof loading and torquing.

2) Use only trained and qualified personnel for anchor installation. b. Installations shall be performed by trained installers having at least

3 years’ experience performing similar installations with similar types of anchors.

B. Special inspection: 1. Provide special inspection of post-installed anchors as specified in this

Section.


A. Deliver post-installed anchors in manufacturer’s standard packaging with labels visible and intact. Include manufacturer’s installation instructions.

B. Handle and store anchors and fasteners in accordance with manufacturer’s recommendations and as required to prevent damage.

C. Protect anchors from weather and moisture until installation.


A. As specified in Section 01_81_01.

B. Seismic Design Category (SDC) for structures is indicated on the Drawings.

PART 2 PRODUCTS

2.01 MANUFACTURED UNITS

A. General: 1. Furnish threaded fasteners with flat washers and hex nuts fabricated from

materials corresponding to the material used for threaded portion of the anchor: a. Cast-in anchors: Provide flat washers and nuts as listed in the ASTM

standard for the anchor materials specified. b. Post-installed anchors: Provide flat washers and nuts supplied for that

product by the manufacturer of each anchor. 2. Size of anchors and fasteners, including diameter and length or minimum

effective embedment depth: As indicated on the Drawings or as specified in this Section. In the event of conflicts, contact Engineer for clarification.


3. Where anchors and connections are not specifically indicated on the Drawings or specified, their material, size and form shall be equivalent in quality and workmanship to items specified.

B. Materials: 1. Provide and install anchors of materials as in this Section.

2.02 CAST-IN ANCHORS AND FASTENERS

A. Anchor bolts: 1. Description:

a. Straight steel rod having one end with integrally forged head, and one threaded end. Embedded into concrete with the headed end cast into concrete at the effective embedment depth indicated on the Drawings or specified, and with the threaded end left to project clear of concrete face as required for the connection to be made.

b. Furnish anchor bolts with heavy hex forged head or equivalent acceptable to Engineer: 1) Rods or bars with angle bend for embedment in concrete (i.e.: “L” or

“J” shaped anchor bolts) are not permitted in the Work. 2. Materials:

a. Type 316 stainless steel: 1) Surfaces descaled, pickled, and passivated in accordance with

ASTM A 308. 2) Bolts: ASTM F 593, Group 2, Condition CW, coarse threads. 3) Nuts: ASTM F 594. Match alloy (group and UNS designation) and

threads of bolts. 4) Washers: Type 316 stainless steel.

b. Type 304 stainless steel: 1) Surfaces descaled, pickled, and passivated in accordance with

ASTM A 308. 2) Bolts: ASTM F 593, Group 1, Condition CW, coarse threads. 3) Nuts: ASTM F 594. Match alloy (group and UNS designation) and

threads of bolts. 4) Washers: Type 304 stainless steel.

c. Galvanized steel: 1) Hot-dip galvanized coating in accordance with ASTM F 2329. 2) Bolt: ASTM F 1554, Grade 36, heavy hex, coarse thread. 3) Nuts: ASTM A 563, Grade A, heavy hex, threads to match bolt. 4) Washers: ASTM F 436, Type 1.

B. Anchor rods: 1. Description: Straight steel rod having threads on each end or continuously

threaded from end to end. One threaded end is fitted with nuts or plates and embedded in concrete to the effective depth indicated on the Drawings, leaving the opposite threaded end to project clear of the concrete face as required for the connection to be made at that location.

2. Materials: a. Stainless steel: Type 316:

1) Surfaces descaled, pickled, and passivated in accordance with ASTM A 308.


2) Rod: ASTM F 593, Group 2, Condition CW, coarse threads. 3) Nuts: ASTM F 594. Match alloy (group and UNS designation) and

threads of rods. 4) Washers: Type 316 stainless steel. 5) Plates (embedded): ASTM A 240.

b. Stainless steel: Type 304: 1) Surfaces descaled, pickled, and passivated in accordance with

ASTM A 308. 2) Rod: ASTM F 593, Group 1, Condition CW, coarse threads. 3) Nuts: ASTM F 594. Match alloy (group and UNS designation) and

threads or rods. 4) Washers: Type 304 stainless steel. 5) Plates (embedded): ASTM A 240.

c. Galvanized: steel: 1) Hot-dip galvanized with coating in accordance with ASTM F 2329. 2) Rod: ASTM F 1554, Grade 36, coarse thread. 3) Nuts: ASTM A 563, Grade A, threads to match rod. 4) Washers: ASTM F 436, Type 1. 5) Plates (embedded): ASTM A 36.

C. Concrete insert: Ductile embed: 1. Description: 1-piece, integrally hot forged sleeve for embedment in concrete.

Provided with flange for nailing to forms and female threaded coupler at the exposed concrete face, and washer-faced hex headed foot to resist pullout from concrete at the embedded end.

2. Manufacturers: One of the following or equal as approved by the Engineer: a. Dayton Superior: F-54 Ductile Embed Insert.

3. Materials: a. Galvanized steel:

1) Hot-dip galvanized coating in accordance with ASTM A 123 or A 153 where indicated on the Drawings.

2) Steel: ASTM A 29 hot rolled, Grade 1045.

D. Deformed bar anchors: 1. Description: Steel rod with rebar-like deformations along its length and welding

ferrule at one end for attachment to structural steel members (plates or shapes).

2. Manufacturers: One of the following or equal as approved by the Engineer: a. Nelson Stud Welding Company: D2L Deformed Bar Anchors (D2L-DBA). b. Stud Welding Products, Inc.: Deformed Anchor Studs.

3. Materials: a. Galvanized steel:

1) Hot dip galvanized coating in accordance with ASTM A 153 where indicated on the Drawings.

2) Steel: ASTM A 496 wire deformed for concrete reinforcement.

E. Welded studs: 1. Description: Anchor with forged head for embedment into concrete on one

end, and welding ferrule for attachment to steel on the other. Welded to steel members or plates to provide anchorage for steel connections to concrete.

2. Acceptance criteria: a. Welded studs in accordance with AWS D1.1, Type B.


3. Manufacturers: One of the following or equal as approved by the Engineer: a. Nelson Stud Welding Company: H4L Concrete Anchors or S3L Shear

Connectors as indicated on the Drawings. b. Stud Welding Products: Headed Concrete Anchors (HCA) or Headed

Shear Connectors (HSC) as indicated on the Drawings. 4. Materials:

a. Stainless steel: Type 316L: 1) Where indicated on the Drawings.

b. Stainless steel: Type 304L: 1) Where indicated on the Drawings.

c. Galvanized steel: 1) Hot-dip galvanized after fabrication with coating in accordance with

ASTM A 123. 2) Steel: Carbon steel in accordance with ASTM A 108 with

50,000-pounds per square inch minimum yield strength, and 60,000-pounds per square inch minimum tensile strength.

F. Steel plates or shapes for fabrications including assemblies with welded studs or deformed bar anchors: 1. Stainless steel: Type 316L or Type 304L:

a. Plates (embedded): ASTM A 240. 2. Galvanized steel:

a. Hot dip galvanized in accordance with ASTM A 123. b. Steel: ASTM A 36.

2.03 POST-INSTALLED ANCHORS AND FASTENERS – ADHESIVE

A. Epoxy bonding of reinforcing bars, all thread rods, and threaded inserts in concrete: As specified in Section 03_21_17.

2.04 POST-INSTALLED ANCHORS AND FASTENERS – MECHANICAL

A. General: 1. Post-installed anchors used for the Work shall hold a current ICC Evaluation

Service Report demonstrating acceptance for use under the building code specified in Section 01_41_00. Reports prepared by other recognized evaluation agencies may be submitted for consideration if acceptable to the Engineer and to the authority having jurisdiction: a. Conditions of use: The acceptance report shall indicate acceptance of the

product for use under the following conditions: 1) In regions of concrete where cracking has occurred or may occur. 2) To resist short-term loads due to wind forces. 3) To resist short-term loading due to seismic forces for the Seismic

Design Category of the structure where the product will be used. 2. Substitutions: When requesting product substitutions, submit calculations,

indicating the diameter, effective embedment depth and spacing of the proposed anchors, and demonstrating that the substituted product will provide load resistance that is equal to or greater than that provided by the anchors listed in this Section. a. Calculations shall be prepared by and shall bear the signature and sealed

of a Professional Engineer licensed in the State of California.


b. Decisions regarding the acceptability of proposed substitutions shall be at the discretion of the Engineer.

B. Concrete anchors: 1. Description. Post-installed anchor assembly consisting of a threaded stud and

a surrounding wedge expansion sleeve that is forced outward by torquing the center stud to transfer loads from the stud to the concrete through bearing, friction, or both. (Sometimes referred to as “expansion anchors” or “wedge anchors.”): a. Do not use slug-in, lead cinch, and similar systems relying on deformation

of lead alloy or similar materials to develop holding power. 2. Concrete anchors for anchorage to concrete:

a. Acceptance criteria: 1) Concrete anchors shall have a current ICC-ES Report demonstrating

that the anchors have been tested and qualified for performance in both cracked and un-cracked concrete, and for short term loading due to wind and seismic forces for Seismic Design Categories A through F in accordance with ACI 355.2 and with ICC-ES AC193 (including all mandatory tests and optional tests for seismic tension and shear in cracked concrete).

2) Concrete anchor performance in the current ICC-ES Report shall be “Category 1” as defined in ACI 355.2.

b. Manufacturers: One of the following or equal as approved by the Engineer: 1) Hilti: Kwik Bolt TZ Expansion Anchor. 2) Powers fasteners: PowerStud+ SD2. 3) Simpson Strong-Tie®: Strong Bolt 2 Wedge Anchor.

c. Materials. Integrally threaded stud, wedge, washer and nut: 1) Stainless steel: Type 316:

a) Type 304 stainless steel acceptable for use at wet and moist locations when accepted in writing by the Engineer.

2) Galvanized: Carbon steel, zinc plated in accordance with ASTM B 633, minimum 5 microns (Fe/Zn 5).

3. Concrete anchors for anchorage to concrete masonry (fully grouted cells): a. Acceptance criteria: Concrete anchors shall have a current ICC-ES

Report demonstrating that the anchors have been tested and qualified in accordance with ICC-ES AC01, including all mandatory tests and optional seismic tests.

b. Manufacturers: One of the following or equal as approved by the Engineer: 1) Hilti: Kwik Bolt 3 Expansion Anchor. 2) Powers fasteners: Power-Stud+ SD1. 3) Simpson Strongtie: Wedge-All Anchor.

c. Materials. Integrally threaded stud, wedge, washer and nut: 1) Stainless steel: Type 316:

a) Type 304 stainless steel acceptable for use at wet and moist locations when accepted in writing by the Engineer.

2) Galvanized: Carbon steel, zinc plated in accordance with ASTM B 633, minimum 5 microns (Fe/Zn 5) or mechanically galvanized in accordance with ASTM B 695, Class 55, Type 1.

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C. Flush shells: 1. Description: Post-installed anchor assembly consisting of an internally

threaded mandrel that is forced into a pre-drilled concrete hole with a setting tool until the top of the anchor is flush with the face of the concrete. Once installed, a removable threaded bolt is installed in the mandrel.

2. Flush shell anchors are not permitted in the Work.

D. Sleeve anchors: 1. Description: Post-installed, torque-controlled anchor assembly consisting of an

externally threaded stud with a spacer sleeve near the surface of the base material, and an expansion sleeve on the lower part of the stud. The expansion sleeve is forced outward by torquing of the center stud to transfer load: a. Do not use slug-in, lead cinch, and similar systems relying on deformation

of lead alloy or similar materials in order to develop holding power. 2. Sleeve anchors for anchorage to concrete:

a. Acceptance criteria: 1) Sleeve anchors shall have a current ICC-ES Report demonstrating

that the anchors have been tested and qualified for performance in both cracked and un-cracked concrete, and for short term loading due to wind and seismic forces for Seismic Design Categories A through F in accordance with ACI 355.2 and with ICC-ES AC193 (including all mandatory tests and optional tests for seismic tension and shear in cracked concrete).

2) Sleeve anchor performance in the current ICC-ES Report shall be “Category 1” as defined in ACI 355.2.

b. Manufacturers: One of the following or equal as approved by the Engineer: 1) Hilti: HSL-3 Heavy Duty Expansion (sleeve) Anchor. 2) Powers fasteners: Power Bolt+ Heavy Duty Sleeve Anchor.

c. Materials: 1) Galvanized steel: Carbon steel, zinc plated in accordance with

ASTM B 633, minimum 5 microns (Fe/Zn 5).

E. Screw anchors: 1. Description: Post-installed concrete anchor that develops tensile strength from

mechanical interlock provided by creating a helical “key” that is larger than the diameter of the bolt itself along the length of the anchor shaft.

2. Screw anchors for anchorage to concrete: a. Acceptance criteria:

1) Screw anchors shall have a current ICC-ES Report demonstrating that the anchors have been tested and qualified for performance in both cracked and un-cracked concrete, and for short term loading due to wind and seismic forces for Seismic Design Categories A through F in accordance with ACI 355.2 and ICC ES AC193 (including all mandatory tests and optional tests for seismic tension and shear in cracked concrete).

2) Screw anchor performance in the current ICC-ES Report shall be “Category 1” as defined in ACI 355.2.


b. Manufacturers: Screw anchor: One of the following or equal as approved by the Engineer: 1) Hilti: Hex head: HUS-EZ Screw Anchor:

a) With internally threaded head: HUS-EZ I Hanger Anchor. 2) Powers fasteners: Wedge-Bolt+:

a) With internally threaded head: Vertigo+ Rod Hanging System. 3) Simpson strong-tie: Titen HD Screw Anchor:

a) With internally threaded head: Titen HD Rod Hanger. c. Materials:

1) Stainless steel: Not available. 2) Galvanized steel: Carbon steel, zinc plated in accordance with

ASTM B 633, minimum 5 microns (Fe/Zn 5); or equal as approved by the Engineer.

3. Screw anchors for anchorage to concrete masonry (fully grouted only): a. Acceptance criteria:

1) Acceptance criteria. Screw anchors shall have a current ICC-ES Report demonstrating that anchors have been tested and qualified for performance in masonry, including short term loading due to wind and seismic forces in accordance with ICC-ES AC106.

b. Manufacturers: One of the following or equal as approved by the Engineer: 1) Hilti: HUS-EZ Screw Anchor. 2) Simpson strong-tie: Titen HD Screw Anchor.

c. Materials: 1) Galvanized steel: Carbon steel. Zinc plated in accordance with

ASTM B 633, minimum 5 microns (Fe/Zn 5); or mechanically galvanized in accordance with ASTM B 695; Class 55, Type I.

F. Undercut concrete anchors: 1. Description: Post-installed concrete anchor that develops tensile strength from

mechanical interlock provided by creation of an undercut “key” at the embedded end of the anchor. The undercut may be achieved with a special drill before anchor installation, or by the anchor itself during installation.

2. Acceptance criteria: a. Acceptance criteria:

1) Undercut concrete anchors shall have a current ICC-ES Report demonstrating that the anchors have been tested and qualified for performance in both cracked and un-cracked concrete, and for short term loading due to wind and seismic forces for Seismic Design Categories A through F in accordance with ACI 355.2 and ICC ES AC193 (including all mandatory tests and optional tests for seismic tension and shear in cracked concrete).

2) Undercut anchor performance in the current ICC-ES Report shall be “Category 1” as defined in ACI 355.2.

b. Use pre-setting units. Through setting units are not allowed unless prior written acceptance for specific locations is obtained from the Engineer.

3. Manufacturers: One of the following or equal as approved by the Engineer: a. Hilti: HDA (carbon steel) or HAD-R (stainless steel) Undercut Anchor. b. Powers fasteners: Atomic+ Undercut Anchor. c. Simpson strong-tie: Torq-Cut Anchor. d. USP Structural Connectors: DUC-L Undercut Anchors.


4. Materials: a. Stainless steel: Corrosive, and wet and moist and locations: Type 316. b. Galvanized: Carbon steel, zinc plated in accordance with ASTM B 633,

minimum 5 microns (Fe/Zn 5).

2.05 APPURTENANCES FOR ANCHORING AND FASTENING

A. Anchor bolt sleeves: 1. Having inside diameter approximately 2 inches greater than bolt diameter and

minimum 10-bolt diameters long. 2. Plastic sleeves:

a. High-density polyethylene, corrugated sleeve, threaded to provide adjustment of location on the anchor bolt.

3. Fabricated steel sleeves: a. Anchor posts into concrete by grouting posts into formed holes in

concrete, into stainless steel sleeves cast in concrete; or bracket mount to face of concrete surfaces.

b. At galvanized carbon steel anchor bolts, provide galvanized carbon steel sleeves.

c. At stainless steel anchor bolts, provide stainless steel sleeves of same Type (304 or 316) as bolt, except that sleeves shall be constructed from low carbon stainless steel for welding (304L or 316L).

B. Forged steel hardware: 1. Forged steel structural hardware:

a. Clevises and turnbuckles: Forged steel in accordance with AISI C-1035. b. Eye nuts / Eye bolts: Forged steel in accordance with AISI C-1030.

1) Having geometric and strength characteristics (including proof load, breaking strength, tensile strength, bend test, and impact strength) of eyebolts in accordance with ASTM A489, Type 1.

c. Sleeve nuts: Forged steel in accordance with AISI C-1018 Grade 2.

C. Isolating sleeves and washers: 1. Manufacturers: One of the following or equal as approved by the Engineer:

a. Central Plastics Company, Shawnee, Oklahoma. b. Corrosion Control Products, PSI Inc., Gardena, CA.

2. Sleeves: Mylar, 1/32 inch thick, 4,000 volts per mil dielectric strength, of proper size to fit bolts and extending half way into both steel washers.

3. One sleeve required for each bolt. 4. Washers: The inside diameter of all washer shall fit over the isolating sleeve

and both the steel and isolating washers shall have the same inside diameter and outside diameter: a. Proper size to fit bolts. 2 insulating washers are required for each bolt. b. Two 1/8-inch thick steel washers for each bolt. c. G3 Phenolic:

1) Thickness: 1/8 inch. 2) Base material: Glass. 3) Resin: Phenolic. 4) Water absorption: 2 percent. 5) Hardness (Rockwell): 100. 6) Dielectric strength: 450 volts per mil. 7) Compression strength: 50,000 pounds per square inch.


8) Tensile strength: 20,000 pounds per square inch. 9) Maximum operating temperature: 350 degrees Fahrenheit.

D. Coating for repair of galvanized surfaces: 1. Manufacturers: One of the following or equal as approved by the Engineer:

a. Galvinox. b. Galvo-Weld.

E. Thread coating: For use with threaded stainless steel fasteners: 1. Manufacturers: One of the following or equal as approved by the Engineer:

a. Never Seez Compound Corporation, Never-Seez. b. Oil Research, Inc., WLR No. 111.

PART 3 EXECUTION

3.01 EXAMINATION

A. Examine Work in place to verify that it is satisfactory to receive the Work of this Section. If unsatisfactory conditions exist, do not begin this Work until such conditions have been corrected.

3.02 INSTALLATION: GENERAL

A. Where anchors and fasteners are not specifically indicated on the Drawings or specified, make attachments with materials specified in this Section.

B. Substitution of anchor types: 1. Post-installed anchors may not be used as an alternative to cast-in / built-in

anchors at locations where the latter are indicated on the Drawings. 2. Cast-in/built-in anchors may be used as an alternative to post-installed

mechanical anchors at locations where the latter are indicated on the Drawings.

C. Protect products from damage during installation. Take special care to protect threads and threaded ends.

D. Accurately locate and position anchors and fasteners: 1. Unless otherwise indicated on the Drawings, install anchors perpendicular to

the surfaces from which they project. 2. Install anchors so that at least 2 threads, but not more than 1/2 inch of

threaded rod, projects past the top nut.

E. Interface with other products: 1. Where steel anchors come in contact with dissimilar metals (aluminum,

stainless steel, etc.), use stainless steel anchors and separate or isolate dissimilar metals using isolating sleeves and washers.

2. Prior to installing nuts, coat threads of stainless steel fasteners with thread coating to prevent galling of threads.


3.03 INSTALLATION: CAST-IN ANCHORS

A. General: 1. Accurately locate cast-in and built-in anchors:

a. Provide anchor setting templates to locate anchor bolts and anchor rods. Secure templates to formwork.

b. Brace or tie off embedments as necessary to prevent displacement during placement of plastic concrete or of surrounding masonry construction.

c. Position and tie cast-in and built-in anchors in place before beginning placement of concrete or grout. Do not “stab” anchors into plastic concrete, mortar, or grout.

d. Do not allow cast-in anchors to touch reinforcing steel. Where cast-in anchors are within 1/4 inch of reinforcing steel, isolate the metals by wrapping the anchors with a minimum of 4 wraps of 10-mil polyvinyl chloride tape in area adjacent to reinforcing steel.

2. For anchoring at machinery bases subject to vibration, use 2 nuts, with 1 serving as a locknut.

3. Where anchor bolts or anchor rods are indicated on the Drawings as being for future use, thoroughly coat exposed surfaces that project from concrete or masonry with non-oxidizing wax. Turn nuts down full length of the threads, and neatly wrap the exposed thread and nut with a minimum of 4 wraps of 10-mil waterproof polyvinyl tape.

B. Anchor bolts: 1. Minimum effective embedment: 10-bolt diameters, unless a longer embedment

is indicated on the Drawings. 2. Where indicated on the Drawings, set anchor bolts in plastic, galvanized steel

or stainless steel sleeves to allow for adjustment. Fill sleeves with grout when a machine or other equipment is grouted in place.

C. Anchor rods: 1. Install as specified for anchor bolts.

D. Concrete inserts: 1. Provide inserts with minimum clear concrete cover not less than that specified

for reinforcing bars.

E. Deformed bar anchors: 1. Butt weld to steel fabrications with automatic stud welding gun as

recommended by manufacturer. 2. Ensure that butt weld develops the full strength of the anchor.

F. Welded studs: 1. Butt weld to steel fabrications with automatic stud welding gun as

recommended by the manufacturer. 2. Ensure that butt weld develops full strength of the stud.

3.04 INSTALLATION: POST-INSTALLED ADHESIVE ANCHORS

A. Epoxy and acrylic adhesive bonding of reinforcing bars, all thread rods, and internally threaded inserts in concrete and masonry: As specified in Section 03_21_17.


3.05 INSTALLATION: POST-INSTALLED MECHANICAL ANCHORS

A. General: 1. Install anchors in accordance with the manufacturer’s instructions, ACI 355.2,

the anchor’s ICC-ES Report. Where conflict exists between the ICC-ES Report and the requirements in this Section, the requirements of the ICC-ES Report shall control.

2. Where anchor manufacturer recommends the use of special tools and/or specific drill bits for installation, provide and use such tools.

3. After anchors have been positioned and inserted into concrete or masonry, do not: a. Remove and reuse/reinstall anchors. b. Loosen or remove bolts or studs.

B. Holes drilled into concrete and masonry: 1. Do not drill holes in concrete or masonry until the material has achieved its

minimum specified compression strength (f’c or f’m). 2. Accurately locate holes:

a. Before drilling holes, use a reinforcing bar locator to identify the position of all reinforcing steel, conduit, and other embedded items within a 6-inch radius of each proposed hole.

b. If the hole depth exceeds the range of detection for the rebar locator, the Engineer may require radiographs of the area designated for investigation before drilling commences.

3. Exercise care to avoid damaging existing reinforcement and other items embedded in concrete and masonry: a. If embedments are encountered during drilling, immediately stop work and

notify the Engineer. Await Engineer’s instructions before proceeding. 4. Unless otherwise indicated on the Drawings, drill holes perpendicular to the

concrete surface into which they are placed. 5. Drill using anchor manufacturer’s recommended equipment and procedures:

a. Unless otherwise recommended by the manufacturer, drill in accordance with the following: 1) Drilling equipment: Electric or pneumatic rotary type with light or

medium impact. Where edge distances are less than 2 inches, use lighter impact equipment to prevent micro-cracking and concrete spalling during drilling process.

2) Drill bits: Carbide-tipped in accordance with ANSI B212-15. Hollow drills with flushing air systems are preferred.

6. Drill holes at manufacture’s recommended diameter and to depth required to provide the effective embedment indicated.

7. Clean and prepare holes as recommended by the manufacturer and as required by the ICC-ES Report for that anchor: a. Unless otherwise recommended by anchor manufacturer, remove dust

and debris using brushes and clean compressed air. b. Repeat cleaning process as required by the manufacturer’s installation

instructions. c. When cleaning holes for stainless steel anchors, use only stainless steel

or non-metallic brushes.


C. Insert and tighten (or torque) anchors in full compliance with the manufacturer’s installation instructions: 1. Once anchor is tightened (torque), do not attempt to loosen or remove its bolt

or stud.

D. Concrete anchors: Minimum effective embedment lengths unless otherwise indicated on the Drawings:

Concrete Anchors

Nominal Diameter

Minimum Effective Embedment Length Minimum required member thickness In concrete In grouted masonry

3/8 inch 2 1/2 inch 2 5/8 inch 8 inch



3/4 inch 5 inch 5 1/4 inch 12 inch

E. Flush shell anchors: 1. Flush shell anchors are not permitted in the Work. 2. If equipment manufacturer’s installation instructions recommend the use of

flush shell anchors, contact Engineer for instructions before proceeding.

F. Sleeve anchors: 1. Minimum effective embedment lengths unless otherwise indicated on the

Drawings:

Sleeve Anchors

Nominal Diameter

Minimum Effective Embedment Length Minimum Member

Thickness In concrete In grouted masonry

M8 (1/2 inch) 70 mm (2 3/4 inch) Not accepted 100 mm (8 inch)

M10 (5/8 inch) 76 mm (3 inch) Not accepted 250 mm (10 inch)


2. Install with the sleeve fully engaged in the base material.

G. Screw anchors: 1. Minimum effective embedment lengths unless otherwise indicated on the

Drawings:

Screw Anchors

Nominal Diameter





Screw Anchors

Nominal Diameter




5/8 inch 4 inch 5 inch 10 inch


2. Install screw anchors using equipment and methods recommended by the manufacturer. Continue driving into hole until the washer head is flush against the item being fastened.

H. Undercut concrete anchors: 1. Minimum effective embedment lengths unless otherwise indicated on the

Drawings:

Sleeve Anchors

Nominal Diameter

(bolt)


Thickness1 In concrete In grouted masonry




M20 (7/8 inch) 250 mm (10 inch) Not accepted 510 mm (20 inch) Note: 1. Thickness indicated is for pre-set units If through-set units are accepted, obtain

minimum member thickness requirements from the Engineer.

2. Installations of undercut anchors shall not be allowed where edge distances are less than 12 times the nominal diameter of the anchor stud.

3. Undercut bottom of hole using cutting tools manufactured for this purpose by the manufacturer of the undercut anchors being placed.

3.06 FIELD QUALITY CONTROL

A. Contractor shall provide quality control over the Work of this Section: 1. Expenses associated with work described by the following paragraphs shall be

paid by the Contractor.

B. Cast-in and built-in anchors: 1. Special inspection in accordance with this Section..

C. Post-installed anchors: 1. Review anchor manufacturer’s installation instructions and requirements of the

Evaluation Service Report (hereafter referred to as “installation documents”) for each anchor type and material.


2. Observe hole-drilling and cleaning operations for conformance with the installation documents.

3. Certify in writing to the Engineer that the depth and location of anchor holes, and the torque applied for setting the anchors conforms to the requirements of the installation documents.

3.07 FIELD QUALITY ASSURANCE

A. Owner will provide on-site observation and field quality assurance for the Work of this Section: 1. Expenses associated with work described by the following paragraphs shall be

paid by the Owner.

B. Field inspections and special inspections: 1. Required inspections: Observe construction for conformance to the approved

Contract Documents, the accepted submittals, and manufacturer’s installation instructions for the products used.

2. Record of inspections: a. Maintain record of each inspection. b. Submit copies to Engineer upon request.

3. Statement of special inspections: At the end of the project, prepare and submit to the Engineer and the authority having jurisdiction inspector’s statement that the Work was constructed in general conformance with the approved Contract Documents, and that deficiencies observed during construction were resolved.

C. Special inspections: Anchors cast into concrete and built into masonry: 1. Provide special inspection during positioning of anchors and placement of

concrete or masonry (including mortar and grout) around the following anchors: a. Anchor bolts. b. Anchor rods. c. Concrete inserts (all types). d. Deformed bar anchors. e. Welded studs.

2. During placement, provide continuous special inspection at each anchor location to verify that the following elements of the installation conform to the requirements of the Contract Documents: a. Anchor:

1) Type and dimensions. 2) Material: Galvanized steel, Type 304 stainless steel, or Type 316

stainless steel as specified in this Section or indicated on the Drawings.

3) Positioning: Spacing, edge distances, effective embedment, and projection beyond the surface of the construction.

4) Reinforcement at anchor: Presence, positioning, and size of additional reinforcement at anchors indicated on the Drawings.

3. Following hardening and curing of the concrete or masonry surrounding the anchors, provide periodic special inspection to observe and confirm the following: a. Base material (concrete or grouted masonry):

1) Solid and dense concrete or grouted masonry material within required distances surrounding anchor.


2) Material encapsulating embedment is dense and well-consolidated.

D. Special Inspections: Post-installed mechanical anchors placed in hardened concrete and in grouted masonry: 1. Provide special inspection during installation of the following anchors:

a. Concrete anchors. b. Adhesive anchors c. Sleeve anchors. d. Screw anchors. e. Undercut concrete anchors.

2. Unless otherwise noted, provide periodic special inspection during positioning, drilling, placing, and torquing of anchors: a. Provide continuous special inspection for post-installed anchors in

“overhead installations” as defined in this Section. 3. Requirements for periodic special inspection:

a. Verify items listed in the following paragraphs for conformance to the requirements of the Contract Documents and the Evaluation Report for the anchor being used. Observe the initial installation of each type and size of anchor, and subsequent installation of the same anchor at intervals of not more than 4 hours: 1) Any change in the anchors used, in the personnel performing the

installation, or in procedures used to install a given type of anchor, shall require a new “initial inspection.”

b. Substrate: Concrete or masonry surfaces receiving the anchor are sound and of a condition that will develop the anchor’s rated strength.

c. Anchor: 1) Manufacturer, type, and dimensions (diameter and length). 2) Material (galvanized, Type 304 stainless steel, or Type 316 stainless

steel). d. Hole:

1) Positioning: Spacing and edge distances. 2) Drill bit type and diameter. 3) Diameter, and depth. 4) Hole cleaned in accordance with manufacturer’s required

procedures. Confirm multiple repetitions of cleaning when recommended by the manufacturer.

5) Anchor’s minimum effective embedment. 6) Anchor tightening/installation torque.

4. Requirements for continuous special inspection: a. The special inspector shall observe all aspects of anchor installation,

except that holes may be drilled in his/her absence provided that he/she confirms the use of acceptable drill bits before drilling, and later confirms the diameter, depth, and cleaning of drilled holes.

E. Field tests: 1. Owner may, at any time, request testing to confirm that materials being

delivered and installed conform to the requirements of the Specifications: a. If such additional testing shows that the materials do not conform to the

specified requirements, the Contractor shall pay the costs of these tests. b. If such additional testing shows that the materials do conform to the

specified requirements, the Owner shall pay the costs of these tests.


2. Field testing: Post-Installed Anchors: a. Proof load testing:

1) In addition to performing special inspections, the Owner may select up to 20 percent of each type and size of post-installed mechanical anchor for proof-load testing for pullout or shear. Tests shall be non-destructive whenever possible.

2) Perform tension testing in accordance with ASTM E 488. Apply proof loads using a calibrated hydraulic ram.

b. Torque load testing: 1) Using a calibrated torque wrench, apply manufacturer’s

recommended installation torque. c. Acceptance criteria.

1) Minimum anchor embedment, proof load for pullout and shear, and torque shall be as specified in this Section.

2) Anchors that fail to resist their designated proof load or installation torque requirements shall be regarded as non-performing.

3) If more than 10 percent of the tested anchors fail to achieve their specified torque or proof load, all anchors of the same diameter and type as the failed anchors shall be tested.

4) Remediate non-performing anchors as specified in “non-conforming work.”

3.08 NON-CONFORMING WORK

A. Remove miss-aligned or non-performing anchors.

B. Fill empty anchor holes and repair failed anchor locations using high-strength, non-shrink, non-metallic grout.

C. If more than 10 percent of all tested anchors of a given diameter and type fail to achieve their specified torque or proof load, the Engineer will provide directions for required modifications. Make such modifications, up to and including replacement of all anchors, at no additional cost to the Owner.

3.09 SCHEDULES

A. Stainless steel. Provide and install stainless steel anchors at the following locations: 1. “Corrosive locations” as defined in this Section: Type 316 stainless steel. 2. “Wet and moist locations” as defined in this Section: Type 316 stainless steel. 3. “Other locations:”

a. For connecting steel and stainless steel members to concrete or masonry: Type 304 stainless steel.

b. For connecting aluminum members to concrete or masonry. 4. At locations indicated on the Drawings.

B. Galvanized: Provide and install galvanized carbon steel anchors at the following locations: 1. Locations not requiring stainless steel. 2. At locations indicated on the Drawings.

C. Where anchors are in contact with a metal that differs from that of the anchor, provide isolation sleeves and washers.

END OF SECTION


SECTION 09_96_56.05

HIGH-BUILD EPOXY COATINGS

PART 1 GENERAL

1.01 SUMMARY

A. Work included: Provide high-build epoxy coatings as shown on the drawings and as specified herein.

1.02 REFERENCES

A. Good Painting Practice, SSPC Painting Manual, Volume 1.

B. Systems and Specifications, SSPC Painting Manual, Volume 2: 1. SSPC-SP 5, White Metal Blast Cleaning. 2. SSPC-SP 10, Near White Blast Cleaning. 3. SSPC-PA 1, Shop, Field & Maintenance Painting.

1.03 SUBMITTALS

A. Product data: Submit manufacturer's current specifications or technical information that proves compliance with the specified requirements.

B. Manufacturer's instructions: Submit manufacturer's written instructions and recommendations for surface preparation, coating repair, application of coating system, curing of coating system, and maximum recoat time.

C. Submit list of all coatings proposed for use: 1. Identify each coating by brand name and manufacturer, and indicate what

items will be painted with the coating.


A. Qualifications: 1. Applicator: Regularly engaged in application of similar coatings for at least two

years immediately prior to this work. 2. Workers: Experienced and knowledgeable in preparation for and application of

high performance industrial coatings.

B. Workmanship: Conform to standards and recommendations of SSPC Vol 1, especially Chapters 5.1. and 6.

C. Weather conditions: 1. Do not abrasive blast when ambient temperature is less than 5 degrees F

above dew point. 2. Apply coatings only when conditions are within the limits prescribed by the

manufacturer but, in any case, do not apply coating when: a. Metal temperature is less than 50 degrees F. b. Ambient temperature is less than 5 degrees F above dew point.


c. Relative humidity is greater than 85 percent. d. Ambient temperature is below 40 degrees F or expected to drop below

40 degrees F within 6 hours.

PART 2 PRODUCTS

2.01 COATING SYSTEM MATERIALS

A. Primer, intermediate, and finish coats shall be of same manufacturer.

B. Coatings in contact with potable water shall be certified by the National Sanitation Foundation in accordance with ANSI/NSF Standard 61.

C. Protective interior coatings for valves and hydrants shall conform to the requirements of American Water Works Association coating standard C550.

D. Liquid-epoxy coating for the interior and exterior of steel water pipelines shall conform to the requirements of American Water Works Association coating standard C210.

E. Acceptable products (Water Contact): 1. High build epoxy coatings:

a. Scotchkote 306, Scotchkote 314, 3M Corrosion Protection Products, (800) 722-6721.

b. Americoat 90HS, Americoat 233ER, Americoat 395FD, Amerilock 2, Amerlock 400, Ameron International, (800) 825-5075.

c. Series N140 Pota-Pox Plus, Series N140F Pota-Pox Plus Fast Cure, Tnemec Company, Inc., (816) 474-3400.

d. Carboguard 891, Carboline Company, (800) 848-4645. e. Or equal as approved by the Engineer.

F. Acceptable products (air contact): 1. High build epoxy coatings:

a. Carboguard 890, Carboline Company, (800) 848-4645. b. Hi-Build Epoxy V78 Series, Valspar Corporation, (800) 637-7793. c. Tnemec Series N69, Tnemec Co., (707) 792-2646. d. Interseal 670 HS, International Protective Coatings. Local supplier:

International Paint, (800) 821-2871. e. Bar-rust 235, Devoe Coatings Co., local supplier: ICI Paints Store,

3356 Piedmont Avenue, Oakland, CA 94611, (510) 547-4924. Or equal as approved by the Engineer.

G. Acceptable products (top coat): 1. Urethane coatings (where urethane finish is specified):

a. Tnemec Co. Series 1075 Urethane. b. Carbothane 134 VOC Aliphatic Urethane. c. Or equal as approved by the Engineer.

H. Thinners and solvents as specified by the coating system manufacturer.


PART 3 EXECUTION

3.01 PREPARATION

A. Prepare surfaces to be coated in accordance with the manufacturer's instructions but not less than specified herein.

B. Grind off weld beads, slag, projections, and weld spatter and grind sharp edges of all metal round and smooth, so that it is ready for painting.

C. Surface preparation shall conform to the following: 1. SSPC-SP 5 for surfaces which will be submerged or buried. 2. SSPC-SP 10 for all other surfaces, except:

a. Pretreat galvanized surfaces in accordance with the manufacturer's recommendations.

3. Anchor profile as recommended by coating system manufacturer. If manufacturer does not recommend, anchor profile shall be 1.5 to 3.0 mils.

D. Install an oil and moisture separator in air line between compressor and blast machine. Use Clemco Triplex filter or equal as approved by the Engineer.

3.02 APPLICATION

A. Mix, thin, and apply all coatings in accordance with the manufacturer's instructions, the applicable requirements of SSPC-PA 1, and as specified herein.

B. Surface to be painted shall have specified surface preparation at the time of application of coating.

C. Minimum Dry Film Thickness (DFT) of coating system: 12 mils. Maximum DFT per manufacturer’s data: 1. Apply a 3-coat system consisting of:

a. Primer: 4 to 5 mils DFT high build epoxy. b. Intermediate coat: 4 to 5 mils DFT high build epoxy. c. Topcoat: 2.5 to 3.5 mils DFT urethane topcoat.

D. Coating shall be free of holidays and pinholes.

E. Apply coatings by air or airless spray except: 1. Stripe all welds and edges by brush prior to applying first full coat.

F. Each coat shall be a different color than the preceding coat. Additional coats, where required, shall be tinted to provide color contrast but final coat shall be color specified.

G. After each coat and immediately prior to application of a subsequent coat, clean surface as required to remove dirt, dust, overspray, and other contaminants that may affect adhesion of the subsequent coat.

H. Discard all catalyzed coatings at the end of each work day or at end of manufacturer's recommended pot life, whichever is first.


I. Final coat shall be well bonded, uniform in color over the entire surface, and smooth to touch with no sags, runs, overspray, cracks, or other surface defects.

J. Coating repairs: 1. Touch up or refinish all chipped, abraded, or otherwise unsatisfactory portions

of the work in accordance with the manufacturer's recommendations. 2. Recoat or touch-up all damaged shop coated surfaces after installation.

3.03 QUALITY CONTROL

A. The District may inspect the surface preparation and the application of the coating system. Provide notification for Engineer to be present for abrasive blasting.

B. Contractor shall furnish test equipment and personnel for testing.

C. Contractor's tests shall be made in the presence of the Engineer. The Engineer may conduct his own coating tests at shop and after installation.

D. Measure coating thickness after each coat using non-destructive magnetic dry film gauges.

E. Adhesion: 1. The adhesion of properly applied and cured coating shall be such that it cannot

be removed except by sand or grit-blasting or by power brushing. 2. The second coat shall show complete adhesion to the first coat 72 hours after

its application. 3. Adhesion will be determined by use of a sharp scraping tool. 4. Cured coating shall show no peeling of coating from metal or separation

between coats.

F. Contractor shall test all coated surfaces for holidays and pinholes after application of the final coat and before application of urethane topcoat (if required): 1. Perform test after coating has cured as recommended by the manufacturer. 2. As directed by the Engineer, use either a low voltage wet sponge holiday

detector or a high voltage holiday detector: a. Low voltage wet sponge holiday detector shall be equal as approved by

the Engineer to K-D Bird Dog or Tinker-Rasor M-1. Add a non-sudsing wetting agent, such as Eastman Kodak Photo-Flo to the water used to saturate the sponge.

b. High voltage holiday detector shall be equal as approved by the Engineer to Tinker-Rasor AP-W or D. E. Stearns Model 14/20. Use in accordance with coating manufacturers recommendations except use voltage of 150 volts per mil of coating.

3. Retest after coating repairs.

END OF SECTION


SECTION 26_05_19

LOW VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Work necessary to provide a complete and operable low voltage cable system

as specified herein.

B. Related sections: Refer to other divisions and sections of the contract documents to determine the extent and character of related electrical work specified elsewhere, but which shall be done under this section: 1. Section 26_05_53 - Identification of Electrical Systems.

1.02 REFERENCES

A. American Society for Testing and Materials (ASTM): 1. B 3 - Standard Specification for Soft or Annealed Copper Wire. 2. B 8 - Standard Specification for Concentric-Lay-Stranded Copper Conductors,

Hard, Medium-Hard, or Soft. 3. B 33 - Standard Specification for Tinned Soft or Annealed Copper Wire for

Electrical Purposes.

B. California Standards Building Standards Code, Title 24. 1. Part 3 - California Electrical Code (CEC).

C. Insulated Cable Engineers Association (ICEA). 1. S-73-532 - Standard for Control, Thermocouple Extension and

Instrumentation Cables. 2. S-95-658 - Standard for Nonshielded Power Cables rated 2000 Volts or less.

D. National Fire Protection Association (NFPA): 1. NFPA 70 - National Electrical Code (NEC).

E. National Electrical Manufacturers Association (NEMA).

F. Underwriters Laboratory (UL): 1. Standard 44 - Thermoset Insulated Wires and Cables. 2. Standard 83 - Thermoplastic Insulated Wires and Cables. 3. Standard 1063 - Machine Tool Wires and Cables. 4. Standard 1581 - Reference Standard for Electrical Wires, Cables and Flexible

Cords.

1.03 SUBMITTALS

A. Make submittals in accordance with Section 01_33_00.



A. Low voltage wire and cable shall be UL listed.

PART 2 PRODUCTS

2.01 GENERAL

A. The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired only. Products of other manufacturers will be considered in accordance with the Division 01, General Requirements.

2.02 CONDUCTORS

A. Provide cables as specified under the type number in this section (Type 1, Type 2, etc.).

B. Type 11 (Power and control cables 600 Volts and less): 1. Unless otherwise indicated, provide stranded copper conductors with size as

indicated on the drawings. 2. Provide the following types of insulation:

a. Type XHHW-2 insulation for conductors No. 14 and larger having cross linked polyethylene insulation rated at 90 degrees C in wet and dry locations.

b. Insulation shall be self-lubricating for sizes #8 AWG and larger. 3. Single conductor control wiring shall be No. 14 AWG and shall have insulation

type XHHW-2. 4. Acceptable manufactures:

a. Southwire, SIMpull Type XHHW-2. b. Cerrowire, SLiPWire XHHW-2. c. Or equal as approved by the Engineer.

C. Type 28 (VFD cable 600V and less): 1. For installation between VFD and motor. 2. Three stranded XLPE insulated circuit conductors with one full sized insulated

PVC ground. 3. Jacket shall be oil resistant PVC type. 4. 100 percent overall shield and 85 percent braid coverage. 5. Provide cable that is UL listed and conforms to the requirements of UL 1277

Type TC per NEC Article 336. 6. Acceptable manufactures:

a. Belden No. 29XXX. b. Or equal as approved by the Engineer.


D. Multi-conductor power, control, and instrumentation cable 600 volts and less: 1. Provide cable that is UL listed and conforms to the requirements of UL 1277

and CEC Article 336, or UL listed Power Limited Circuit Cable that conforms to the requirements of Article 725 of the National Electrical Code. Provide cables permanently and legibly marked with the manufacturer's name, the nominal voltage, the type of cable, and the UL label (or submit evidence of UL listing): a. Type 10 (600-Volt, Twisted, Shielded Pair or Triad Instrumentation

Cable): 1) General: Type TC, single pair or triad instrumentation cable

designed for noise rejection for process control, computer, or data log applications. Suitable for installation in conduit, cable tray, or other approved raceways. Minimum cable temperature rating shall be 90 degrees C dry locations, 75 degrees C wet locations.

2) Individual conductors: No. 18 AWG stranded bare soft annealed copper, Class B, 7-strand concentric per ASTM B 8, 7-strand tinned copper drain wire.

3) Insulation and jacket: Each conductor 15-mil nominal PVC/nylon insulation. Pair conductors pigmented black and white; triad conductors pigmented black, white, and red. Jacket flame-retardant and sunlight- and oil-resistant PVC with 45 mil nominal thickness. Aluminum/polyester shield overlapped to provide 100 percent coverage.

4) Acceptable manufacturers: a) Belden No. 9341 (pairs); Belden No. 1121A (triads). b) Okonite Okoseal-N Type P-OS. c) Or equal as approved by the Engineer.

b. Type 14 (600-volt individually shielded pairs with a common overall shield instrumentation cable): 1) General: Type TC, twisted, shielded pairs of instrument cables,

grouped in a single cable, designed for use for instrumentation, process control, and computer applications. Suitable for installation in conduit, wireway, or other approved raceways. Minimum cable temperature rating shall be 90 degrees C dry locations and 75 degrees C wet locations.

2) Conductors: No. 18 stranded bare annealed copper, Class B, 7-strand, concentric per ASTM B 8. Tinned copper drain wires sized as shown on the Drawings, one for each pair and one for the overall group.

3) Insulation and jacket: Each conductor 15-mil PVC and 4-mil nylon insulation. Pair conductors pigmented black and red or black and white, with red or white conductor numerically printed for group identification. Outer jacket flame-retardant and sunlight- and oil-resistant PVC with 45 mil minimum thickness. Individual pair shield aluminum/polyester. Group shield aluminum/polyester, overlapped for 100 percent coverage.

4) Acceptable manufacturers: a) Belden No. 1048A (2 pairs), 1049A (4 pairs), 1050A (8 pairs). b) Okonite Okoseal-N Type SP-OS. c) Or equal as approved by the Engineer.


c. Type 19 (600-volt multi-conductor control cable): 1) General: UL listed, Type TC-ER, 600V multi-conductor copper

control cable with Class B stranding per ASTM B 8, #10 AWG unless noted otherwise. Suitable for installation in conduit, cable tray, or other approved raceways. Minimum cable temperature rating 90 degrees C dry and wet locations.

2) Conductors. 3) Insulation and jacket: Provide conductors having 30-mil

ethylene-propylene rubber (EPR) insulation and 60-mil chlorinated polyethylene (CPE) jacket. Color code the conductor group in accordance with ICEA S-61-402, Appendix K, Method 1, Table E-2.

4) Acceptable manufacturers: a) The Okonite Company, Okonite-FMR Okolon TS-CPE Type

TC-ER Cable. b) Allied Wire and Cable, FR-EPR/CPE Unshielded Control Cable

(E-2 Color Code). c) Or equal as approved by the Engineer.

d. Type 27 (600-volt, individually shielded triads with a common overall shield instrumentation cable): 1) General: Twisted, shielded triads of instrument cables, grouped in a

single cable, designed for use for instrumentation, process control, and computer applications. Suitable for installation in conduit, wireway, or other approved raceways. Minimum cable temperature rating shall be 90 degrees C dry locations and 75 degrees C wet locations.

2) Conductors: No. 18 AWG stranded bare annealed copper, Class B, 7-strand, concentric per ASTM B 8, size as indicated on the drawings. Tinned copper drain wires, one for each triad and one for the overall group.

3) Insulation and jacket: Each conductor 15-mil PVC and 4-mil nylon insulation. Triad conductors pigmented black, red, and blue, or black, white, and red, with red or white conductor numerically printed for group identification. Outer jacket flame-retardant and sunlight- and oil-resistant PVC with 60 mil minimum thickness. Individual triad shield 1.35-mil aluminum/polyester. Group shield 2.35-mil aluminum/polyester, overlapped for 100 percent coverage.

4) Conductors shall be numerically printed for group identification. 5) Acceptable manufacturers:

a) Belden No. 1094A (8 triads). b) Okonite Okoseal-N Type SP-OS(multiple triads). c) Or equal as approved by the Engineer.

E. Type 15 (6/C RS-485): 1. General: industrial low-capacitance shielded cables for EIA RS-485

applications, including security access card readers, suitable for outdoor use and installation in conduit and other approved raceways.

2. Conductors: 3 pairs of conductors, 6 conductors total, 22 AWG, 7 strand tinned copper conductors.

3. Insulation: foam high density polyethylene insulation, pairs colored white/blue and blue/white, white/orange and orange/white, white/green and green/white.


4. Shield: aluminum foil polyester tape providing 100 percent coverage, tinned copper braid providing 90 percent coverage, 7-strand tinned copper 24 AWG drain wire.

5. Jacket: UV and oil resistant PVC, 0.420 inch overall nominal diameter, 300 volt, -20 degrees C to +60 degrees C operating temperature.

6. Applicable standards: CEC/UL CM and PLTC OIL RES II, UL 1685 Flame Test, UL 1581 Sunlight Resistance Test.

7. Acceptable manufacturers: a. Belden No. 3108A. b. Or equal as approved by the Engineer.

F. Flexible cord and cable sealing fittings: 1. Provide liquid-tight strain relief connectors for exposed flexible cord and power

cable where cables enter electrical panels and enclosures. 2. Acceptable manufacturers:

a. O-Z/Gedney. b. Hubbell. c. Appleton. d. Or equal as approved by the Engineer.

G. Electrical tape for color coding: 1. Electrical tape shall be premium grade, not less than 7 mils thick, rated for

90 degree C minimum, flame-retardant, weather resistant, and available in suitable colors for color coding. The tape shall be resistant to abrasion, ultraviolet rays, moisture, alkalis, solvents, acids, and suitable for indoor and weather-protected outdoor use. The tape shall be suitable for use with PVC and polyethylene jacketed cables, and meet or exceed the requirements of UL 510.

2. Acceptable manufactures: a. 3M 35 Scotch Vinyl Electrical Tape for Color Coding. b. Plymouth Rubber Company Premium 37 Color Coding Tape. c. Or equal as approved by the Engineer.

PART 3 EXECUTION

3.01 GENERAL

A. Tighten all screws and terminal bolts using torque type wrenches and/or drivers to tighten to the inch-pound requirements of the CEC and UL.

B. Terminate no more than two control conductors per terminal point. Terminate all spare conductors on terminal blocks.

C. Low voltage power and control conductors shall be in separate conduits.

D. Only combine conductors with no more than two wire sizes difference to prevent possible installation damage to the smaller conductors; otherwise use separate conduits.


3.02 CONDUCTOR 600 VOLTS AND BELOW

A. Soldered mechanical joints insulated with tape will not be acceptable.

B. Color coding on wire sizes larger than No. 6 AWG shall be by taping the individual conductors with the appropriate colored self-adhesive vinyl electrical tape. Vinyl plastic insulating tape for wire and cable splices and terminations shall be flame retardant, 7-mil thick minimum, rated for 90 degrees C minimum meeting the requirements of UL 510.

C. Provide terminals and connectors acceptable for the type of material used.

D. Arrange wiring inside control panels, motor starters, etc., neatly cut to proper length, remove surplus wire, and bridle and secure in an acceptable manner. Identify all circuits entering motor starters, control panels, etc., in accordance with the cable schedules on the drawings. Terminate cable conductors on the same side of the terminal blocks as shown on the drawings.

E. Terminate control and instrumentation wiring with methods consistent with terminals provided, and in accordance with terminal manufacturer's instructions. Where terminals provided will accept such lugs, terminate all control and instrumentation wiring with insulated, ring terminal compression lugs. Control panel incoming field wireway sizes indicated on the drawings are considered minimum. Contractor shall adjust wireway sizes to meet CEC percentage fill requirements.

F. For control and instrumentation wire terminals designed to accept only bare wire compression terminations, use insulated wire ferrules on ends of wire. Tighten all terminal screws with torque screwdriver to recommended torque values.

G. Attach compression lugs with a tool specifically designed for that purpose which provides a complete, controlled crimp where the tool will not release until the crimp is complete. Use of plier type crimpers is not acceptable.

H. Cap spare conductors and conductors not terminated with UL listed end caps.

I. Where conductors pass through holes or over edges in sheet metal, remove all burrs, chamfer all edges, and install bushings and protective strips of insulating material to protect the conductors.

J. Do not strip cables more than eight inches from the nearest termination point of that cable.

K. Bundle and label all spare pairs with the cable designation. Tag all individual pairs to enable identification of spare pairs when making future terminations.

3.03 MULTI-CONDUCTOR POWER, CONTROL, AND INSTRUMENTATION CABLES 600 VOLTS AND LESS

A. Maintaining the integrity of shielding of instrumentation cables is essential to the operation of the control systems. Take special care in cable installation to ensure that grounds do not occur because of damage to the jacket over the shield. Shields shall be grounded at one location only as shown on the drawings.


3.04 CONDUCTOR COLOR CODING

A. Color coding of multiconductor control and instrumentation cable is specified in the individual cable type specification.

B. For power conductors, provide all single conductors and individual conductors of multiconductor power cables with integral insulation pigmentation of the designated colors, except conductors larger than No. 6 AWG may be provided with color coding by wrapping the conductor at each end and at all accessible locations with vinyl tape. Where this method of color coding is used, wrap at least six full overlapping turns of tape around the conductor covering an area 1-1/2 to 2 inches wide at a visible location at all conductor termination and pulling points.

C. Phase A, B, C implies a positive sequence connection (i.e., counterclockwise electrical phasor rotation and clockwise motor rotation).

D. Use the following colors: System Conductor Color All Systems Equipment Grounding Green 208Y/120 Volts, Grounded Neutral White 3-Phase, 4-Wire Phase A Black Phase B Red Phase C Blue 480Y/277 Volts, Grounded Neutral (if used) White, Black Tracer 3-Phase, 4-Wire Phase A Brown Phase B Orange Phase C Yellow 48V DC Positive Red 48V DC Negative Black Single Conductor, AC Red Multiple Conductor ICEA Method 1 Control Cables Table K-2 Multiple Conductor ICEA Method 1,

Power Cables Option D Twisted shield pair Positive White Return Black Twisted shield triad Positive Red (for RTDs) Compensation White Return Black


24V DC Positive Blue 24V DC Negative Gray Single-Conductor, DC Purple Alarm, Annunciator, Instrumentation, and Telemetering (if not shielded)

E. All conductors carrying AC foreign voltage over 100 VAC into control panels, switchboards, and other enclosures shall be yellow. Multi-conductor cables carrying such foreign voltage shall be marked with yellow tape at each termination point.

3.05 LACING OF WIRES AND CABLES

A. Lace all wires and cables at each termination. Lace wires and cables so that the wires of the individual circuits are laced together by circuit and the laced-together circuit or cable shall be tagged with the cable number. Bundle all wiring entering and exiting the control panels into groups. Bundle and lace wiring as specified herein.

END OF SECTION


SECTION 26_05_29

HANGERS AND SUPPORTS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Mounting and supporting electrical equipment and components.




3. The following sections are related to the Work described in this Section. This list of related sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 01_41_00 - Regulatory Requirements. c. Section 01_81_02 - Seismic Design Criteria.

1.02 REFERENCES

A. ASTM International (ASTM): 1. A 123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron

and Steel Products. 2. A 153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware. 3. A 240 – Standard Specification for Chromium and Chromium-Nickel Stainless


1.03 DEFINITIONS


A. Design requirements: 1. Conform to the requirements of the Building Code as specified in

Section 01_41_00. 2. Demonstrate the following using generally accepted engineering methods:

a. That the anchors to the structure are adequate to resist the loads generated in accordance with the Building Code and equipment requirements.

b. That the required load capacity of the anchors can be fully developed in the structural materials to which they are attached.

3. Design loading and anchoring requirements: a. As indicated in the Building Code unless otherwise specified.


b. Seismic loading requirements: 1) Freestanding or wall-hung equipment shall be anchored in place by

methods that will satisfy the requirements for the seismic design specified in Section 01_81_02.

c. Minimum safety factor against overturning: 1.5. d. The foundation and structures to which hangers and supports are

attached shall be capable of withstanding all anchor loads.

B. Performance requirements: 1. Hangers and supports individually and as a system shall resist all weights and

code-required forces without deflections and deformations that would damage the supporting elements, the equipment supported, or the surrounding construction.

1.05 SUBMITTALS

A. Furnish submittals as specified in Sections 01_33_00.

B. Product data: 1. Supports:

a. Materials. b. Geometry. c. Manufacturer.

2. Hardware: a. Materials. b. Manufacturer.

C. Shop drawings: 1. Complete dimensioned and scalable shop drawings of all supporting

structures, trapezes, wall supports, etc. 2. Complete anchoring details for equipment, lighting and raceway, supporting

structures, trapezes, wall supports for all equipment in excess of 200 pounds, and all freestanding supports: a. Stamped by a professional engineer licensed in the state where the

Project is being constructed. b. Said submittals, by virtue of the fact that they bear the stamp of a

registered engineer, will be reviewed for general consistency with the requirements specified in the Contract Documents, but not for context, accuracy, or method of calculation.

3. Include data on attachment hardware and construction methods that will satisfy the design loading and anchoring criteria.

D. Installation instructions: 1. Furnish anchorage instructions and requirements based on the seismic

conditions of the Site: a. Stamped by a professional engineer licensed in the state where the

Project is being constructed.


1.06 SEQUENCING (NOT USED)

1.07 SCHEDULING (NOT USED)

1.08 WARRANTY (NOT USED)

1.09 SYSTEM STARTUP (NOT USED)

1.10 OWNER'S INSTRUCTIONS (NOT USED)

1.11 MAINTENANCE (NOT USED)

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal as approved by the Engineer: 1. Thomas & Betts. 2. Power-Strut. 3. Unistrut. 4. Cooper B-Line. 5. Robroy. 6. Aickinstrut.

2.02 EXISTING PRODUCTS (NOT USED)

2.03 MATERIALS

A. Use materials appropriate for the area: 1. Hangers and supports in the ozone generator and outside area shall be

stainless steel. 2. Hangers and supports in the PSU and destruct areas shall be hot dip

galvanized steel

B. Hot dip galvanized steel: 1. Supports:

a. In accordance with ASTM A 123 or A 153. b. Minimum zinc coating thickness of 2.5 mils.

2. Hardware: a. Electro-galvanized. b. In accordance with ASTM A 153.

C. Stainless steel: 1. Supports:

a. In accordance with ASTM A 240. b. ANSI Type 316 material.

2. Hardware: a. ANSI Type 316 material.

2.04 MANUFACTURED UNITS (NOT USED)

2.05 EQUIPMENT (NOT USED)


2.06 COMPONENTS (NOT USED)

2.07 ACCESSORIES

A. Anchor bolts: 1. As specified in Section 05_05_24.

2.08 MIXES (NOT USED)

2.09 FABRICATION (NOT USED)

2.10 FINISHES (NOT USED)

2.11 SOURCE QUALITY CONTROL (NOT USED)

PART 3 EXECUTION

3.01 EXAMINATION (NOT USED)

3.02 PREPARATION (NOT USED)

3.03 INSTALLATION

A. Mount all raceways, cabinets, boxes, fixtures, instruments, and devices on Contractor-fabricated racks unless otherwise indicated on the Drawings: 1. Provide the necessary sway bracing to keep trapeze type structures from

swaying.

B. Brace and anchor freestanding equipment supports using methods that provide structural support based on the seismic loads and wind loads: 1. Lateral deflection at top of supports not to exceed support height divided by

240 unless otherwise approved by the Engineer.

C. Provide fabricated steel support pedestals for wall mounted panels that weigh more than 200 pounds: 1. Fabricate pedestals out of welded angle, tube sections, or preformed channel. 2. If the supported equipment is a panel or cabinet, match the supported

equipment in physical appearance and dimensions. 3. Provide auxiliary floor supports for transformers hung from stud walls and

weighing more than 200 pounds.

D. Corrosion protection: 1. Isolate dissimilar metals, except where required for electrical continuity:

a. Use neoprene washers, 9-mil polyethylene tape, or gaskets for isolation.

E. Re-coat all scratches, cuts, and drilled holes in galvanized surfaces with CRC "Zinc-It" or similar product.

3.04 ERECTION, INSTALLATION, APPLICATION, CONSTRUCTION (NOT USED)

3.05 REPAIR/RESTORATION (NOT USED)


3.06 RE-INSTALLATION (NOT USED)

3.07 COMMISSIONING AND PROCESS START-UP


3.08 FIELD QUALITY CONTROL (NOT USED)

3.09 ADJUSTING (NOT USED)

3.10 CLEANING (NOT USED)

3.11 PROTECTION (NOT USED)

3.12 SCHEDULES (NOT USED)

END OF SECTION



SECTION 26_05_33

RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. This section covers the work necessary to furnish and install complete

raceways and boxes for electrical systems.

B. Related sections: 1. Section 01_33_00 - Submittal Procedures. 2. Section 01_81_02 - Seismic Design Criteria. 3. Section 26_05_53 - Identification for Electrical Systems.

1.02 REFERENCES

A. California Code of Regulations: 1. Title 24, Part 3 - California Electrical Code (CEC).


A. Seismic design requirements for conduit hangers and supports: 1. All raceway systems to be furnished under this Section shall be designed and

constructed to meet the seismic requirements of Section 01_81_02.

B. The Contractor shall require that all persons engaged in the installation of PVC coated rigid steel conduit, elbows, nipples, and fittings attend installation training classes given by the approved manufacturer at the job site before any conduit installation work begins. The classes shall be carried out by technically competent and experienced instructors who are certified manufacturer's employees and instructors acceptable to the Engineer. The Contractor shall notify the Engineer two weeks in advance of the scheduled classes.

C. The Contractor shall demonstrate to the Engineer that the approved manufacturer's recommended installation tools and methods are being utilized on the job site by all persons engaged in the installation of PVC coated rigid steel conduit, elbows, nipples, and fittings. These tools and methods shall include, but not be limited to, clamp inserts for use on power driven units of chain vises, new die heads and enlarged pipe guides in conduit threading machines, and strap wrenches and extra wide wrench jaws for use in conduit assembly.

D. Raceway and boxes shall be UL listed.

1.04 SUBMITTALS

A. Make submittals in accordance with Section 01_33_00.


PART 2 PRODUCTS

2.01 GENERAL

A. Rigid steel conduit: 1. Hot-dipped galvanized rigid steel conduit, including threaded type couplings,

elbows, nipples, and other fittings, shall meet the requirements of ANSI C80.1, ANSI C80.4, UL and the CEC. Do not use setscrew or threadless type couplings, bushings, elbows, nipples, and other fittings, except when approved in writing by the Engineer.

2. Acceptable manufacturers: a. Allied Tube and Conduit. b. Western Tube and Conduit. c. Or equal as approved by the Engineer.

B. PVC-coated rigid steel conduit: 1. PVC-coated rigid steel conduit shall be hot-dipped galvanized rigid steel

conduit meeting the requirements of NEMA RN 1 or ETL PVC-001, UL and the CEC, and a factory installed PVC coating 40 mils nominal thickness, and applied over and permanently bonded to the galvanized surface, with an interior 2 mil urethane coating. All male threads on conduit, elbows, and nipples shall be protected by an application of a urethane coating. Couplings, elbows, nipples and other fittings shall be threaded and galvanized and shall have integral plastic sleeves which overlap the plastic-coated conduit with pressure sealing sleeves. Use PVC coated conduit suitable for conductors with 75 degrees C insulation.

2. Acceptable manufacturers: a. Robroy Plasti-Bond Red. b. Perma-Cote Industries Supreme Conduit System. c. Or equal as approved by the Engineer.

C. Flexible metal conduit, liquid-tight: 1. Flexible metal conduit shall be UL listed, liquid-tight, consisting of galvanized

steel flexible conduit covered with an extruded gray PVC jacket and terminated with nylon bushings or bushings with steel or malleable iron body and insulated throat and sealing O-ring.

2. Acceptable manufacturers: a. Anaconda Sealtite Type UA. b. Electri-Flex Liquatite Type LA. c. Or equal as approved by the Engineer.

D. Raceway fittings: 1. Fittings for rigid steel:

a. Watertight hubs for rigid steel conduit shall be male thread type zinc-plated malleable iron with recessed "O" ring seal, insulated throat, and locking screw: 1) Acceptable manufacturers:

a) O-Z/Gedney, Type CHM-T. b) Cooper Crouse-Hinds, Raintight Malleable Iron “MHUB”. c) Or equal as approved by the Engineer.


b. Provide all malleable iron conduit bodies and covers with captive stainless steel screws and neoprene gaskets: 1) Acceptable manufacturers:

a) Appleton, Form 35 Threaded Unilets. b) Killark, Duraloy 5 Series Malleable Iron. c) Or equal as approved by the Engineer.

2. Fittings for liquid-tight flexible metal conduit: a. Straight, 45 degree angle, or 90 degree angle connectors with malleable

iron gland nut, polyethylene compression ring, steel ferrule, malleable iron conduit assembly with insulated throat, steel lock nut, and copper grounding lug: 1) Acceptable manufacturers:

a) Cooper Crouse-Hinds, Liquidator Series. b) Steel Electric Products. c) Or equal as approved by the Engineer.

3. Fittings for PVC-coated rigid steel conduit: a. Watertight and corrosion resistant hubs for PVC coated rigid steel conduit

shall have a minimum 40 mil PVC exterior coating, a urethane interior coating, and pressure sealing sleeves: 1) Acceptable manufacturers:

a) Robroy Plasti-Bond Red Type ST Hub. b) Perma-Cote Industries Supreme Type ST Hub. c) Or equal as approved by the Engineer.

b. For corrosion resistant conduit bodies for use with PVC coated rigid steel conduit sized as required by the CEC, use cast iron conduit bodies and covers with captive stainless steel screws, a 40 mil minimum PVC exterior coating and nominal 2 mil internal urethane coating, and pressure sealing sleeves on all conduit openings: 1) Acceptable manufacturers:

a) Robroy Plasti-Bond Red Conduit Bodies. b) Perma-Cote Industries Supreme Conduit Bodies. c) Or equal as approved by the Engineer.

c. In NEMA 4X areas, provide zinc-plated malleable iron or galvanized steel insulated throat connectors for liquid-tight flexible metal conduit, suitable for use in wet locations, with a minimum 40 mil PVC exterior coating and pressure sealing sleeves: 1) Acceptable manufacturers:

a) Robroy Plasti-Bond Red Liquid Tight Connectors. b) Perma-Cote Industries Supreme Liquidtight Connectors. c) Or equal as approved by the Engineer.

E. Supports and fittings: 1. For areas not designated as NEMA 4X on the drawings, supports and fittings

for support systems for electrical equipment and raceways shall be channel supports sized to meet seismic requirements. Finish shall be hot-dipped galvanized steel for strut, pipe straps, clamp back spacers, hanger rod, strut nuts, U-bolts, beam clamps, and other supports and fittings: a. Acceptable manufacturers:

1) Unistrut, B-Line. 2) Power Strut. 3) Or equal as approved by the Engineer.


2. For areas designated as NEMA 4X on the drawings; supports and fittings for support systems for electrical equipment and raceways shall be channel supports sized to meet seismic requirements. Materials of construction shall be 40 mil PVC coated hot-dipped stainless steel, or self-extinguishing fiberglass which meets UL-94V-0 flammability tests, for strut, pipe straps, clamp back spacers, hanger rod, strut nuts, U-bolts, beam clamps, and other supports and fittings: a. Acceptable manufacturers:

1) Robroy Plastibond-Red PVC Coated Steel Strut and accessories. 2) Fiberglass Strut and accessories. 3) Perma-Cote Supreme PVC Coated Steel Channel and accessories. 4) Or equal as approved by the Engineer.

3. NEMA 12 terminal boxes, junction boxes, pull boxes, etc., shall be sheet steel unless otherwise shown on the drawings. Boxes shall have continuous welded seams and mounting feet. Welds shall be ground smooth. Boxes shall be flanged and shall not have holes or knockouts. Box bodies shall not be less than 14 gauge metal and covers shall not be less than 14 gauge metal. Covers shall be gasketed with rolled lip and fastened with stainless steel clamps. Furnish boxes with continuous hinged doors, terminal mounting straps, and brackets. Terminal blocks shall be NEMA type, not less than 20A, 600V: a. Acceptable manufacturers:

1) Hoffman Engineering Co. 2) Lee Products Co. 3) Keystone/Rees, Inc. 4) Or equal as approved by the Engineer.

4. For NEMA 4 and NEMA 4X locations, terminal boxes, junction boxes, pull boxes etc., shall be Type 304 stainless steel (NEMA 4 locations) or Type 316L stainless steel (NEMA 4X locations) unless otherwise shown on the drawings. Boxes shall have continuous welded seams and mounting feet. Welds shall be ground smooth. Boxes shall be flanged and shall not have holes or knockouts. Box bodies shall not be less than 14 gauge metal and covers shall not be less than 12 gauge metal. Covers shall be gasketed and fastened with stainless steel clamps. Furnish terminal boxes with hinged doors, terminal mounting straps and brackets. Terminal blocks shall be NEMA type, not less than 20A, 600V: a. Acceptable manufacturers:

1) Hoffman Engineering Co. 2) Lee Products Co. 3) Keystone/Rees, Inc. 4) Or equal as approved by the Engineer.

5. All boxes and fittings used with PVC coated conduit shall be furnished with a PVC coating bonded to the metal, the same thickness as used on the coated steel conduit. The ends of couplings and fittings shall have a minimum of one pipe diameter PVC overlap to cover threads and provide a seal.

6. Device boxes shall be malleable iron with zinc electroplate and epoxy powder coat finish, malleable iron covers, and stainless steel screws. Provide the “deep” configuration for all devices boxes: a. Acceptable manufacturers:

1) Appleton, UNILETS Malleable Iron, Type FD. 2) Steel Electric Products, Type FD. 3) Or equal as approved by the Engineer.


7. All terminal boxes, junction boxes, and metallic pull boxes shall have two conduit drain fittings installed in the bottom of the box to permit water to drain from the box continuously. Drain fittings shall be stainless steel, designed for use with 1/2” hubs or 1/2” drilled and tapped conduit openings: a. Acceptable manufacturers:

1) Killark, KDB-1. 2) O-Z/Gedney, DB-50.

PART 3 EXECUTION

3.01 GENERAL

A. Material and equipment installation: 1. Follow manufacturer's installation instructions explicitly, unless otherwise

indicated. Wherever any conflict arises between manufacturer's installation instructions, codes and regulations, and these contract documents, follow Engineer's decision. Keep copy of manufacturer's installation instructions on the jobsite available for review at all times.

3.02 INSTALLATION

A. Use no circular raceway less than 3/4-inch unless otherwise approved by the Engineer.

B. Raceway type for location and installation method unless noted otherwise on the drawings: 1. Exterior, exposed (higher than 6-inches above grade), all locations except

those designated as NEMA 4X: a. Rigid steel conduit.

2. Interior, exposed or concealed (not embedded in concrete), all locations except those designated as NEMA 4X: a. Rigid steel conduit.

C. Location, routing, and grouping: 1. Paint all threads of galvanized conduits with zinc-rich paint or liquid

galvanizing compound before assembling. Touch up after assembly to cover nicks or scars.

D. Special locations: 1. Final connection to equipment:

a. Make final connection to motors, local instrumentation, and other equipment where flexible connection is required to facilitate removal or adjustment of equipment with 18-inch minimum, 60-inch maximum lengths unless otherwise approved by the Engineer, of liquid-tight, PVC-jacketed flexible conduit where the required conduit size is 4 inches or less. For larger sizes, use rigid steel conduit as specified.

b. The flexible conduit shall be long enough to allow the item to which is connected to be withdrawn or moved off its base. Use liquid-tight flexible metal conduit in outside areas, process areas exposed to moisture, and areas required to be oil-tight and dust-tight.


E. Support: 1. Support raceways at intervals not exceeding CEC requirements unless

otherwise indicated. Support multiple raceways adjacent to each other by ceiling trapeze. Support individual raceways by wall brackets, strap hangers, or ceiling trapeze, fastened by toggle bolts on hollow masonry units, expansion shields on concrete or brick, and machine screws or welded thread studs on steelwork.

F. Bends: 1. Make changes in direction of runs with symmetrical bends or cast metal

fittings. Make bends and offsets of the longest practical radius. Avoid field-made bends and offsets where possible, but where necessary, make with an acceptable hickey or conduit bending machine. Do not heat metal raceways to facilitate bending.

2. Make bends in parallel or banked runs of raceways from the same center or centerline so that bends are parallel and of neat appearance. Factory elbows may be used in parallel or banked raceways if there is a change in the plane of the run and the raceways are of the same size. Otherwise, make field bends in parallel runs.

3. Make no bends in flexible conduit that exceed allowable bending radius of the cable to be installed or that significantly restricts the conduits flexibility.

G. Threaded joints: 1. Paint all field-cut threads with zinc rich paint or liquid galvanizing compound for

rigid steel conduit and for PVC-coated rigid steel conduit after removal of chips and cleaning with solvent. Use approved, highly conductive jointing compound on all joints: a. Approved manufacturers:

1) Appleton Type TLC. 2) Or equal as approved by the Engineer.

H. Bushing and insulating sleeves: 1. Where rigid steel conduit, PVC coated rigid steel conduit, or liquid-tight flexible

metal conduit enters metal enclosures, install an insulated throat grounding bushing on the end of each conduit. Install a bonding jumper from the bushing to any equipment ground bus or ground pad. Interconnection of bonding jumpers from each conduit grounding bushing to the equipment ground bus or ground pad is acceptable.

2. If neither a ground bus or ground pad exists, connect the bonding jumper to the metallic enclosure with a bolted-lug connection.

3. Make conduit connections to NEMA 3R, NEMA 4, or NEMA 4X enclosures, junction boxes, terminal junction boxes, or device outlet boxes with watertight, corrosion resistant hubs. The conduit connections shall maintain the integrity of the enclosure NEMA rating.

I. PVC coated rigid steel conduit: 1. Install in strict accordance with the manufacturer's instructions. Touch up any

damage to the coating with conduit manufacturer acceptable patching compound. PVC boot shall cover all threads. Where belled conduits are used, bevel the unbelled end of the joint before joining. Leave no metallic threads uncovered. Clean field threads with solvent and coat with urethane touch-up. Keep two cans of urethane touch-up at each threading station.


J. Preparation for pulling in conductors: 1. Do not install crushed or deformed raceways. Avoid traps in raceways. Take

care to prevent the lodging of dirt, or trash in raceways, boxes, fittings, and equipment during the course of construction. Make raceways entirely free of obstructions or replace them. Ream all raceways, remove burrs, and clean raceway interior before introducing conductors or pull tape.

END OF SECTION



SECTION 26_05_53

IDENTIFICATION FOR ELECTRICAL SYSTEMS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. All electrical equipment and systems shall include identification tags or

nameplates as shown on the drawings and as specified herein. 2. The Contractor shall develop a tagging system in accordance with the

information shown on the Drawings and the procedure specified in this Section.

B. Related sections: 1. Section 01_33_00 - Submittal Procedures.

1.02 SUBMITTALS

A. Submittals shall be made in accordance with Section 01_33_00.

B. In addition to the requirements of Section 01_33_00: 1. A tagging system scheme or schedule shall be submitted to the Engineer for

review and approval prior to tagging of equipment.

PART 2 PRODUCTS

2.01 PRODUCTS

A. Conduit Identification Tags: 1. Conduit tags shall be of the reusable labeling type so that changing of the

labels can occur without removing the tag from the conduit. Construct the label holder so that the labels can slide on and off when they need to be changed or replaced. The conduit tags shall be suitable for industrial use: a. Outdoor or indoor, below grade locations:

1) For exposed outdoor, below or above grade locations, provide an aluminum tag holder of sufficient size to hold the alphanumeric conduit tag designations specified in the conduit schedule on the drawings.

2) For indoor, below grade locations, provide screen printed aluminum tags with black letters on yellow background. Provide horizontal orientation with nominal 1” letter height using Helvetica Black Condensed font.

b. Indoor locations, above grade locations: 1) Provide a polyethylene tag holder of sufficient size to hold the

alphanumeric conduit tag designations specified in the conduit schedule on the drawings.


2) Provide hot stamped polyethylene tags with black letters on yellow background. Provide horizontal orientation with nominal 1” letter height using Helvetica Black Condensed font.

2. Attach the conduit tag holder to the conduit using #18 AWG 316 tie wire. 3. Attach the conduit tag holder using #18 AWG 16 tie wire. 4. Provide equipment and tools to make the labels and connect the tags to the

conduits. 5. In addition the conduit number tag, provide a separate “Caution Fiber Optic

Cable” labels where fiber optic conduits are shown on the Drawings. 6. Acceptable Manufacturers:

a. Almetek ID Marking Systems, Mini-Tag or E-Z Tags. b. Outdoor tag holder: TH-0X-A/SL, where X is the number of characters. c. Indoor tag holder: TC-CP, where X is the number of characters.

B. Wire labels for #1 AWG and smaller: 1. Wire labels relying on adhesives or taped-on markers are not acceptable. 2. Individual wires #1 AWG and smaller in each cable or wire bundle shall be

identified with legible permanent sleeve of white heat-shrink polyolefin with machine printed weatherproof black marking.

3. Meet UL Standard 224 for flammability. 4. Provide necessary tools and accessories to print labels and shrink labels. 5. Acceptable manufacturers:

a. Brady Model B-342 Brady PermaSleeve 1.5” width one-sided thermal transfer labels.

b. Panduit. c. Or equal as approved by the Engineer.

C. Wire labels for #1/0 and larger sizes and cable identification tags: 1. Cable tags shall be of the reusable labeling type so that changing of the labels

can occur without removing the tag from the conduit. Construct the label holder so that the labels can slide on and off when they need to be changed or replaced. The conduit tags shall be suitable for industrial use.

2. Tag holders shall be PVC for horizontal orientation sized to hold the alphanumeric conduit tag designations specified in the cable schedule on the drawings.

3. Tags shall be black letters on yellow background. 4. Attach the cable tag holder to the cable or wire bundle using UV protected,

self-locking black nylon cable ties. 5. Acceptable manufacturers:

a. Almetek ID Marking Systems. Mini Tags. b. Tyco Electronics, K-Type cable Markers. c. Or equal as approved by the Engineer.

D. Equipment nameplates: 1. Reference Drawing 992-G-007 for nameplate letter and background color

requirements. Note that per Drawing 992-G-007, all cabinet nameplates shall have white background and black lettering. For hanging tag applications, use the color schedule shown on the Drawing.

E. Pushbutton legend plates: 1. Provide legend plates for pushbuttons, selector switches, and pilot lights with

inscription as shown on the drawings. Provide adapter ring as necessary to fit


devices with legend plates. Legend plates shall be made by same manufacturer as pushbutton device, selector switch, and pilot light.

2. Acceptable manufacturers: a. Cutler-Hammer HT800 Series. b. General Electric CR104P Series. c. Allen Bradley Bulletin 800T. d. Or equal as approved by the Engineer.

F. Phase rotation markers 1. 2” X “ yellow polyester marker with black lettering. Markers are required for the

following power distribution equipment: a. Each 480 volt control panel. b. Each power supply unit. c. Each ozone generator.

2. Acceptable manufacturers: a. Electromark – Phase/Order. b. Or equal as approved by the Engineer.

PART 3 EXECUTION

3.01 GENERAL

A. Conductor identification: 1. Identification system shall use the format shown on Cable Schedule Drawings.

For single conductor cables, the wire bundle shall be considered as an overall cable and a cable tag applied accordingly.

2. Identify conductors at each termination and in all accessible locations such as control panels, terminal boxes, motor starters, disconnect switches, etc. For identification, use type of conductor and cable tags specified herein. A typical circuit will have the following identification: conduit tag, overall cable tag, and individual wire labels.

B. Legend plates and nameplates: 1. Provide legend plate engraving for pilot devices as shown on the drawings; if

not shown, Contractor shall submit a schedule showing proposed legend plate text for the Engineer’s approval.

3.02 TAGGING OF WIRES AND CABLES

A. All wires and cables shall be tagged and laced in pull or junction boxes, and at each termination. Wires and cables shall be laced so that the wires of the individual circuits are laced together by circuit and the laced-together circuit or cable shall be tagged with the cable number. Power, lighting, control, alarm, annunciator, and instrumentation wiring shall be bundled, laced, and tagged, as specified herein.

B. All wires and cables within control panels, terminal junction boxes, etc., shall be tagged at each termination with conductor tags as specified. All circuit identification tags shall be readily accessible for inspection at the locations cited above.

C. Identify multi-circuit control cables and individual instrumentation and control circuits as indicated on the Drawings. Multi-circuit cable shall be tagged with the cable name around the entire cable assembly and shall have the individual circuits tagged


as well. Tag twisted, shielded pairs and where exposed, multi-pair cable twisted pairs around each pair separately.

D. Identify each individual conductor at each termination. This includes such locations as switchgear, switchboards, motor control centers, variable frequency drives, control panels, junction/terminal boxes, all field devices, security panels and junction boxes, and all other locations where conductors are terminated. Identify the termination of these conductors in accordance with the accepted shop drawings. Tag conductors with sleeve type labels.

E. Where more than 1 nominal voltage system exists, identify each ungrounded system conductor by phase and system. Permanently post means of identification at each branch-circuit panelboard, switchboard, switchgear, motor control center, or other type of power distribution equipment.

F. Include the following minimum information for wire and cable identification: 1. Circuit number or load identification tag number. 2. Origin (from source). 3. Destination (to load).

G. Wire numbers: 1. The Contractor shall coordinate the wire numbering system with all vendors of

equipment so that each and every field wire has a unique wire number associated with it for the entire system: a. Wire numbers for field instrumentation and circuits shall correspond to the

designation shown in the cable schedule and the E-200 or E-400 series drawings. Generally, the instrument tag is the wire number, with appropriate suffix modifiers to give each wire a unique name. Examples.

b. Control circuit C1C1 (from the cable schedule) connecting a temperature switch with tag number TSH-001 to a process control panel would have wire numbers specified in the E-200 or E-400 series drawings as TSH001+, TSH001-, and TSH001SH, assuming a twisted shield pair.

c. Control circuit C9J1 (from the cable schedule) connecting a thermostat to an air handling unit with tag number TE-075 would have wire numbers TE075+, TE075-, TE075RTN, and TE075SH, assuming a twisted shield triad.

d. Control circuit A1C1 does not have any specific wire numbers shown on the E-200 or E-400 drawings. Therefore, use A1C1-1, -2, -3, etc., assuming a multi-conductor cable.

e. Wire numbers for field power circuits shall correspond to the designation shown in the cable schedule on the drawings, with appropriate suffix modifiers to give each wire a unique name. Examples.

f. Power circuit M1P1 on the cable schedule going to a three-phase motor: use suffix modifiers -1, -2, -3, and -G for the individual three-phase and ground conductors).

g. Power circuits for receptacles and lighting: use the panelboard circuit number(s) where the branch circuit originates (for example, L5P16 with suffix modifiers -L, -N, and –G for a 120VAC lighting circuit originating at panelboard 5, circuit 16).

h. For telecommunication and specialty control circuits, provide the cable designation shown on the cable schedule. Unless otherwise specified on


the Drawing, it is not necessary to provide individual wire numbers for these applications.

END OF SECTION



SECTION 26 05 83

LOW VOLTAGE MOTORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. AC Motors, up to 500 horsepower, furnished under other Sections of these

Specifications, shall be in conformance with the requirements listed in this Section unless otherwise noted.

B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 75 17 – Field Testing and Startup. 3. Section 26 29 23 – Low-Voltage Variable-Frequency Motor Controllers.

1.02 REFERENCES

A. Institute of Electrical and Electronics Engineers (IEEE): 1. IEEE Std 43, "IEEE Recommended Practice for Testing Insulation Resistance

of Electric Machinery.” 2. IEEE Std 112, "Standard Test Procedure for Polyphase Induction Motors and

Generators." 3. IEEE Std 114, "Standard Test Procedures for Single-Phase Induction Motors." 4. IEEE Std 841, “IEEE Standard for Petroleum and Chemical Industry – Severe

Duty Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors – Up To and Including 370 KW (500 HP).”

B. National Electrical Manufacturers Association (NEMA): 1. NEMA MG1, "Motors and Generators."

1.03 SUBMITTALS

A. Submittals shall be made in accordance with Section 01 33 00.

B. Provide the following submittal documentation: 1. Clearly mark on submittals that the motors being supplied meet or exceed the

requirements of IEEE Std 841. 2. Descriptive bulletins, including manufacturer's technical data on features,

performance, electrical ratings, and characteristics. 3. Complete nameplate data. 4. Motor dimensioned outline drawing, mounting details, weight, location and size

of conduit boxes, location of conduit entries. 5. Motor performance data sheet. 6. Manufacturer’s installation and maintenance manual showing details relating to

shipment, handling, storage, foundation requirements, initial installation, normal operation, doweling, disassembly, reassembly, lubrication, recommended renewal parts and procedure to obtain service, relevant cutaway drawings, and troubleshooting matrix.


7. Manufacturer’s recommended renewal parts list. 8. Diagrams, including motor lead wiring connection, space heater connection,

and temperature detector connection.

C. Provide the following “typical” prototype performance test data for each type of motor specified: 1. Locked-rotor (zero-speed) torque and current. 2. Speed-torque curve at 80 percent and 100 percent nominal line voltage. 3. Speed-current curve. 4. Bearing and winding temperature rise tests at rated horsepower. 5. Full-load current and slip. 6. Efficiency at 100 percent, 75 percent, and 50 percent of full load. 7. Power factor at 100 percent, 75 percent, and 50 percent of full load. 8. Airborne sound power watts and sound pressure in dBA.

D. Provide the following factory test reports for the actual motors provided (i.e., not typical data), in accordance with NEMA Standard MG1-Part 12, with tests conducted in accordance with IEEE Std 112: 1. Winding resistance. 2. No-load current, voltage, and speed. 3. Unfiltered vibration velocity in inches/second with two readings perpendicular

to each other in the radial plane on both ends of the motor (near each bearing) plus one axial reading (5 total unfiltered vibration readings).

4. Shaft extension runout (TIR). 5. High-potential test. 6. Insulation resistance/polarization index.

E. Provide the following additional test reports required for the application: 1. Bearing life calculation. 2. Acceleration time vs. amperes curve:

a. The driven equipment supplier shall provide the load WK2 and load speed vs torque curve to the motor supplier in order to construct this curve. Provide curves at 80 percent and 100 percent nominal line voltage.

3. Equivalent circuit parameters. 4. Motor thermal damage, logarithmic inverse time vs. percent full load current

curve. 5. Short circuit time constant and X/R ratio for power system fault current

analysis. 6. Motor rotor moment of inertia. 7. Mass elastic data. 8. Shaft drawing. 9. Shaft stiffness and modulus of elasticity. 10. Reed critical frequency.

F. IEEE-841 Data Sheet for each three-phase motor with all data fields marked “Seller With Proposal” and “Seller After Order” completed by the motor vendor.


A. Single speed, totally-enclosed fan cooled, squirrel-cage polyphase induction motors shall be designed and manufactured in accordance with the latest version of IEEE Standard 841.


B. Unless noted otherwise herein, routine tests shall be performed on representative motors in accordance with IEEE Standard 112, and shall include the information described on NEMA MG1-Part 12. Efficiency shall be determined in accordance with IEEE Publication No. 112, Method B. Power factor shall be measured on representative motors.


A. Delivery, Handling, and Unloading: 1. Handle the motor in accordance with the manufacturer’s installation, operation,

and maintenance manual. Equipment needed to handle motors in the frame size of this specification typically includes a hoist and spreader bar arrangement of sufficient strength to lift the motor safely using the lifting lugs or eyebolts on the machine.

B. Acceptance at Site: 1. Upon receipt of the motor, carefully inspect the unit for any signs of damage

that may have occurred during shipment.

C. Storage and Protection: 1. Store motors indoors in a clean, dry location with space heaters energized to

preclude moisture buildup. Connect heaters upon delivery of the motor. 2. Cover the motors with a canvas tarpaulin. Do not wrap the motor in plastic. The

cover shall extend to the ground and fit loosely over the motor to allow the captive air space to breath, minimizing the formation of condensation.

3. Coat all machined surfaces, including the shaft extension, with rust preventative material, Rust Veto No. 342 by E.F. Houghton, Co., or equal as approved by the Engineer. Check the coating every month and re-coat as necessary.

4. Rotate the shaft once a month to maintain lubricant film on the bearing races and journals.

5. Bearings: a. Grease:

1) Completely fill grease lubricated cavities with the lubricant specified in the manufacturer’s installation, operation, and maintenance manual. Remove the drain plug and fill cavity with grease until grease begins to purge from the drain opening.

2) Inspect grease monthly for moisture and oxidation by purging a small quantity of grease through the drain. If any contamination is present, completely remove and replace the grease.

6. Insulation resistance testing: a. Disconnect all external accessories that have leads connected to the

winding and connect them to a common ground. Connect all other accessories that are in contact with the winding to a common ground.

b. Perform a one minute insulation resistance test on the winding using 500 VDC for one minute. Correct the reading to 40 deg C. The minimum acceptable insulation resistance is 5 megohms.

c. Perform a polarization index (PI) test by taking the ratio of a 10 minute reading to the one minute reading. The minimum acceptable PI is 2.0. If the one minute insulation resistance reading corrected to 40 deg C is above 5,000 megohms, disregard the PI reading.


1.06 COMMISSIONING

A. Commission the equipment as specified in Section 01 75 17.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. U.S. Motors/NIDEC.

B. Toshiba.

C. Siemens.

D. Or equal as approved by the Engineer.

2.02 RATING

A. Each motor shall develop ample torque for its required service throughout its acceleration range at a voltage 10 percent below nameplate rating. Where shown on the drawings or required in the specifications to be operated on a reduced voltage motor starter or variable frequency drive, the motor shall develop ample torque under the conditions imposed by the starting method.

B. Motors shall not be required to deliver more than its rated nameplate horsepower, at unity (1.0) service factor, under any condition of mechanical or hydraulic loading.

C. All motors shall be continuous time rated for operation at 40 degrees C ambient and altitudes less than 1,000 meters unless noted otherwise.

D. Specific motor data such as horsepower, RPM, etc., is specified under the detailed specification for the mechanical equipment with which the motor is supplied.

2.03 THREE-PHASE MOTORS

A. General: 1. Unless otherwise specified, motors 1/2 horsepower and larger shall be

3-phase, squirrel cage induction type. 2. Motors one horsepower and above shall meet or exceed the requirements of

IEEE 841. 3. Unless otherwise specified, the standard voltage rating for all motors shall be

460V at 60Hz, 3-phase. 4. Unless otherwise required by the load, all polyphase motors shall be premium

efficiency NEMA Design B and provide normal starting torque. Locked rotor KVA/HP shall not exceed Code Letter G as described in NEMA Standard MG1-10.37 for motors 20 HP and larger.

5. Unless otherwise specified in the driven equipment specifications, vertical motors shall be provided in the vertical solid shaft configuration.

B. Required features and accessories: 1. Motors one horsepower and above shall have the following IEEE-841 features:

a. Premium efficiency.


b. Corrosion resistant cast iron construction with TEFC enclosure. c. Non-wearing, non-contacting, radial-axial labyrinth bearing isolator

(INPRO/SEAL) on both ends for a horizontal motor. d. 1.15 service factor. e. Ground lug in conduit box. f. Ground terminal on frame. g. Class F insulation with Class B (80 deg C) rise at 1.0 Service Factor for

TEFC enclosures (Resistance Method). h. Special (“refined”) balance – 0.08 inches/second peak maximum vibration. i. Special shaft run-out tolerance – 0.001 inches maximum. j. Oversized main conduit box. k. NEMA Design B. l. Non-witnessed IEEE 841 enhanced no-load test. m. AFBMA bearing numbers stamped on the motor nameplate. n. 50,000 hour bearing L-10 life. o. 3-year warranty.

2. Provide insulation treatment of one cycle of vacuum pressure impregnation of 100 percent solid epoxy resins.

3. For motors 40 hp and larger, provide a separate, dedicated, accessory conduit terminal box with terminal strip connectors to terminate the leads of internal accessories such as space heaters and thermostats.

4. Provide 120V single-phase space heaters for all three-phase motors. 5. Thermal protection:

a. Motors < 250 hp: 1) Provide factory installed, embedded, bi-metallic temperature switches

with leads terminating in the main conduit box or separate accessory conduit box where specified herein. The switches shall have normally closed contacts. Provide three detectors for each motor, one switch per phase. These devices shall protect the motor against damage from overheating caused by single phasing, overload, high ambient temperature, abnormal voltage, locked rotor, frequent starts or ventilation failure.

6. Finishes: a. Provide safety yellow enamel exterior finish coating, Federal Standard

color No. 13591.

C. Variable Frequency Drive (VFD) applications: 1. Polyphase motors for use with variable frequency drives shall be rated as

definite-purpose inverter fed as defined under NEMA MG-1, Part 31. 2. Provide a shaft grounding ring for all VFD-driven motors regardless of size:

a. Acceptable manufacturers: 1) AEGIS SGR. 2) INPRO/SEAL CDR. 3) Or equal as approved by the Engineer.

D. Fractional Horsepower Motors: 1. Fractional horsepower motors shall be premium-efficiency type, TEFC, with a

1.15 service factor.

2.04 SINGLE-PHASE MOTORS

A. Unless otherwise specified, motors smaller than 1/2 horsepower shall be single phase, capacitor start, with TEFC enclosure. Small fan motors may be split-phase or


shaded pole type if such are standard for the equipment. Wound rotor or commutator type single-phase motors are not acceptable unless their specific characteristics are necessary for the application.

B. Motors shall be rated for operation at 115 or 208 volts, single phase, 60 Hz.

C. Locked rotor current shall not be greater than specified in NEMA Standard MG1-Part 12, Design "N".

D. Motors shall be totally-enclosed in conformance with NEMA Standard MG1-Part 1.

E. Motors shall be provided with sealed ball bearings lubricated for 10 years normal use.

F. Acceptable manufacturers: 1. U.S. Motors/NIDEC. 2. Baldor. 3. Or equal as approved by the Engineer.

PART 3 EXECUTION

3.01 GENERAL

A. Install all motors in accordance with the manufacturer's printed recommendations and as required under the specific specification sections for the driven equipment.

3.02 PREPARATION PRIOR TO INSTALLATION

A. Inspect, clean, and restore the motor to the “as-shipped” condition.

B. If the motor has been subject to vibration during storage, disassemble and inspect each bearing for damage.

C. When storage time has been six months or more, change the lubrication (oil and/or grease). For motors with oil lubricated bearings, do not move the motor with oil in the reservoir.

3.03 INSTALLATION

A. Bolt the motor to the equipment or rigid foundation using bolts of the largest size permitted by the holes in the motor bracket. Do not install motors in such a way as to restrict motor ventilation.

3.04 SCHEDULES

A. The IEEE 841 Datasheets following “END OF SECTION” are a part of this specification section. These data sheets contain the summary “Buyer with Request for Quotes” details for each IEEE-841 motor scheduled on the project. During the submittal process, the motor vendor shall complete the data fields marked “Seller With Proposal” and “Seller After Order.”

END OF SECTION

February 2016 26_05_83-7

9905A10

pw://Carollo/Documents/Client/CA/EBMUD/9905A10/02 Pre-Purchase/Specifications/26_05_83 (FINAL)

IEEE-841 Data Sheet for AC Squirrel Cage Induction Motors [370 kW(500 hp) and below] Client: EBMUD Engineering Org: Spec. No.: Project Title: Specification XXXX Location: Date: Location: Contract No.: Equip No.: Unit: Specifier Name: Tele. No.: P.O. No.: Data Provided by: □ Buyer with Request for Quotes • Seller with Proposal ◊ Seller After Order Site Conditions: Data Supplied by Manufacturer: □ Altitude: ______________________________ m • Frame Size: ____________________________ □ Ambient Temp.: Max _________ °C □ Min _________°C • Full Load Speed: _________________ rpm □ Area Class __________ Div _________ Group _________ • Full Load Current: □ Nonhazardous □ Auto Ignition Temp _____________°C ◊ Locked Rotor Current @ Full Voltage: ◊ Locked Rotor Current @ 90% Voltage: Data Supplied by User: • Allowable Stall Time @ Full Voltage: □ Power: __________________kW ______________hp • Allowable Stall Time @ 90% Voltage: □ Synchronous Speed: ___Per Sections 46_31_54, 46_31_55 and 46_31_57 ___________________________

• Sound Power Level (No Load): 90 dBA (max.) _________

□ Voltage: ___460____________________________________

• Insulation System:

□ Phase: 3 Class F Minimum: ________________________ □ Frequency: 60 Hz Random/Form Wound: ___________________ □ Insul. System: Random/Form Wound (see note below) • Temperature Rise at Rated Load: _____________ °C Max. □ Enclosure: TEFC • Service Factor: (see note below) _____________________ □ Coupled Drive: Per Sections 46_31_54, 46_31_55 and 46_31_57

• Motor Terminal Leads: _____________________________

□ Mounting Position: Horizontal/Vertical □ Shaft Up or Down (Vertical Mtg. Only) ________________ Bearing Information: □ Service Factor: (see note below) ____________________ • Type: ___________________________________________ □ Motor Thrust Loads: ______________________________ • Lubrication Method: ______________________________ □ Special Load Conditions: ___________________________ ◊ Recommended Lubricant: __________________________ □ Space Heaters: __________________________________ • Temp. Rise @ Full Load: ____________________________ □ Space Heater Maximum Surface Temperature: _______°C ◊ Manufacturer & Number: __________________________ □ Space Heater Leads Location: ______________________ ODE _________________ DE _______________ □ Rotation Direction: _______________________________ • Motor Guaranteed Min. Eff. @ Full Load: ______________ □ Starting Method: ________________________________ • Terminal Box(es) Materials of Construction: ___________ □ Main Terminal Box Location: _______________________ _________________________________________________ _________________________________________________ • Fan Material: ____________________________________ □ Other Data: (Bearing type, lubrication method, motor • Space Heater Term. Box Location: ____________________

February 2016 26_05_83-8

9905A10

pw://Carollo/Documents/Client/CA/EBMUD/9905A10/02 Pre-Purchase/Specifications/26_05_83 (FINAL)

IEEE-841 Data Sheet for AC Squirrel Cage Induction Motors [370 kW(500 hp) and below] mounting information, unusual service conditions, etc.) • Space Heater Max. Sheath Temperature: ______________ _________________________________________________ _________________________________________________ • Other Data: _____________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ NOTES: Shop Inspection & Tests: 1) Motor should be applied within its rating based on service factor of 1.0.

□ Shop Inspection Required: (Yes/No) __________________

2) Motor insulation system: □ Final Tests Witnessed by Customer: (Yes/No) ___________ - Random wound 600 V class for kW (hp) < 190 (250) □ Other Special Tests: _______________________________ - Random/form wound 600 V class for kW (hp) >150 (200) __________________________________________________ - Form wound 2300 V and 4000 V _________________________________________________


SECTION 26 09 13

ELECTRICAL POWER MONITORING AND CONTROL

PART 1 GENERAL

1.01 DESCRIPTION

A. Work included: 1. Electrical power monitoring and control units (PMUs) as shown on the

drawings and as specified herein.

B. Related sections: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 75 17 - Field Testing and Startup. 3. Section 01 79 00 – Demonstration and Training.


A. Coordinate with the suppliers of the ozone power supply equipment to ensure sufficient space is available for mounting current transformers, voltage transformers, control power transformers, and PMUs.

B. Electrical power monitoring and control equipment shall be UL listed.

1.03 SUBMITTALS

A. Submittals shall be made in accordance with Section 01 33 00.

B. Furnish submittals for approval as outlined below: 1. Product data. 2. PMU outline and dimensional drawings showing device layout, interconnection

points and mounting requirements. 3. Submit wiring, interconnection, and mounting diagrams for the PMU. Submit

detailed drawings including wire numbers and terminals for each installation. Standard or generic diagrams will not be acceptable.

4. Submit details of the communications interface. Submit complete configuration instructions including addressing, register allocation, and options.

5. Submit complete details of trending, waveform capture, harmonic analysis, and power analysis software. Submit license agreements indicating all software has been licensed to the District.

1.04 REFERENCES

A. American National Standards Institute (ANSI)/ Institute of Electrical and Electronics Engineers (IEEE): 1. ANSI/IEEE C37.90.1 - IEEE Standard Surge Withstand Capability (SWC)

Tests for Relays and Relay Systems Associated with Electric Power Apparatus.


B. American National Standards Institute (ANSI)/National Electrical Manufacturers Association (NEMA): 1. ANSI/NEMA C12.20 – Electricity Meters 0.2 and 0.5 Accuracy Classes.

PART 2 PRODUCTS

2.01 METERING

A. General: 1. Multifunction digital recording power meter for use on a three-phase, four-wire

power systems.

B. Acceptable manufacturers: 1. Electro Industries, Nexus 1252, part number 1252-A-120-D2-60-V1-INP200-X-

P40N+ - P41N+ - P43N+: a. 4MB memory option. b. 120: 208Y/120 VAC, three-phase, four-wire operating voltage. c. D2: 120 VAC control power. d. 60: 60Hz frequency. e. V1: Standard Nexus 1252 Meter. f. INP200: Total Web solution, 10/100 Base T Ethernet port. g. X: No Revenue Seal. h. P40N+ “Volts” master display. i. P41N+ “Amps” slave display. j. P43N+ “Power” slave display.

2. No substitutions.

C. Provide a test switch for the power monitoring CT and VT connections as follows: 1. Acceptable manufacturers

a. SecuControls, ST switch, no substitutions. 2. Labels:

a. Top: 1) Blank 2) Color: WH|WH|WH|WH|WH|WH|WH|WH|WH|WH|

b. Bottom: 1) Text: VA | LO- | -HI | VB | LO- | -HI | VC | LO- | -HI | VN 2) Color: RD|WH|WH|RD|WH|WH|RD|WH|WH|RD|

3. Disconnecting Pins: a. Labelling: VA | IA – IA | VB | IB – IB | VC | IC – IC | VN b. Color: RD | WH – WH | RD | WH – WH | RD | WH – WH | RD

4. Provide clear covers and stud terminals.

PART 3 EXECUTION

3.01 INSTALLATION

A. PMUs shall be mounted inside the ozone power supply unit as specified herein. Provide all mounting hardware and installation details including grounding requirements to ensure that the PMUs are installed in conformance with the manufacturer and the supplier of the equipment.


B. PMU installation within the equipment shall not violate the manufacturer’s warranty for the PMU or the respective equipment.

END OF SECTION



SECTION 26_28_16

ENCLOSED SWITCHES AND CIRCUIT BREAKERS

PART 1 GENERAL

1.01 DESCRIPTION

A. Section includes: 1. Fusible and nonfusible disconnect switches. 2. Enclosed circuit breakers.

B. Related sections: 1. Section 01_81_02 - Seismic Design Criteria. 2. Section 26_05_33 - Raceway and Boxes for Electrical Systems.

1.02 SUBMITTALS

A. Provide submittals for approval as outlined below: 1. Product data. 2. Warranty. 3. Bill of materials. 4. Plan, elevation, and section drawings including overall weights, dimensions,

and anchoring details. 5. Conduit entry/exit locations. 6. Equipment seismic anchorage calculations and details as specified in this

section. 7. Instruction manuals. 8. As-built documents and Operation and Maintenance (O&M) manuals.


A. Enclosed switches and circuit breakers shall be UL listed.

1.04 REFERENCES

A. California Standards Building Standards Code, Title 24. 1. Part 3 - California Electrical Code (CEC).

B. National Electrical Manufacturers' Association (NEMA): 1. NEMA AB 1 - Molded-Case Circuit Breakers, Molded-Case Switches and

Circuit Breaker Enclosures. 2. NEMA KS 1 - Enclosed and Miscellaneous Distribution Equipment Switches

(600 Volts Maximum). 3. NEMA 250 - Enclosures for Electrical Equipment (1,000 Volts Maximum).

C. Underwriters Laboratories (UL): 1. 98 - UL Standard for Safety Enclosed and Dead-Front Switches. 2. 489 - Molded-Case Circuit Breakers, Molded-Case Switches and Circuit

Breaker Enclosures.


PART 2 PRODUCTS

2.01 DISCONNECT SWITCHES

A. Ratings: 1. Ampere rating: as required or specified. 2. Number of poles: as required or specified. 3. Voltage rating:

a. 125VDC systems: 600VDC, 2-pole. b. 208VAC or 240VAC single-phase, two-wire systems: 600VAC, 2-pole. c. 208VAC three-phase, three-wire systems: 600VAC, 3-pole. d. 480VAC three-phase, three-wire systems: 600VAC, 3-pole.

B. General: 1. Unless otherwise specified herein or indicated on the drawings, disconnect

switches shall be in steel NEMA 12 enclosures for indoor installations and in Type 316 stainless steel NEMA 4X enclosures for outdoor or indoor wet/corrosive installations as identified on the drawings.

C. Applications: 1. Below 1hp (AC only) and all 120VAC applications:

a. Horsepower-rated manual toggle switch, number of poles as required, with padlock guard for locking in the OFF position.

b. Overload protection is not required unless otherwise indicated on the drawings.

c. Mount toggle switch in an FD box as specified in Section 26_05_33. d. Acceptable manufacturers:

1) Cutler-Hammer, Type B230 or B330. 2) Square D Company, Class 2510. 3) Or equal as approved by the Engineer.

2. 1hp and above, all applications: a. Horsepower rated, single-throw, heavy-duty 600VAC/600VDC safety

switch with a quick-make, quick-break operating mechanism and full cover, defeatable, coin-proof interlock and indicator handle capable of being padlocked in the OFF position.

b. Provide cover viewing window in enclosure. c. Switch blades shall be visible when the switch is OFF and the cover is

open. d. Accessories:

1) Provide with fuses as required. 2) Furnish 1 set of spare fuses for each fused disconnect switch. 3) Provide normally open electrical interlock(s) on all disconnect

switches that will break the motor control circuit when the disconnect switch is opened. Interlock contact shall be activated by the disconnect switch pivot arm before the main switch blades break. Number of interlocks required for each disconnect switch shall be as shown on the drawings. Where no interlocks are specified, provide one spare interlock for each disconnect switch as a “spare”.

3. Acceptable manufacturers: a. General Electric, Heavy-duty, Type TH. b. Cutler-Hammer, Heavy-duty, Type DH.


c. Or equal as approved by the Engineer.

2.02 ENCLOSED CIRCUIT BREAKERS

A. Circuit breaker: 1. Protective devices shall be molded case circuit breakers with inverse time and

instantaneous tripping characteristics. 2. Circuit breakers shall be operated by a toggle-type handle and shall have a

quick-make, quick-break over-center switching mechanism that is mechanically trip-free. Automatic tripping of the breaker shall be clearly indicated by the handle position. Contacts shall be non-welding silver alloy.

3. Circuit breakers shall have the following minimum symmetrical interrupting capacity unless otherwise indicated on the drawings: a. 10,000 Amperes for 125VDC systems. b. 10,000 Amperes for 120/240VAC and 208Y/120V systems. c. 65,000 Amperes for 480V systems.

4. Trip units: a. Circuit breakers with trip settings less than 100 Amperes shall have non-

interchangeable thermal-magnetic trip units and inverse time-current characteristics.

b. Circuit breakers with trip settings between 100 and 250 Amperes shall have interchangeable trip, true digital rms sensing electronic trip units.

c. Circuit breakers 400 Ampere frame and higher shall have interchangeable trip, true digital rms sensing electronic trip units with a digital current display.

5. Provide UL-listed DC molded-case circuit breakers for use in all grounded and ungrounded battery supply circuits. Standard AC circuit breakers are not acceptable.

6. Ground fault protection shall be provided where indicated. 7. Series rated circuit breakers are not acceptable. 8. Acceptable manufacturers:

a. Circuit breakers with less than 100 Ampere trip rating: 1) General Electric, Thermal-Magnetic Trip. 2) Cutler-Hammer, Series C thermal-magnetic trip. 3) Or equal as approved by the Engineer.

b. Circuit breakers with trip settings between 100 and 250 Amperes: 1) General Electric, Spectra RMS with digital, solid-state, RMS sensing

trip system. 2) Cutler-Hammer, Series C with Digitrip 310 LSIG trip unit. 3) Or equal as approved by the Engineer.

c. Circuit breakers 400 Ampere frame and higher: 1) General Electric, Spectra RMS with MicroVersaTrip Plus LSIG trip

unit. 2) Cutler-Hammer, Series C with OPTIM 550 LSIG trip unit. 3) Or equal as approved by the Engineer.


B. Enclosures: 1. Unless otherwise specified herein or indicated on the drawings, enclosed

circuit breakers shall be in steel NEMA 12 enclosures for indoor installations and in Type 316 stainless steel NEMA 4X enclosures for outdoor or indoor wet/corrosive installations as identified on the drawings.

2. All enclosed circuit breakers shall have nameplates that contain a permanent record of catalog number and maximum rating. Provide handle mechanisms that are padlockable in the OFF position.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install devices in accordance with manufacturer's instructions and accepted shop drawings.

END OF SECTION


SECTION 26 29 13

ACROSS-THE-LINE MOTOR CONTROLLERS

PART 1 GENERAL

1.01 DESCRIPTION

A. Work included: 1. Furnish, install and test low voltage across-the-line combination motor starters

in accordance with these specifications.

B. Related sections: 1. Section 40_61_05 - Packaged Control System.

1.02 SUBMITTALS

A. The Contractor shall furnish submittals for approval as outlined below: 1. Product Data. 2. Warranty. 3. Bill of Materials. 4. Manufacturer’s nameplate data. 5. Dimensions (elevations, plan views, sections). 6. Schematic (elementary) diagrams and wiring diagrams. 7. Interconnection wiring diagrams. 8. Seismic anchorage calculations. 9. As-built documentation. 10. Certified factory test reports. 11. Proposed field functional tests. 12. Field functional test reports.

1.03 REFERENCE STANDARDS

A. NEMA ICS-2 – Industrial Control and Systems: Controllers, Contactors, and Overload Relays, Rated 600 Volts.

B. UL 508 – Industrial Control Equipment.


A. Equipment shall be UL listed.

PART 2 PRODUCTS

2.01 ENCLOSED COMBINATION MOTOR STARTERS

A. General: 1. The drawings indicate the approximate horsepower and intended control

scheme of the motor driven equipment. Provide the NEMA size starter, circuit


breaker trip ratings, and control power transformers ratings matched to the motors and control equipment actually supplied. All variations necessary to accommodate the motors and controls as actually furnished shall be made without extra cost to the District.

B. Components: 1. Provide enclosed 600 volt single and three phase across-the-line non-

reversing combination motor starters manufactured in accordance with the latest NEMA standards.

2. Starters shall include a side-mounted operating handle, thermal magnetic circuit breaker or motor circuit protector (MCP) in series with a magnetic starter, overload protective device, control power transformer, selector switches, pushbuttons, indicating lights, control relays, and terminal blocks contained inside a NEMA 12 or NEMA 4X enclosure as indicated on the drawings.

3. The operating handle shall always remain connected to the circuit breaker or MCP. The handle shall not be mounted in the front door of the enclosure, but to the side of the door for safe stand-aside operation. Position of the handle shall indicate ON, OFF, or TRIPPED condition of the circuit breaker or MCP. Mechanical interlock provisions shall not permit unauthorized opening of the enclosure door with the operating handle in the ON position. The operating handle shall be capable of being padlocked while in the OFF position.

4. Circuit breakers shall be molded case bolt-on type with fixed thermal magnetic trips.

5. Provide control relays and timers, and pilot devices as specified in Section 40_61_05.

6. Motor starters: 3 pole, 600 volt, electrically operated, of the types required. Provide NEMA sizes as required for the horsepowers of the furnished equipment. Minimum size shall be NEMA Size 1. Fractional size starters are not acceptable. Starters shall have 120 volt encapsulated operating coils; individual control power transformers with primary and secondary fuses and silver cadmium oxide renewable line contacts.

7. Microprocessor Motor Overload Protection: The overload protection shall consist of one current sensor located in each phase monitored by the Microprocessor that yields a time current curve closely paralleling that of motor heating damage boundary, accurate to 2 percent. Running overload protection shall be DIP switch selectable for the specific motor full load amperes within the starter range. Provide DIP switch selectable overload trip class of 10, 20, and 30. Provide auxiliary alarm contacts where shown on the drawings: a. Motor starters to monitor current in each phase to provide phase loss and

phase unbalance protection, such that if the unbalance on any of two phases is greater than 30 percent of the DIP switch selected trip rating, a phase loss/unbalance trip occurs. Provide phase loss/unbalance protection which requires no time delay for reset.

b. Motor starters to provide class II ground fault protection. Ground fault protection shall be set at 20 percent of maximum continuous ampere rating and have a start delay of 20 seconds, and a run delay of 1 second to prevent nuisance trip on starting.

c. Microprocessor shall measure control circuit nominal voltage and prevent closing of the coil on low voltage (78 volts AC nominal) and/or high


voltage (135 volts AC nominal) conditions which are outside of the coil ratings.

d. Microprocessor shall apply voltage to the coil such that a guaranteed maximum of 2 milliseconds of main contact bounce occurs on contactor closure.

e. Microprocessor shall continuously measure coil circuit voltage and current so as to maintain constant coil power at a level to maintain main contact closure and minimize coil power consumption.

f. Provide Control Modules to perform the indicated input/output control functions specified in the equipment specifications. Module to incorporate faceplates having membrane type pushbuttons and LED’s. All pushbutton and LED functions to be furnished with clear written identification. Modules to be provided with the ability to replace conventional start, stop, hand, auto, and control functions, and when utilized in starter applications, overload reset function. Modules to be provided with the ability to replace conventional indicating light status of run, off, selector switch pushbutton position, and when utilized in starter applications, overload alarm, overload trip.

8. Auxiliary contacts: Form C, NEMA A600 rating, as required by the control schemes on the drawings. Provide 1-normally open and 1-normally closed spare contacts on each starter. Furnish additional auxiliary contacts as required by the control descriptions and specifications.

9. Control power transformers: Two winding type, 120 VAC secondary, with primary and secondary fuses in accordance with the CEC. Provide oversized control power transformers to include control circuit loads, motor space heaters, and a minimum 50 percent extra capacity.

C. Provide for remote control interlocks as shown on the drawings.

D. Acceptable manufacturers: 1. Cutler-Hammer Freedom Series. 2. Allen-Bradley Bulletin 509. 3. General Electric 300 Line. 4. Or equal as approved by the Engineer.

PART 3 EXECUTION

3.01 INSTALLATION

A. Starters shall be firmly bolted to the appropriate surface per approved shop drawings.

END OF SECTION


SECTION 26_29_23

LOW-VOLTAGE VARIABLE-FREQUENCY MOTOR CONTROLLERS

PART 1 GENERAL

1.01 DESCRIPTION

A. Work included: 1. Provide labor, equipment, supervision and materials for the installation, testing

and start-up of the variable frequency drive(s) (VFD) as shown on the drawings and as specified herein.

2. Where VFDs are provided as part of a packaged system, the system supplier shall indicate that the motor is suitable for operation with a VFD.

3. As a minimum, provide input line reactors for all drives furnished under this Section as specified in Part 2.

B. Related Sections: 1. Section 01_33_00 – Submittal Procedure.


A. VFDs shall utilize a field proven design. The VFD manufacturer shall demonstrate at least three years of continuous field operating experience with equipment of similar size and design.

B. A factory authorized service and parts organization shall be located within 100 miles of the project location. Provide the name and address of the factory authorized service and parts organization nearest to the project location at the time of the bid.

C. Equipment shall be UL or ETL labeled.

1.03 SUBMITTALS

A. Submit shop drawings and product data, in accordance with Section 01_33_00, as follows: 1. Equipment outline drawings showing elevation, plan and interior views, front

panel arrangement, dimensions, and weight. 2. Indicate all options, special features, ratings and deviations from the

specifications. 3. Power and control schematics including external connections. Show wire and

terminal numbers and color coding. 4. Drive performance specifications. 5. Instruction and replacement parts books. 6. Certified shop test reports. 7. Field test and inspection reports.


8. Submit information demonstrating the drive output will not harm the motors through dV/dt reflected waves. Indicate specifically if output reactors will be required to protect the motors.

1.04 DELIVERY, STORAGE AND HANDLING

A. Package the equipment for maximum protection during delivery and storage.

B. Store the equipment indoors in a clean, dry, heated storage facility until ready for installation. Do not install the equipment in its final location until the facilities are permanently weather tight. Furnish, install and wire temporary electric space heaters in the equipment until the permanent heating equipment is operational. Protect the equipment at all times from exposure to moisture and chemicals.


A. IEEE Standard 519 (latest revision) - "IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems."

B. National Electrical Code (NFPA 70) latest edition.

C. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.

1.06 PROJECT/SITE REQUIREMENTS

A. The VFD shall not produce motor noise in excess of the manufacturers published noise standards for 60-Hz operation.

B. The VFD shall be capable of continuous operation in an average ambient temperature between 0 degrees C and 40 degrees C.

1.07 SPARE PARTS

A. Provide the following spare parts drive in the quantities specified: 1. One complete VFD or each size provided for each water treatment plant.

B. Spare parts shall be boxed or packaged for long term storage. Identify each item with manufacturers name, description and part number on the exterior of the package.

PART 2 PRODUCTS

2.01 ACCEPTABLE MANUFACTURES

A. Manufactures: Subject to compliance with these specifications, the typical equipment, systems and accessories installed shall be manufactured by: 1. General Electric, AF-600FP 18-pulse. 2. ABB, Model ACS800. 3. Or equal as approved by the Engineer.


2.02 RATING

A. Service Conditions: 1. Input power: 460 VAC, ±10 percent, 3 phase, 60 Hz. 2. Input frequency: 57 to 63 Hz. 3. Ambient temperature: 0 degrees C to 40 degrees C. 4. Elevation: Up to 3300 feet above mean sea level. 5. Relative humidity: Up to 90 percent non-condensing.

B. Minimum drive efficiency: 97 percent or better at 4/4 motor base speed and rated torque.

C. Displacement power factor: 95 percent or higher throughout the entire speed range, measured at drive input terminals.

D. Drive output: 100 percent rated current continuous, suitable for operation of the driven equipment over the required speed range without overloading. Drives shall be capable of a continuous overload up to 110 percent rated current for variable torque loads and 150 percent rated current for constant torque loads. Starting torque shall be matched to the load.

E. Output frequency drift: No more than plus or minus 0.5 percent from setpoint.

F. Drives shall withstand five cycle transient voltage dips of up to 15 percent of rated voltage without an undervoltage trip or fault shutdown, while operating a variable torque load.

2.03 CONSTRUCTION

A. General: 1. The VFDs shall utilize a digital pulse width modulated (PWM) design to

convert the fixed AC input to a variable voltage, variable frequency AC output. Construction shall be modular, using plug-in type component mounting or keyed ribbon cable connections wherever possible to minimize downtime during repair.

2. The VFD shall operate satisfactorily when connected to a bus supplying other solid state power conversion equipment which may be causing up to 10 percent total harmonic voltage distortion and commutation notches up to 36,500 volt microseconds, or when other VFD's are operating from the same bus. The drive shall include transient voltage suppression to allow reliable operation on a typical commercial power distribution system.

3. The output shall be generated by IGBTs which shall be controlled by six identical, optically isolated base driver circuits. The VFD shall have an output voltage regulator to maintain correct output Volt/Hertz despite incoming voltage variations. The VFD shall have a continuous output current rating equal to or greater than the motor full load nameplate current.

B. Operator interface: 1. Provide a door-mounted digital keypad/display, capable of controlling the drive

and setting drive parameters. The digital display shall normally display: a. Speed demand in percent.


b. Output current in amperes. c. Frequency in Hertz. d. Control mode - manual or automatic.

2. The digital keypad shall allow operators to enter exact numerical settings in English engineering units. A user menu shall be provided as a guide to parameter settings. Coded messages on keypad will not be acceptable. Parameters are to be factory set in EEPROM and resettable in the field. Parameters shall be password protected. The EEPROM stored variables shall be transferable to new and spare boards.

3. The keypad/display module shall have a key switch to control operation of the keypad. The key shall be removable in either the "Enabled" or "Disabled" positions. The keypad module shall contain a "self-test" software program that can be activated to verify proper keypad operation. The keypad display shall contain a full alphanumeric character set.

4. The drive shall have a graphic back-lit liquid crystal display which can be configured to display frequency, current, function code set points, drive status, and fault codes. At a minimum, the display shall display 4 lines with 13 characters of text.

5. At a minimum the following controls and indicators shall be provided, either separately or as part of the keypad/display: a. POWER ON, RUN AND FAULT indication. b. FAULT RESET control. c. LOCAL-OFF-REMOTE control mode selector. d. Manual START/STOP controls. e. Manual speed adjust capability.

C. Auxiliary Contacts: 1. Provide two set(s) of Form C auxiliary dry contacts for remote indication of

VFD running status. 2. Provide two set(s) of Form C auxiliary dry contacts for remote indication of

VFD fault.

D. Auxiliary Power: Provide 120 VAC auxiliary power on drive terminal strips for use in powering auxiliary control devices.

2.04 PROTECTIVE AND OPERATIONAL FEATURES

A. Make provisions for field adjustment of the following parameters through the keypad/display: 1. Current limit and boost. 2. Voltage (Volts/Hertz.) 3. Frequency (Minimum and Maximum). 4. Independently adjustable acceleration and deceleration rates. 5. Auto restart delay. 6. Up to five critical bands where drive operation is inhibited.

B. Make provisions to accept a remote dry contact closure to start and stop the drive(s) with the drive control system in the AUTO mode.


C. Make provisions to accept a 4-20 mA DC input signal for remote speed control. Input shall be isolated at the drive and active with the drive control system in the AUTO mode. Zero and span adjustability shall be provided.

D. Provide a 4-20 mA DC isolated output signal proportional to speed for remote speed indication.

E. Provide the following short circuit and input protective features: 1. Input circuit breaker. 2. Solid state instantaneous overcurrent trip. 3. Undervoltage protection with automatic restart. 4. Ground fault protection.

F. Provide the following internal protective features: 1. Transient surge protection. 2. Overcurrent protection. 3. Current limit, inverse time type. 4. DC bus fuse protection and discharge circuit. 5. DC bus overvoltage trip.

G. Provide the following output protective features: 1. Inverse time motor overload protection.

H. Harmonic and Radio Noise Mitigation: 1. All VFDs shall be clean power, utilizing an 18-pulse configuration or active

front-end technology to reduce voltage and current harmonic levels at the input terminals of the drive to IEEE 519 limits. a. Lower pulse count inverters with filters shall not be acceptable.

2. Provide EMI/RFI filters to limit radio frequency noise in excess of the limits specified by FCC Docket 20780 (Part 15, Subpart J) or if the drives create noise in a frequency range which will interfere with other sensitive equipment at the installation (such as lighting systems, telecommunications systems, instrumentation and monitoring equipment).

2.05 DIAGNOSTIC AND FAULT CAPABILITY

A. The following conditions shall cause an orderly drive shutdown and lockout: 1. Incorrect phase sequence. 2. Blown input fuse or single phasing of supply. 3. Control power supply failure. 4. Instantaneous overcurrent. 5. Sustained overload. 6. Transistor overcurrent.

B. Provide complete built-in diagnostic and test capability to enable maintenance personnel to rapidly and accurately identify the cause of equipment failure.


2.06 SURFACE PREPARATION AND SHOP COATINGS

A. All non-current carrying metal parts of the equipment cabinet shall be cleaned of all weld spatter and other foreign material and given a heat cured, phosphatized chemical pre-treatment to inhibit rust.

B. Unpainted non-current carrying parts shall receive a protective zinc plating to prevent corrosion. Printed circuit boards shall be coated with a protective conformal epoxy. All device contacts shall be silver cadmium plated.

2.07 FACTORY TESTING

A. Perform manufacturers standard production testing and inspection.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install the equipment in accordance with the manufacturer's instructions.

3.02 FACTORY QUALITY CONTROL

A. Provide manufactures standard factory test.


3.04 ADJUSTMENT

A. Make all VFD internal adjustments and all adjustments necessary for manual and automatic operation of the entire system of driven equipment.


END OF SECTION


SECTION 33_12_01

BASIC MECHANICAL MATERIALS AND METHODS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Basic design and performance requirements for all mechanical equipment and systems.

B. Related sections: 1. Section 01_33_00 - Submittals Procedures. 2. Section 01_81_01 - Project Design Criteria. 3. Section 01_81_02 - Seismic Design Criteria. 4. Section 01_75_17 - Commissioning and Process Startup. 5. Section 01_78_23 - Operating and Maintenance Data. 6. Section 09_96_56.05 - High Build Epoxy Coatings. 7. Section 40_05_23.01 - Stainless Steel Pipe and Tubing. 8. All Sections in Division 26 - Electrical. 9. All Sections in Division 33 - Utilities.

C. Provisions specified under each individual technical equipment specification section prevail over and supersede conflicting provisions as specified in this section.

1.02 REFERENCE STANDARDS FOR DESIGN, INSTALLATION & TESTING

A. Reference the latest versions of the following standards unless otherwise specified.

B. Associated Air Balance Council (AABC): Various.

C. American Bearing Manufacturers Association (ABMA): 1. ABMA 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. ABMA 11 - Load Ratings and Fatigue Life for Roller Bearings. 3. Various.

D. American Gas Association (AGA): Various.

E. American Gear Manufacturer's Association (AGMA) Standards: 1. ANSI/AGMA 2001-D - Fundamental Rating Factors and Calculation Methods

for Involute Spur and Helical Gear Teeth. 2. ANSI/AGMA 6000-B - Specification for Measurement of Linear Vibration on

Gear Units. 3. ANSI/AGMA 6010-F - Standard for Spur, Helical, Herringbone, and Bevel

Enclosed Drives. 4. ANSI/AGMA 6019-B - Standard for Gear motors using Spur, Helical,

Herringbone, Straight Bevel or Spiral Bevel Gears. 5. ANSI/AGMA 6025-D - Sound for enclosed Helical, Herringbone and Spiral

Bevel Gear Drives. 6. Various.


F. American National Standards Institute (ANSI) Standards: 1. Z535.1 - Safety Color Code. 2. Various.

G. American Petroleum Institute (API) Standards: 1. 5L - Specification for Line Pipe. 2. 541 - Form-wound Squirrel-Cage Induction Motors - 500 Horsepower and

Larger. 3. 598 - Valve Inspection and Testing. 4. 609 - Butterfly Valves. 5. 610 - Centrifugal Pumps. 6. 617 - Centrifugal Compressors. 7. 618 - Reciprocating Compressors. 8. 619 - Rotary-Type Positive Displacement Compressors. 9. 650 - Welded Steel Tanks for Oil Storage. 10. 686 - Machinery Installation and Installation Design (Recommended Practice). 11. Various.

H. American Society of Heating, Refrigerating and Air-conditioning Engineers (ASHRAE) Standards: Various.

I. American Society of Mechanical Engineers (ASME): 1. B16.1 - Cast Iron Pipe Flanges and Flanged Fittings. 2. B16.3 - Malleable Iron Threaded Fittings. 3. B16.5 - Pipe Flanges and Flanged Fittings. 4. B16.9 - Factory-Made Wrought Buttwelding Fittings. 5. B16.11 - Forged Fittings, Socket-Welding and Threaded. 6. B16.14 - Cast Bronze Threaded Fittings. 7. B16.18 - Cast Copper Alloy Solder Joint Pressure Fittings. 8. B16.22 - Wrought Copper and Copper Alloy Solder Joint Pressure Fittings. 9. B16.24 - Cast Copper Alloy Pipe Flanges and Flanged Fittings: Classes 150,

300, 400, 600, 900, 1500, and 2500. 10. B16.28 - Wrought Steel Buttwelding Short Radius Elbows and Returns. 11. B16.34 - Valves, Flanged, Threaded and Welding End. 12. B16.36 - Orifice Flanges. 13. B16.42 - Ductile Iron Pipe Flanges and Flanged Fittings, Class 150 and 300. 14. B16.47 - Large Diameter Steel Flanges. 15. B31.1 - Power Piping. 16. B31.9 - Building Services Piping. 17. B31.2 - Fuel Gas Piping. 18. B31.3 - Process Piping. 19. B36.10M - Welded and Seamless Wrought Steel Pipe. 20. B36.19M - Stainless Steel Piping. 21. PTC 9 - Displacement Compressors, Vacuum Pumps and Blowers. 22. ASME PTC 8.2 - Performance Test Code for Centrifugal Pumps. 23. ANSI/ASME PTC 10 - Performance Test Code - Compressors and

Exhausters. 24. ANSI/ASME PTC 17 - Performance Test Code - Reciprocating Internal-

Combustion Engines. 25. ANSI/ASME PTC 11 - Performance Test Code - Measurement of Shaft

Horsepower - Instruments and Apparatus. 26. Boiler and Pressure Vessel Code - Section VIII.


27. Various.

J. American Society for Testing and Materials (ASTM): 1. A 36 - Standard Specification for Structural Steel. 2. A 53 - Standard Specification for Pipe, Steel, Black and Hot Dipped,

Zinc-Coated, Welded and Seamless. 3. A 48 - Standard Specification for Gray Iron Castings. 4. A 106 - Standard Specification for Seamless Carbon Steel Pipe for

High-Temperature Service. 5. A 526 - Standard Specification for Steel Sheet, Zinc Coated by the Hot Dip

Process, Commercial Quality. 6. A 802-2006, “Standard Practice for Steel Castings, Surface Acceptance

Standards, Visual Examination”. 7. A 834-2006, “Standard Specification for Common Requirements for Iron

Castings for General Industrial Use”. 8. A 903-2007, “Standard Specification for Steel Castings, Surface Acceptance

Standards, Magnetic Particle and Liquid Penetrant Inspection”. 9. A 1011 - Standard Specification for Steel, Sheet and Strip, Hot Rolled, Carbon,

Structural, High-Strength Low-Alloy and High-Strength Low Alloy with Improved Formability.

10. A 1018 - Standard Specification for Steel, Sheet and Strip, Heavy Thickness Coils, Hot Rolled, Carbon, Structural, High-Strength Low-Alloy, Columbium or Vanadium, and High-Strength Low-Alloy with Improved Formability.

11. B 61 - Standard Specification for Steam or Valve Bronze Castings. 12. B 62 - Standard specification for Composition Bronze or Ounce Metal

Castings. 13. E 527 - Standard Practice for Numbering Alloys and Metals (UNS). 14. D 3370-95a - Standard Practices for Sampling Water from Closed Conduits. 15. D 6284-02 Standard Test Method for Rubber Property - Effect of Aqueous

Solutions with Available Chlorine and Chloramine. 16. Various.

K. American Water Works Association (AWWA) Standards: 1. C207 - Steel Pipe Flanges. 2. C208 - Dimensions for Fabricated Steel Water Pipe Fittings. 3. C504 - Rubber-Seated Butterfly Valves. 4. C507 - Ball Valves. 5. C508 - Swing Check Valves. 6. C509 - Resilient Seated Gate Valves. 7. C512 - Air Release, Air/Vacuum and Combination Air Valves. 8. C515 - Reduced - Wall, Resilient-Seated Gate Valves. 9. C518 - Dual-Disc Swing Check Valves. 10. C540 - Power-Actuating Devices for Valves and Slide Gates. 11. Various.

L. American Welding Society (AWS) Standards: 1. A2.4 - Standard Symbols for Welding, Brazing and NDE. 2. A3.0 - Standard Welding Terms and Definitions. 3. D1.1 - Structural Welding Code. 4. Various.

M. Compressed Gas Association (CGA) Standards: Various.


N. Ductile Iron Pipe Research Association (DIPRA) Publications: Various.

O. EBMUD Engineering Standard Practices (ESPs).

P. EBMUD Engineering Standard Drawings: 1. 9494-G-1 and 2, Abbreviations for Water Facilities. 2. 9492-G-001 thru 007. 3. Various.

Q. Hydraulic Institute Standards (HI): 1. 1.1-1.5 - Centrifugal Pumps - Nomenclature, Definitions, Application and

Operation. 2. 1.6 - Centrifugal Pump Tests. 3. 2.1-2.5 - Vertical Pumps - Nomenclature, Definitions, Application and

Operation. 4. 2.6 - Vertical Pump Tests. 5. 3.1-1.5 - Rotary Pumps - Nomenclature, Definitions, Application and Operation. 6. 3.6 - Rotary Pump Tests. 7. 4.1-4.6 - Sealless Rotary Pumps - Nomenclature, Definitions, Application,

Operation and Test. 8. 5.1-1.6 - Sealless Centrifugal Pumps - Nomenclature, Definitions, Application,

Operation and Test. 9. 6.1-6.5 - Reciprocating Power Pumps - Nomenclature, Definitions, Application

and Operation. 10. 7.1-7.5 - Controlled Volume Pumps - Nomenclature, Definitions, Application

and Operation. 11. 9.1-9.5 - Pumps - General Guidelines for Types, Definitions, Application and

Sound Measurement. 12. Various.

R. Institute of Electrical and Electronic Engineers (IEEE): 1. 803.1 - Recommended Practice for Unique Identification in Power Plants and

Related Facilities – Component Function Identifiers. 2. Various.

S. Instrumentation, Systems, and Automation Society (ISA) Standards: 1. S5.1 - Instrumentation Symbols and Identification. 2. S20 - Specification Forms for Process Measurement and Control Instruments,

Primary Elements, and Control Valves. 3. S75.11 - Inherent Flow Characteristics and Rangeability of Control Valves. 4. Various.

T. Manufacturers Standardization Society (MSS) Standards: 1. SP-54 - Quality Standard for Steel Castings for Valves, Flanges and Fittings

and Other Piping Components – Radiographic Examination Method. 2. SP-55 - Quality Standard for Steel Castings for Valves, Flanges and Fittings

and Other Piping Components – Visual Method for Evaluation of Surface Irregularities.

3. SP-58 - Pipe Hangers and Supports – Materials, Design and Manufacturer. 4. SP-68 - High Pressure Offset Seat Butterfly Valves. 5. SP-69 - Pipe Hangers and Supports – Selection and Application. 6. SP-89 - Pipe Hangers and Supports – Fabrication and Installation Practices.


7. SP-91 - Guidelines for Manual Operation of Valves. 8. SP-101 - Part-Turn Valve Actuator Attachment. 9. SP-108 - Resilient-Seated Cast-Iron Eccentric Plug Valves. 10. Various.

U. National Electrical Testing Association (NETA): 1. MG-1 - Motors and Generators. 2. Various.

V. National Fire Code.

W. National Fire Protection Association (NFPA) Standards: 1. Fire Prevention Code Handbook, 2012 Edition. 2. NFPA13 - Installation of Sprinkler Systems. 3. NFPA30 - Flammable & Combustible Liquids Code. 4. NFPA54 - National Fuel Gas Code. 5. NFPA58 - Liquefied Petroleum Gas Code. 6. Various.

X. National Sanitation Foundation (NSF) Standards: 1. 61G - Drinking Water System Components – Health Effects and Lead Content. 2. 372 - Drinking Water System Components – Lead Content. 3. Various.

Y. Occupational Safety and Health Act (OSHA): Various.

Z. Pipe Fabrication Institute (PFI): 1. ES-3 - Fabricating Tolerances. 2. ES-4 - Hydrostatic Testing of Fabricated Piping. 3. ES-24 - Pipe Bending Methods, Tolerances, Process and Material

Requirements.

AA. Sheet Metal and Air Conditioning Contractors National Association (SMACNA): 1. HVAC Systems Duct Design. 2. Various.

BB. Ten States Standards: 1. Recommended Standards for Water Works. 2. Recommended Standards for Wastewater Facilities.

CC. Underwriters’ Laboratories, Inc. (UL) Approvals: Various.

1.03 DEFINITIONS

A. Special tools: Tools that have been specifically made for use on unit of equipment for assembly, disassembly, repair, or maintenance.

B. Resonant frequency: That frequency at which a small driving force produces an ever-larger vibration if no dampening exists.

C. Rotational frequency: The revolutions per unit of time usually expressed as revolutions per minute.


D. Critical frequency: Same as resonant frequency for the rotating elements or the installed machine and base.

E. Peak vibration velocity: The root mean square average of the peak velocity of the vibrational movement times the square root of 2 in inches per second.

F. Rotational speed: Same as rotational frequency.

G. Maximum excitation frequency: The excitation frequency with the highest vibration velocity of several excitation frequencies that are a function of the design of a particular machine.

H. Critical speed: Same as critical frequency.

I. Free field noise level: Noise measured without any reflective surfaces (an idealized situation); sound pressure levels at 3 feet from the source unless specified otherwise.

J. Noise limits and abatement: 1. The design of any equipment installations shall conform to the maximum

acceptable noise level and duration as defined by OSHA, city codes and applicable CEQA documentation. Noise shall be within both workplace limits for personnel exposure and property line limits. Insulation, sound traps, sound enclosures, and silencers shall be used as required to obtain acceptable levels.


A. General: 1. Provide equipment and parts that are suitable for stresses, which may occur

during fabrication, transportation, erection, and operation. 2. Provide equipment that has not been in service prior to delivery, except as

required by tests. 3. Like parts of duplicate units are to be interchangeable. 4. When 2 or more units of equipment for the same purpose are required, provide

products of same manufacturer. 5. Equipment manufacturer's responsibility extends to selection and mounting of

gear drive units, motors or other prime movers, accessories, and auxiliaries required for proper operation.

6. When necessary, modify manufacturer's standard product to conform to the specified requirements or requirements indicated on the drawings and contained in laws and regulations.

B. Material requirements: 1. Materials: Suitable for superior corrosion resistance and for services under

conditions normally encountered in similar installations. 2. Dissimilar metals: Separate contacting surfaces with dielectric material.

C. Power transmission systems: 1. Power transmission equipment: V-belts, sheaves, shaft couplings, chains,

sprockets, mechanical variable-speed drives, variable frequency drives, gear reducers, open and enclosed gearing, clutches, brakes, intermediate shafting, intermediate bearings, and U-joints are to be rated for 24 hour-a-day


continuous service or frequent stops-and-starts intermittent service, whichever is most severe, and sized with a minimum service factor of 1.5: a. Apply a 1.5 service factor to nameplate horsepower and torque of prime

source of power and not to actual equipment loading. b. Apply service factors higher than 1.5 when recommended for continuous

24 hour-per-day operation and shock loadings specified in AGMA 6010-E88, other applicable AGMA standards, or other applicable referenced standards.

c. When manufacturer recommends service factor greater than 1.5, manufacturer's recommendation takes precedence.

D. Vibration: 1. Resonant frequency: Ensure there are no natural resonant torsional, radial, or

axial frequencies within 25 percent above or below the operating rotational frequencies or multiples of the operating rotational frequencies that may be excited by the equipment design.

2. Design, balance and align equipment to meet the vibration criteria specified in individual equipment specification sections.

E. Equipment mounting and anchoring: 1. Mount equipment on cast iron or welded steel bases with structural steel

support frames. Utilize continuous welds to seal seams and contact edges between steel members. Grind welds smooth.

2. Provide bases and supports with machined support pads, dowels for alignment or mating of adjacent items, adequate openings to facilitate grouting, and openings for electrical conduits.

3. Provide jacking screws in bases and supports for equipment weighing over 1,000 pounds.

4. Anchor equipment base to concrete pad. Determine number, size, type, and location of bolts, anchor bolts, or other connections.

5. Provide bolt sleeves for anchor bolts for heavy equipment. Adjust bolts to final location and fill sleeve with non-shrink grout per API 686-96, Machinery Installation and Installation Design (Recommended Practice).

F. Structural design: 1. Design connections and related details for seismic design criteria as specified

in Section 01_81_02. 2. For equipment with operating weight of 400 pounds or more provide

calculations for: a. Determination of operating weight and centroid of equipment:

1) Operating weight is to be weight of unit plus weight of fluids or solids normally contained in unit during operation.

b. Determination of seismic forces and overturning moments. c. Determination of shear and tension forces in connections. d. Design of connection details based on calculated shear and tension

forces.

G. Equipment units weighing 50 pounds or more: Provide with lifting lugs or eyes to allow removal with hoist or other lifting device.


1.05 SUBMITTALS

A. General: The following submittal requirements are in addition to the submittal requirements specified under each individual technical specification section and the requirements in Section 01_33_00.

B. Product data: 1. For each item of equipment:

a. Design features. b. Load capacities. c. Efficiency ratings. d. Material designations by UNS alloy number and ASTM Specification and

Grade. e. Data needed to verify compliance with the Specifications. f. Catalog data. g. Name plate data. h. Clearly mark submittal information to show specific items, materials and

accessories or options being furnished. 2. Gear reduction units:

a. Engineering information per applicable AGMA standards. b. Gear mesh frequencies.

C. Shop drawings: 1. Drawings for equipment:

a. Drawings that include outline drawings, cut-away drawings, parts lists, material specification lists, and other information required to substantiate that proposed equipment complies with specified requirements.

2. Outline drawings showing equipment, driver, driven equipment, pumps, seal, motor(s) or other specified drivers, variable frequency drive, shafting, U-joints, couplings, drive arrangement, gears, baseplate or support dimensions, anchor bolt sizes and locations, bearings, and other furnished components.

3. Installation and checkout instructions including leveling and alignment tolerances, grouting, lubrication requirements, and initial start-up procedures.

4. Wiring, control schematics, control logic diagrams and ladder logic or similar for computer based controls.

5. Recommended or normal operating parameters such as temperatures and pressures.

6. Alarm and shutdown setpoints for all controls furnished.

D. Calculations: 1. Calculations and other information to substantiate base plates, supports, and

anchor bolts meet minimum design strength requirements and seismic design criteria specified in Section 01_81_02.

2. Bearing L10 life calculations in accordance with ABMA 9 or ABMA 11 calculation methods for drivers, pumps, gears, shafts, motors, and other drive line components with bearings.

3. Calculations and other information to substantiate that operating rotational frequencies meet the requirements of this Section.

4. Torsional analysis of power transmission systems: When torsional analysis is specified in the equipment Sections, provide: a. Sketch of system components identifying physical characteristics

including mass, diameter, thickness, and stiffness.


b. Results of analysis including first and second critical frequencies of system components and complete system.

5. Calculations for connection details demonstrating compliance with specified structural design requirements.

E. Quality control submittals: 1. Source quality control reports and certified test data as specified in

Section 01_75_17. 2. Submit factory test reports before shipment. 3. Certified static and dynamic balancing reports for rotating equipment. 4. Final field alignment values (signed and dated by journeyman millwright). 5. Field quality control reports and test data as specified in Section 01_75_17. 6. Start-up plan: Proposed plan for field testing equipment as specified in

Section 01_75_17. 7. Certificate of Proper Installation: Provide as required in the individual technical

specification sections. 8. Submit material test reports as specified in the equipment sections. 9. Submit NSF/ANSI 61 certification for all materials in contact with drinking

water. If NSF certified before January 4, 2014 the material must be certified as meeting CA low lead requirement (NSF/ANSI 61 Annex G or NSF/ANSI 372).

10. References: Provide references from a minimum of 3 installations currently operating the same model equipment in continuous service for a minimum of 2 years under similar operating conditions. Reference information shall include location, service, contact person, and contact phone number.

F. Operation and maintenance manuals: 1. As specified in Section 01_78_23. 2. Provide at project site complete and final manuals for use by field personnel

and Engineer prior to equipment delivery to the site. 3. Include manufacturer and model number of every bearing; include calculated

ball pass frequencies of the installed equipment for both the inner and outer raceways.

4. Include motor rotor bar pass frequencies. 5. Factory and field settings: Include a complete and detailed list of all final

factory and field settings for all instruments and devices. Insert this information into the final O&M manuals when available. This information shall also be included in all electronic versions of the O&M manuals.


A. Qualifications: Equipment manufacturer and system component manufacturers to have a minimum of 5 years’ experience in the design, manufacture, and assembly of the specified equipment and components with an established record of successful operation of such equipment and components.

B. Manufacturer's field services: 1. Provide as required in the individual technical specification sections.



A. Packing and shipping: 1. Equipment: Pack in boxes, crates, or otherwise protect from damage and

moisture, dust, or dirt during shipment, handling, and storage: a. Include vendors name, model number, and equipment tag number.

2. Bearings: Separately pack or otherwise suitably protect during transport in accordance with manufacturer’s instructions.

3. Spare parts: Deliver spare parts in accordance with Section 01_11_00 and deliver in boxes labeled with contents name, part number, equipment to which spare parts belong, and name of Contractor.

B. Storage: 1. Equipment having bearings: Store in enclosed facilities. Rotate units at least

once per month or more often as recommended by the manufacturer to protect rotating elements and bearings.

2. Gear boxes: Oil filled or sprayed with rust preventive protective coating.

C. Protection: 1. Equipment: Protect equipment from deleterious exposure. 2. Painted surfaces: Protect against impact, abrasion, discoloration, and other

damage.

1.08 SEQUENCING AND SCHEDULING

A. Equipment anchoring: Obtain from equipment manufacturers' anchoring material and templates or setting drawings in time for anchors to be cast-in-place when concrete is placed.

B. Coordinate details of equipment with other related parts of the work, including verification that structures, piping, wiring, and equipment components are compatible.

C. General start-up and testing of equipment: 1. Perform general start-up and testing procedures after operation and

maintenance manuals for equipment have been received. 2. Conduct functional testing of mechanical or electrical systems when each

system is substantially complete and after general start-up and testing procedures have been successfully completed.

3. Functional testing requirements as specified in Section 01_75_17 and other individual equipment specification sections.

1.09 MAINTENANCE

A. Special tools: 1. Provide any and all special tools required for operation and maintenance. 2. Mark or tag and list such tools in maintenance and operations instructions.

Describe use of each tool.

B. Spare belts: 1. When spare belts are specified, furnish a minimum of 1 spare belt for every

different type and size of belt-driven unit, unless otherwise indicated: a. Where 2 or more belts are involved, furnish matched sets.


b. Identify as to equipment, design, horsepower, speed, length, sheave size, and use.

c. Package in boxes labeled with identification of contents.

C. Spare parts: 1. Assume responsibility until turned over to District. 2. Store in enclosed facilities. 3. Furnish itemized list and match identification tag attached to every part. 4. List parts by generic title and identification number. 5. Furnish name, address, and telephone number of supplier and spare parts

warehouse.

1.10 SERVICE CONDITIONS

A. Treated water (potable) chemistry: Unless otherwise noted, materials that contact water covered by ozone equipment specifications will be subjected to water that promotes galvanic corrosion. Materials and coatings shall be suitable for use with treated water with the characteristics specified in Section 01_81_01. The presence of chloramines in the water shall not have any effect on the manufacturer's warranty.

PART 2 PRODUCTS

2.01 MATERIALS

A. General: 1. Bronze that contacts with water:

a. All bronze parts furnished that contact with water shall contain no more than 0.25 percent lead. Stainless steel or Monel might be considered an acceptable substitute for bronze as approved by the Engineer.

b. All bronze parts furnished that will contact with water shall contain no more than 16 percent zinc unless otherwise approved be the Engineer. Components made of UNS C87850 (Eco Brass), which contains more than 16 percent zinc, is an exception and is acceptable.

2. Elastomeric linings, seals and gaskets that contact water: a. The material for all elastomeric linings, seals and gaskets furnished that

contact water shall be certified by the manufacturer to be chloramine resistant.

b. EPDM: When the Elastomeric material EPDM is specified for water service, it shall be peroxide-cured type and shall be certified by the manufacturer to be chloramine resistant. Sulfur-cured type EPDM is not acceptable.

3. The material for all bolting in chemical environments shall be 316 stainless steel. This includes but is not limited to flange bolts, assembly bolts and anchor bolts. Provide flange bolts in accordance with Section 40_05_23.01.

B. Materials in contact with drinking water: 1. All materials in contact with drinking water (potable water) shall be tested and

certified as meeting the specifications of NSF/ANSI 61-2013 in accordance with California Code of Regulations, Title 22, Section 64591. The system code for drinking water is “TWS” – Treated Water System per Drawing 9492-G-007.


2. All materials in contact with drinking water (potable water) shall conform to the “Reduction of Lead in Drinking Water Act” of 2014.

2.02 BEARINGS

A. Type: Oil or grease lubricated, ball or roller antifriction type, of standard manufacture.

B. Oil lubricated bearings: Provide either pressure lubricating system or separate oil reservoir splash type system: 1. Oil lubrication systems: Sized to safely absorb heat energy normally generated

in bearings under maximum ambient temperature of 50 degrees Celsius; provide external cooler when required, air cooled if water cooling source not indicated on the drawings. Equip with filler pipe and external level gauge.

C. Grease lubricated bearings, except those specified to be factory sealed: Fit with easily accessible grease supply, flush, drain, and relief fittings: 1. Lubrication lines and fittings:

a. Lines: Minimum 1/4-inch diameter stainless steel tubing. b. Multiple fitting assemblies: Mount fittings together in easily accessible

location. c. Use standard hydraulic type grease supply fittings:

1) Manufacturer: a) Alenite. b) Zurk. c) Or equal as approved by the Engineer.

D. Ratings: Rated in accordance with ABMA 9 or ABMA 11 for L10 rating life of not less than 50,000 hours: 1. Higher ratings, when specified in other Sections, supersede preceding

requirement.

2.03 SAFETY GUARDS

A. Drive assemblies: Enclose sprockets, belts, drive chains, gearings, couplings, and other moving parts on drive assemblies in safety enclosures that are in compliance with applicable Laws and Regulations.

B. Shafts: Provide guards that protect personnel from rotating shafts or components within 7.5 feet of floors or operating platforms.

C. Guard requirements: 1. Allow visual inspection of moving parts without removal. 2. Allow access to lubrication fittings. 3. Prevent entrance of rain or dripping water for outdoor locations. 4. Size belt and sheave guards to allow for installation of sheaves 15 percent

larger and addition of one belt.

D. Materials: 1. Sheet metal: Carbon steel, 12-gauge minimum thickness, hot-dip galvanized

after fabrication. 2. Fasteners: Type 304 stainless steel.


2.04 SPRING VIBRATION ISOLATORS

A. Design requirements: 1. Telescopic top and bottom housing with vertical stabilizers to resist lateral and

vertical forces. 2. Use steel coil springs. 3. Design vibration isolators in accordance with seismic design criteria as

specified in Section 01_81_02.

B. Performance requirements: Minimum spring deflection of 1 inch under static load and capable of limiting transmissability to 10 percent maximum at design operating load.

C. Manufacturers: One of the following or equal as approved by the Engineer: 1. California Dynamics Corporation, Type RJSD. 2. Mason Industries, equivalent product.

D. Materials: 1. Fabricate isolators using welded steel or shatterproof ductile iron in

accordance with ASTM A 536 Grade CS-45-12. 2. Spring Steel: ASTM A 125.

2.05 FABRICATION

A. Nameplates: 1. Engraved or stamped on Type 304 or 316 stainless steel and fastened to

equipment at factory in an accessible and visible location. 2. Indicate following information as applicable:

a. Manufacturer's name. b. Equipment model number and serial number. c. Maximum and Normal rotating speed. d. Horsepower. e. Rated capacity. f. Service class per applicable standards.

3. Nameplates for pumps: Include: a. Rated total dynamic head in feet of fluid. b. Rated flow in gallons per minute. c. Impeller, gear, screw, diaphragm, or piston size.

4. Gear reduction units: Include: a. AGMA Class of service. b. Service factor. c. Input and output speeds.

B. Bolt holes in equipment support frames: Do not exceed bolt diameter by more than 25 percent, up to limiting maximum diameter oversize of 1/4 inch.

C. Coating: 1. Provide factory and field finish coatings with the system and color specified on

the “Finish, Coating and Color Schedule” on Drawing Z-001.


2.06 OILS, GREASE AND LUBRICANTS

A. All oils, grease and lubricants used in association with potable water equipment shall be suitable for the intended service and NSF approved for potable water service.

B. Acceptable products: 1. Wise Solutions (www.wisesolutions.ws). 2. Renewable Lubricants (www.renewablelube.com). 3. Or equal as approved by the Engineer.

PART 3 EXECUTION

3.01 EXAMINATION

A. Inspect all components for shipping damage, conformance to specifications, and proper torques and tightness of fasteners.

3.02 PREPARATION

A. Metal work embedded in concrete: 1. Accurately place and hold in correct position while concrete is being placed. 2. Clean surface of ferrous metal in contact with concrete immediately before

concrete is placed. 3. Embedded metal shall not touch rebar unless otherwise directed by the design

documents.

B. Concrete surfaces designated to receive grout: 1. Give surfaces heavy sandblasting treatment. 2. Clean surfaces of sandblasting sand, grease, oil, dirt, and other foreign

material that may reduce bonding of grout. 3. Concrete Saturation: Saturate concrete with water. Concrete surface shall be

damp concrete at time grout is placed.

3.03 FIELD MEASUREMENTS:

A. Prior to fabrication of equipment, take measurements for installation of equipment and verify dimensions indicated on the drawings. Ensure equipment and ancillary appurtenances fit within available space. Tolerance for horizontal and vertical positioning of equipment shall be within ± 1/8 inch of the dimensions shown on the drawings, unless otherwise shown.

B. Positioning accuracy: 1. Horizontal, vertical elevation and true plumb positioning of piping and

equipment shall be accurately measured using a Total Station Theodolite (TST), which is an electronic theodolite with an integrated Electronic Distance Meter (EDM).

2. The TST used shall be construction grade having a minimum accuracy of: a. Angle: 3-seconds. b. Distance: ± 3-mm + 2-ppm.

3. The TST shall be operated by a qualified surveyor or technician trained and certified for the instrument. Documentation of operator qualifications shall be

http://www.wisesolutions.ws/

http://www.renewablelube.com/


provided to the Engineer upon request. Acceptance or rejection of the qualifications shall be determined by the Engineer.

4. The use of string lines and measuring tapes is not acceptable for final positioning.

3.04 INSTALLATION

A. Install equipment in accordance with manufacturer's installation instructions and recommendations.

B. Lubrication lines and fittings: 1. Lines from fittings to point of use: Support and protect. 2. Fittings:

a. Bring fittings to outside of equipment in manner such that they are readily accessible from outside without necessity of removing covers, plates, housings, or guards.

b. Mount fittings together wherever possible using factory-mounted multiple fitting assemblies securely mounted, parallel with equipment lines, and protected from damage.

c. Fittings for underwater bearings: Bring fittings above water surface and mount on edge of structure above.

C. Alignment of drivers and equipment: 1. All alignment procedures shall be completed by a journeyman millwright. 2. Where drive motors or other drivers are connected to driven equipment by

flexible coupling, disconnect coupling halves and align driver and equipment after complete unit has been leveled on its foundation.

3. Comply with procedures of appropriate Hydraulic Institute Standards, AGMA Standards, alignment tolerances of equipment manufacturers and the following requirements to bring components into angular and parallel alignment: a. Maximum offset misalignment: 2.0 mils Total Indicator Runout (TIR) in any

plane, or per manufacturer’s recommendations; whichever value is smaller.

b. Maximum angular misalignment: 0.5 mils/inch (mils gap differential per instrument travel diameter), or per manufacturer’s recommendations; whichever value is smaller.

c. Utilize jacking screws, wedges, or shims as recommended by the equipment manufacturer and as specified in the equipment sections.

4. Use reverse-indicator arrangement dial type or laser type alignment indicators: a. Mount indicators on the driver/coupling flange and equipment/coupling

flange. Alignment instrumentation accuracy to be sufficient to read angular and offset misalignment at 10 percent or less of the acceptable misalignment.

5. Alignment and calculations to include measurement and allowance for thermal growth, spacer coupling length, indicator separation, and axial spacing tolerances of the coupling.

6. When alignment satisfies most stringent tolerance of system components, tighten anchor bolts and grout between base and foundation. Allow minimum 48 hours for grout to harden. After grout hardens, remove jacking screws, fully tighten anchor bolts, and recheck alignment. Correct alignment as required.

7. After testing is complete, dowel motor or drivers and driven equipment. Comply with manufacturer's instructions.


8. Final alignment report including final misalignment values (both linier and angular) shall be submitted for review. The report shall be dated and signed by the journeyman millwright that completed the alignment.

D. Grouting equipment bases: 1. Comply with manufacturer's installation instructions and API Recommended

Practice 686 Latest Edition, (Chapter 5, Section 3 in April 1996 version) for grouting spaces, and tolerances for level and alignments, both vertical and horizontal.

2. Grout base when piping connections are complete and in alignment with no strain transmitted to equipment.

3. Grout base when equipment is leveled and in alignment.

E. Special techniques: Use applicable special tools and equipment, including precision machinist levels, dial indicators, and gauges as required in equipment installations.

3.05 EBMUD FIELD CALIBRATION TAGS

A. Complete and install Field Calibration Tags on all instruments, pilot valves, relief valves, and other devices with ranges, setpoints, deadbands, and/or offsets. Record the verified settings on the EBMUD Field Calibration Tag with a black extra-fine point black permanent marker and affixed to the instrument with an 18 lb nylon cable tie. The blank tags are furnished by the District. Below is an example of the blank tag:

B. Definitions: 1. Deadband: The area of a signal range where no action occurs to prevent

oscillation or repeated activation-deactivation cycles (“hunting”). 2. Offset: A value entered to compensate for mounting position or other effects.

For pressure transmitters, this is typically compensation for the difference in the mounted elevation of the transmitter relative to the centerline elevation of the process pipe.

3. LRV = Lower Range Value. 4. Setpoints: The desired value specified on the P&ID for controlling a system.

Dual switches will have two. 5. Units: The engineering units used, including: mA, gpm, psig, ft-H2O, deg F,

etc.


6. URV = Upper Range Value.


A. Test equipment as specified in Section 01_75_17 and the individual specification technical sections.

END OF SECTION




SECTION 40_05_00.01

COMMON WORK RESULTS FOR GENERAL PIPING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Basic piping materials and methods.

B. Related sections: 1. Section 01_75_17 - Commissioning and Process Start-Up. 2. Section 40_05_00.09 - Piping Systems Testing. 3. Section 40_05_23.01 - Stainless Steel Pipe.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through 24.

B. American Water Work Association (AWWA): 1. C207 - Standard for Steel Pipe Flanges for Waterworks Services-Size 4 In.

Through 144 In.

C. ASTM International (ASTM): 1. A 193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting

Materials for High Temperature or High Pressure Service and Other Special Purpose Applications.

2. A 194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both.

3. A 307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength.

4. A 563 - Standard Specification for Carbon and Alloy Steel Nuts. 5. F 37 - Standard Test Methods for Sealability of Gasket Materials.

D. California Health and Safety Code.

1.03 DEFINITIONS

A. Exposed pipe: Pipe that is located above ground, or pipe that is located inside a structure, supported by a structure, or cast into a concrete structure.

B. Underwater piping: Piping below tops of walls in basins or tanks containing water.

C. Wet wall: Wall with water on at least 1 side.

1.04 SUBMITTALS

A. Product data: 1. Escutcheons. 2. Flange bolts.


3. Gaskets.

PART 2 PRODUCTS

2.01 FLANGE BOLTS

A. Lubricant for stainless steel bolts and nuts: 1. Chloride-free. 2. Manufacturers: One of the following or equal as approved by the Engineer:

a. Huskey FG-1800.

2.02 GASKETS

A. Gaskets for flanged joints in low pressure air piping: 1. Suitable for pressures equal and less than 150 pounds per square inch gauge,

temperatures equal and less than 300 degrees Fahrenheit, and compressed air service.

2. Material: EPDM elastomer, 1/8 inch thick, 60 Shore hardness, smooth surface. 3. Manufacturers: One of the following or equal as approved by the Engineer:

a. Garlock, Style 8314. b. John Crane, similar product.

B. Gaskets for flanged joints in ductile iron or steel water piping: 1. Suitable for hot or cold water, pressures equal and less than 150 pounds per

square inch gauge, and temperatures equal and less than 160 degrees Fahrenheit.

2. Material: a. Neoprene elastomer, compressed, with non-asbestos fiber reinforcement.

3. Manufacturers: One of the following or equal as approved by the Engineer: a. Garlock, Bluegard 3300. b. John Crane, similar product.

C. Provide gaskets suitable for the specific fluids and pressure and temperature conditions.

PART 3 EXECUTION

3.01 EXAMINATION

3.02 COMMISSIONING AND PROCESS START-UP REQUIREMENTS

A. As specified in Section 01_75_17 and this Section.

3.03 INSTALLATION

A. General: Connections between ferrous and nonferrous metals: 1. Connect ferrous and nonferrous metal piping, tubing, and fittings with dielectric

couplings especially designed for the prevention of chemical reactions between dissimilar metals.

2. Nonferrous metals include aluminum, copper, and copper alloys.


B. Flanged connections between dissimilar metals such as ductile iron pipe and steel pipe: 1. Provide stainless steel bolts with isolation bushings and washers, and full-face

flange gaskets.

3.04 CLEANING

A. Piping cleaning: 1. Prior to shipment to the job site, clean piping interior of foreign matter and

debris. 2. Perform special cleaning when required by the Contract Documents.

B. Cleaning air piping: 1. Perform special cleaning of filtered air piping from the intake clean air plenums

to the discharge points and high-pressure air piping: a. Protect surfaces from contamination.

2. Special cleaning shall include wire brushing, power tool cleaning, wiping down with lint-free cloths, brooming, and vacuuming to remove rust, scale, weld spatter, dust, dirt, oil, and other matter deleterious to operation of the air system: a. Do not sandblast installed piping.

3. To the greatest extent possible, clean piping immediately prior to final closure of piping systems: a. Enter piping, clean and wipe down surfaces, and vacuum out residue. b. Clean surfaces not accessible to this cleaning operation after installation

within 6 hours preceding installation. 4. Subsequent to cleaning, protect surfaces from contamination by dust, dirt,

construction debris, and moisture, including atmospheric moisture: a. Whether or not pipe upstream has been cleaned, temporarily seal

openings in partially completed work except when installation is actively in progress.

b. When installation is actively in progress, seal openings at the end of each day's construction or when construction is temporarily stopped.

5. Suspend cleaning and seal openings when inclement weather, including dust storms, is imminent.

6. Use clean, dry air for testing the piping and other elements of the system. 7. Prior to introduction of air to the system, blow piping clean:

a. Blow with maximum discharge rate possible for minimum 4 hours, using new blowers or compressors and filters.

8. Clean surfaces that become contaminated prior to acceptance.

3.05 PIPING SCHEDULE

February 2016 40_05_00.01-4


UD/9905A10/02 Pre-Purchase/Specifications/40_05_00.01 (FINAL)

PIPING SCHEDULE Process Abbrev. Service Piping

Joints/ Fittings

Test Pressure

Test Pressure/ Method Lining Coating Comments

GOX

Gaseous Oxygen, inside ≤ 2-inch diameter

SS 316L, Schedule 40S Socket-Weld 100 psig AM -- -- Cleaned for oxygen service

Gaseous Oxygen, Inside, ≥ 2 1/2 inch diameter

SS 316L, Schedule 10S Butt-Weld 100 psig AM -- -- Cleaned for oxygen service

OZG

Ozone Feed Gas ≤ 2-inch diameter

SS 316L, Schedule 40S Socket-Weld 100 psig AM -- -- Cleaned for oxygen service

Ozone Feed Gas ≥ 2-1/2-inch diameter

SS 316L, Schedule 10S Butt-Weld 100 psig AM -- -- Cleaned for oxygen service

Analyzer 316 SS tubing 1/4 inch NPT fittings 50 psig AM -- -- Cleaned for oxygen service

V Vent SS 316L, Schedule 10S

Butt-Weld or Flanged 25 psig AM -- -- Ozone Generation Building Only

CW Cooling Water SS 316L Butt-Welded or Flanged 200 psi HH -- --

Abbreviations: AM = Air Method as per Section 40_05_00.09 - Piping Systems Testing. HH = High Head as per Section 40_05_00.09 - Piping Systems Testing.

END OF SECTION


SECTION 40_05_00.09

PIPING SYSTEMS TESTING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Test requirements for piping systems. All testing shall be performed in the factory before shipping the equipment to the project sites.




3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 01_41_00 - Regulatory Requirements. c. Section 40_05_00.01 - Common Work Results for General Piping.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B31.1 - Power Piping. 2. B31.3 - Process Piping.

B. Underwriters Laboratories Inc. (UL).

1.03 TESTING REQUIREMENTS

A. General requirements: 1. Testing requirements are stipulated in Laws and Regulations; are included in

the Piping Schedule in Section 40_05_00.01; are specified in the specifications covering the various types of piping; and are specified in this Section.

2. Requirements in Laws and Regulations supersede other requirements of Contract Documents, except where requirements of Contract Documents are more stringent, including higher test pressures, longer test times, and lower leakage allowances.

3. When testing with water, the specified test pressure is considered to be the pressure at the lowest point of the piping section under test: a. Lower test pressure as necessary (based on elevation) if testing is

performed at higher point of the pipe section.


B. Furnish necessary personnel, materials, and equipment, including bulkheads, restraints, anchors, temporary connections, pumps, water, pressure gauges, and other means and facilities required to perform tests.

C. Unsuccessful tests: 1. Where tests are not successful, correct defects or remove defective piping and

appurtenances and install piping and appurtenances that comply with the specified requirements.

2. Repeat testing until tests are successful.

D. Test completion: Drain and leave piping clean after successful testing.

1.04 SUBMITTALS

A. Submit as specified in Section 01_33_00.

B. Schedule and notification of tests: 1. Submit a list of scheduled piping tests two weeks prior to the schedule test.

1.05 SEQUENCE

A. Clean piping before pressure or leak tests.

B. Test gravity piping underground, including sanitary sewers, for visible leaks before backfilling and compacting.

C. Underground pressure piping may be tested before or after backfilling when not indicated or specified otherwise.

D. Backfill and compact trench, or provide blocking that prevents pipe movement before testing underground piping with a maximum leakage allowance.

E. Test underground piping before encasing piping in concrete or covering piping with slab, structure, or permanent improvement.


PART 3 EXECUTION

3.01 AIR TESTING METHOD FOR PRESSURE PIPING

A. Air test piping, indicated with "AM" in the Piping Schedule in Section 40_05_00.01, with air or inert gas.

B. Test oxygen, ozone, and air piping by the air test method.


C. Test at pressure as specified in Piping Schedule in Section 40_05_00.01: 1. Provide temporary pressure relief valve for piping under test:

a. Set at the lesser of 110 percent of the test pressure or 50 pounds per square inch gauge over the test pressure.

2. Air method test pressures shall not exceed 110 percent of the piping maximum allowable working pressure calculated in accordance with the most stringent of ASME B31.1, ASME B31.3, ASE B31.8, or the pipe manufacturer's stated maximum working pressure.

3. Gradually increase test pressure to an initial test pressure equal to the lesser of 1/2 the test pressure or 25 pounds per square inch gauge.

4. Perform initial check of joints and fittings for leakage. 5. Gradually increase test pressure in steps no larger than the initial pressure.

Check for leakage at each step increase until test pressure reached. 6. At each step in the pressure, examine and test piping being air tested for leaks

with soap solution. 7. Consider examination complete when piping section under test holds the test

pressure for 15 minutes without losses.

3.02 TESTING HIGH-HEAD PRESSURE PIPING

A. Test piping for which the specified test pressure in the Piping Schedule is 20 pounds per square inch gauge or greater, by the high head pressure test method, indicated "HH" in the Piping Schedule.

B. General: 1. Test connections, valves, and closure pieces with the piping. 2. Do not use installed valves for shutoff when the specified test pressure

exceeds the valve's maximum allowable seat differential pressure. Provide blinds or other means to isolate test sections.

3. Do not include valves, equipment, or piping specialties in test sections if test pressure exceeds the valve, equipment, or piping specialty safe test pressure allowed by the item's manufacturer.

4. During the performance of the tests, test pressure shall not vary more than plus or minus 5 pounds per square inch gauge with respect to the specified test pressure.

5. Select the limits of testing to sections of piping. Select sections that have the same piping material and test pressure.

6. When test results indicate failure of selected sections, limit tests to piping: a. Between valves. b. Between a valve and the end of the piping. c. Less than 500 feet long.

7. Test piping for minimum 2 hours for visible leaks test and minimum 2 hours for the pressure test with maximum leakage allowance.

C. Testing procedures: 1. Fill piping section under test slowly with water while venting air:

a. Use potable water for all potable waterlines and where noted on the Piping Schedule.

2. Before pressurizing for the tests, retain water in piping under slight pressure for a water absorption period of minimum 24 hours.


3. Raise pressure to the specified test pressure and inspect piping visually for leaks: a. Consider visible leakage testing complete when no visible leaks are

observed.

D. Pressure test with maximum leakage allowance: 1. Leakage allowance is zero for piping systems using flanged, National Pipe

Thread threaded and welded joints. 2. Pressure test piping after completion of visible leaks test. 3. For piping systems using joint designs other than flanged, threaded, or welded

joints, accurately measure the makeup water necessary to maintain the pressure in the piping section under test during the pressure test period: a. Consider the pressure test to be complete when makeup water added is

less than the allowable leakage and no damage to piping and appurtenances has occurred.

b. Successful completion of the pressure test with maximum leakage allowance shall have been achieved when the observed leakage during the test period is equal or less than the allowable leakage and no damage to piping and appurtenances has occurred.

c. When leakage is allowed, calculate the allowable leakage by the following formula: L = S x D x P1/2 x 133,200-1 wherein the terms shall mean: L = Allowable leakage in gallons per hour. S = Length of the test section in feet. D = Nominal diameter of the piping in inches. P = Average observed test pressure in pounds per square inches gauge, at the lowest point of the test section, corrected for elevation of the pressure gauge. x = The multiplication symbol.

END OF SECTION


SECTION 40_05_23.01

STAINLESS STEEL PIPE AND TUBING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Stainless steel piping and tubing.




3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 01_75_17 - Commissioning and Process Start-up c. Section 40_05_00.01 - Common Work Results for General Piping. d. Section 46_31_58 - Cleaning for Oxygen and Ozone Service.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and

250. 2. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through 24. 3. B16.11 - Forged Fittings, Socket-Welded and Threaded. 4. B31.3 - Process Piping. 5. B36.19 - Stainless Steel Pipe.

B. American Welding Society (AWS): 1. D1.6 - Structural Welding Code - Stainless Steel.

C. ASTM International (ASTM): 1. A 182 - Standard Specification for Forged or Rolled Alloy and Stainless Steel

Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service.

2. A 193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications.

3. A 194 - Standard Specification for Carbon and Alloy Steel Nuts and Bolts for High Pressure or High Temperature Service, or Both.

4. A 240 - Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications.


5. A 269 - Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service.

6. A 276 - Standard Specification for Stainless Steel Bars and Shapes. 7. A 312 - Standard Specification for Seamless, Welded, and Heavily Cold

Worked Austenitic Stainless Steel Pipes. 8. A 380 - Standard Practice for Cleaning, Descaling, and Passivation of

Stainless Steel Parts, Equipment, and Systems. 9. A 403 - Standard Specification for Wrought Austenitic Stainless Steel Piping

Fittings. 10. A 774 - Standard Specification for As-Welded Wrought Austenitic Stainless

Steel Fittings for General Corrosive Services at Low and Moderate Temperatures.

11. A 778 - Standard Specification for Welded, Unannealed Austenitic Stainless Steel Tubular Products.

12. A 789 - Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Tubing for General Service.

13. A 790 - Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Pipe.

14. A 928 - Standard Specification for Ferritic/Austenitic (Duplex) Stainless Steel Pipe Electric Fusion Welded with Addition of Filler Metal.

15. A 967 - Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts.

16. F 593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs.

D. Compressed Gas Association (CGA): 1. G-4.1 - Cleaning Equipment for Oxygen Service.

E. NSF International (NSF): 1. Standard 61 - Drinking Water System Components - Health Effects.

1.03 DESIGN REQUIREMENTS

A. Piping layout: Lay out and fabricate piping systems with piping sections as long as possible, while still allowing shipment, so that joints are minimized: 1. Piping design indicated on the Drawings illustrates piping layout and

configuration and does not indicate the location of every joint and flexible coupling that may be needed to connect piping sections fabricated in the shop.

2. Add joints and flexible couplings in a manner that achieves intent of maximizing size of individual piping sections.

B. Shop fabrication: Fabricate piping sections in the shop and pickle and passivate at point of manufacture.

C. Field assembly: 1. Field welding is prohibited unless the field welds are pickled and passivated as

specified herein.

1.04 SUBMITTALS

A. Submit as specified in Section 01_33_00.


B. Shop Drawings: 1. Detailed layout drawings:

a. Dimensions and alignment of pipes. b. Location of valves, fittings, and appurtenances. c. Location of field joints. d. Location of pipe hangars and supports. e. Connections to equipment and structures. f. Location and details of shop welds.

2. Thickness and dimensions of fittings and gaskets. 3. Photographs, drawings, and descriptions of pipe, fittings, welding procedures,

and pickling and passivating procedures. 4. Material specifications for pipe, gaskets, fittings, and couplings. 5. Data on joint types and components used in the system including, flanged

joints, grooved joint couplings and screwed joints.

C. Cleaning procedures used for liquid oxygen and ozone piping systems in accordance with CGA Standard G-4.1.

D. Provide Manufacturer’s Certificate of Source Testing as specified in Section 01_75_17.

PART 2 PRODUCTS

2.01 STAINLESS STEEL PIPE

A. General: 1. Pipe sizes specified in the Specifications are nominal.

B. Wall thickness: 1. As specified in Section 40_05_00.01. 2. Piping 2 1/2 inches in nominal diameter and greater:

a. For general service applications with pressures less than 250 pounds per square inch gauge, pipe diameter 24-inches or less, minimum wall thickness corresponding to Schedule 10S.

C. Piping material and manufacturing: 1. Comply with the requirements outlined in the following table:

Service Stainless Steel Grade Pipe Manufacturing Process

Oxygen and Ozone Service with chloride concentrations less than 1,000 parts per million and/or free chlorine less than 4 parts per million at ambient temperatures.

Piping 2 1/2 inches in nominal diameter and larger

Type 316L or LDX 2101 stainless steel in accordance

with ASTM A 240

Type 316L in accordance with ASTM A 778

Type LDX 2101 in accordance with ASTM A 790

Piping less than 2 1/2 inches in nominal diameter

Type 316L or LDX 2101 stainless steel in accordance

with ASTM A 240

Type 316L in accordance with ASTM A 312

Type LDX 2101 in accordance with ASTM A 790


D. Fittings for piping 2 1/2 inches in nominal diameter and greater: 1. Material: In accordance with ASTM A 240 stainless steel, grade to match the

pipe. 2. Manufacturing standard: In accordance with ASTM A 774. 3. Wall thickness of fitting: In accordance with ASME B36.19 for the schedule of

pipe specified. 4. End configuration: As needed to comply with specified type of joint. 5. Dimensional standards:

a. Fittings with weld ends: In accordance with ASME B16.11. b. Fittings with flanged ends: In accordance with ASME B16.5, Class 150.

E. Fittings for piping less than 2 1/2 inches in diameter: 1. Material: In accordance with ASTM A 240 stainless steel, grade to match the

pipe. 2. Manufacturing standard: In accordance with ASTM A 403, Class WP. 3. Wall thickness and dimensions of fitting: In accordance with ASME B16.11 and

as required for the schedule of pipe specified. 4. End configuration: As needed to comply with specified type of joint. 5. Forgings in accordance with ASTM A 182, or barstock in accordance with

ASTM A 276. Match forging or barstock material to the piping materials.

F. Piping joints: 1. Joint types, piping greater than 2 inches in diameter, general:

a. Where type of joint is specifically indicated on the Drawings or specified, design and shop-fabricate piping sections utilizing type of joint illustrated or scheduled.

b. Joints at valves and pipe appurtenances: 1) Provide flanged valves and flanged pipe appurtenances in stainless

steel piping systems with flanged ends. 2) Design and fabricate piping sections to make connections with

flanged valves and pipe appurtenances using flanged coupling adapters or flanged joints:

c. Joints in ozone and oxygen piping systems: 1) Aboveground piping: Welded or flanged.

2. Joints in piping 2 inches in diameter and smaller: Flanged socket welded or screwed with Teflon tape thread lubricant, as specified in Section 40_05_00.01.

3. Welded joints: a. Piping 4 inches through 12 inches in diameter: Double butt welded joints. b. Piping less than 4 inches in diameter: Single butt-welded joints. c. Mark each weld with a symbol that identifies the welder.

4. Flanged joints: Conforming to the requirements in accordance with ASME B16.5, Class 150.

5. Flanges for Schedule 40S and Schedule 80S pipe: a. Provide forged stainless steel (type matching piping system) slip-on

flanges in accordance with ASME B16.5 Class 150. b. Material: In accordance with ASTM A 182.

G. Gaskets: 1. Ozone and oxygen service: TFE sheet. 2. All other service applications: EPDM, nitrile, or other materials compatible with

the process fluid.


H. Bolts for flanges: 1. Bolts and nuts: Type 316 stainless steel in accordance with ASTM A 193

heavy hex head: a. Bolt length such that after installation, end of bolt projects 1/8-inch to

3/8-inch beyond outer face of nut. b. Nuts: In accordance with ASTM A 194 heavy hex pattern.

I. Fabrication of pipe sections: 1. Welding: Weld in accordance with ASME B31.3. 2. Weld seams:

a. Full penetration welds, free of oxidation, crevices, pits and cracks, and without undercuts.

b. Provide weld crowns of 1/16 inch with tolerance of plus 1/16 inch and minus 1/32 inch.

c. Where internal weld seams are not accessible, use gas tungsten-arc procedures with internal gas purge.

d. Where internal weld seams are accessible, weld seams inside and outside using manual shielded metal-arc procedures.

J. Cleaning (pickling) and passivation: 1. Following shop fabrication of pipe sections, straight spools, fittings, and other

piping components, clean (pickle) and passivate fabricated pieces. 2. Clean (pickle) and passivate in accordance with ASTM A 380 or A 967:

a. If degreasing is required before cleaning to remove scale or iron oxide, cleaning (pickling) treatments with citric acid are permissible: 1) However, these treatments must be followed by inorganic cleaners

such as nitric acid/hydrofluoric acid. b. Passivation treatments with citric acid are not allowed.

3. Finish requirements: Remove free iron, heat tint oxides, weld scale, and other impurities, and obtain a passive finished surface.

4. For piping less than 2-inches in diameter: a. Following shop fabrication of piping sections, descale, clean and seal

piping section in accordance with CGA Standard G-4.1.

K. Cleaning pipe for ozone and liquid oxygen service: 1. Following shop fabrication of piping sections, descale, clean and seal piping

section in accordance with Section 46_31_58.

2.02 STAINLESS STEEL TUBING

A. Stainless steel tubing: 1. Seamless tubing made of Type 316L stainless steel and in accordance with

ASTM A 269, wall thickness of 0.035 inch.

B. Fittings: Swage ferrule design: 1. Components made of:

a. Type 316 stainless steel. 2. Double acting ferrule design, providing both a primary seal and a secondary

bearing force. 3. Flare type fittings are not acceptable. 4. Manufacturers: One of the following or equal as approved by the Engineer:

a. Crawford Fitting Company, Swagelok.


b. Hoke, Gyrolok. c. Parker, CPI.

C. Valves for use with stainless steel tubing: 1. Ball type valves with swage ends to match tubing diameter. 2. Constructed from:

a. Type 316 stainless steel with TFE seats. 3. Manufacturers: The following or equal as approved by the Engineer:

a. Crawford Fitting Company, Swagelok.

2.03 SPARE PARTS

2.04 SOURCE QUALITY CONTROL

A. Visually inspect pipe for welding defects such as crevices, pits, cracks, protrusions, and oxidation deposits.

B. Provide written certification that the pipe as supplied are in accordance with ASTM A 778. Supplemental testing is not required.

C. Provide written certification that the fittings as supplied are in accordance with ASTM A 774: 1. Supplementary testing is not required.

D. Thoroughly clean any equipment before use in cleaning or fabrication of stainless steel.

E. Storage: Segregate location of stainless steel piping from fabrication of any other piping materials.

F. Shipment to site: 1. Protect all flanges and pipe ends by encapsulating in dense foam. 2. Securely strap all elements to pallets with nylon straps. Use of metallic straps

is prohibited. 3. Cap ends of tube, piping, pipe spools, fittings, and valves with non-metallic

plugs. 4. Load pallets so no tube, piping, pipe spools, fittings, or valves bear the weight

of pallets above. 5. Notify Engineer when deliveries arrive so Engineer may inspect the shipping

conditions. 6. Engineer may reject material due to improper shipping methods or damage

during shipment.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install piping in such a manner as not to impart strain to connected equipment.

3.02 FIELD ASSEMBLY OF SHOP-FABRICATED PIPING SECTIONS

A. Join shop-fabricated piping sections together using flanges.


B. If field welding is required, pickle and passivate the field welds by using a cleaning process as specified in Section 46_31_58 where the Provider uses a cleaning process that also pickles and passivates the interior welds. Exterior field welds shall be pickled and passivated by using K-2 Pickling Paste and K-2 Passivation, or equal as approved by the Engineer, in accordance with the manufacturer's instructions. Use only a stainless steel brush to clean the field welds.


A. Test piping to pressure and by method as specified in Section 40_05_00.01: 1. If pressure testing is accomplished with water:

a. Use only potable quality water. b. Piping: Thoroughly drained and dried or place immediately into service.

B. Visually inspect pipe for welding defects such as crevices, pits, cracks, protrusions, and oxidation deposits.

C. Welds in liquid oxygen and ozone service piping: Examined and inspected in accordance with ASME B31.3.

3.04 PROTECTION

A. Preserve appearance and finish of stainless steel piping by providing suitable protection during handling and installation and until final acceptance of the Work: 1. Use handling methods and equipment to prevent damage to the coating,

include the use of wide canvas slings and wide padded skids. 2. Do not use bare cables, chains, hooks, metal bars, or narrow skids. 3. Store stainless steel piping and fittings away from any other piping or metals.

Storage in contact with ground or outside without projection from bad weather is prohibited.

4. Protect stainless steel piping and fittings from carbon steel projections (when grinding carbon steel assemblies in proximity) and carbon steel contamination (do not contact stainless steel with carbon steel wire brush or other carbon steel tool).

END OF SECTION



SECTION 40_05_52

SPECIALTY VALVES PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Ozone gas control valves. 2. Solenoid valves. 3. Tubing valves.




3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 40_05_57.23 - Electric Actuators.


A. Manufacturer qualifications: Manufactured by manufacturers whose valves have had successful operational experience in comparable service.

1.03 DELIVERY STORAGE AND HANDLING

A. Protect valves from damage during handling and installation.

PART 2 PRODUCTS

2.01 OZONE GAS CONTROL VALVES

A. Manufacturers: 1. DeZurik V-Port Ball Valves. 2. Worcester CPT Series. 3. Or equal as approved by the Engineer.

B. Operation: Ozone Gas Control Valve

Nominal Size As shown on the Drawings

Fluid 8-12% Gaseous Ozone, Balance Oxygen

Temperature 45-100° F

Design Upstream Pressure 15 to 25 psig, as required by Ozone System Supplier


C. Design: 1. V-Port ball valve with flow characteristics capable of providing a 20:1 flow

turndown. 2. Suitable for frequent modulation after long periods of inactivity. 3. ANSI B16.5 Class 150 flanged ends with ANSI B16.10 flange-to-flange

dimensions. 4. All valves shall be cleaned for oxygen service in accordance with Standard G-

4.1. 5. Provide valves with motorized actuators in conformance with Section

40_05_57.23.

D. Materials: 1. Valve Body: Type ASTM A 351, Grade CG8M, 316 or 317 Stainless Steel. 2. Ball: 316 or 317 Stainless Steel, heat treated, nickel overlay. 3. Shafts: 2205 duplex stainless steel. 4. Packing Material: PTFE. 5. Bearings: 316 or 317 stainless steel with wire-reinforced PTFE liner. 6. Seats: Reinforced PTFE.

2.02 SOLENOID VALVES

A. 2-way solenoid valves: 1. Manufacturers: One of the following or equal as approved by the Engineer:

a. Automatic Switch Company, Series 8210. b. Skinner Electric Valve Division, Series C.

B. Design: 1. Unless otherwise indicated on the Drawings, provide valves that:

a. Minimum NEMA Type 4 enclosure. b. 24 VDC operation. c. Suitable for use as indicated on the Drawings. d. Minimum Class F coil insulation.

2. 2-way valves: Furnish with openings of size equal to or larger than the nominal size designation of the valve.

C. Materials: 1. Body: Stainless steel to match piping or tubing material. 2. Seats: Resilient material.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install in accordance with manufacturer's published instructions.

END OF SECTION


SECTION 40_05_57.13

MANUAL ACTUATORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Valve and gate actuators. 2. Handwheel actuators.




3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 09_96_56.05 - High-Build Epoxy Coatings.

1.02 REFERENCES

A. Aluminum Association (AA): 1. DAF-45 - Designation System for Aluminum Finishes.

B. American Water Works Association (AWWA).

1.03 SUBMITTALS

A. Shop drawings and product data: Include shop drawings and product data for manual operators.


A. Provide valve actuators integral with valve or gate.

B. Provide similar actuators by 1 manufacturer.

PART 2 PRODUCTS

2.01 VALVE AND GATE ACTUATORS

A. Position indicators: 1. Dial indicators with clear full-open and closed position indicators, calibrated in

number of turns or percentage of opening.


B. Manual or power actuator size: 1. Sized to deliver maximum force required under most severe specified

operating condition, including static and dynamic forces, seat and wedge friction, and seating and unseating forces with safety factor of 5, unless otherwise specified.

C. Actuator size: Capable of supporting weight of suspended shafting unless carried by bottom thrust bearings; shaft guides with wall mounting brackets.

D. Operation: Counterclockwise to open with suitable and adequate stops, capable of resisting at least twice normal operating force to prevent overrun of valve or gate in open or closed position.

E. Open direction indicator: Cast arrow and legend indicating direction to rotate actuator on handwheel, chain wheel rim, crank, or other prominent place.

F. Worm gear actuators: Provide gearing on worm gear actuators that is self-locking with gear ratio such that torque in excess of 160 foot-pounds will not need to be applied to operate valve at most adverse conditions for which valve is designed.

G. Traveling nut actuators: Capable of requiring maximum 100 foot-pounds of torque when operating valve under most adverse condition; limit stops on input shaft of manual actuators for fully open and closed positions; non-moving vertical axis of operating nut when opening or closing valve.

2.02 HANDWHEEL ACTUATORS

A. Manufacturers: One of the following or equal as approved by the Engineer: 1. Rodney Hunt Company. 2. Waterman Industries, Incorporated.

B. Coating: Handwheel as specified in Section 09_96_56.05.

C. Bearings above and below finished threaded bronze operating nut: Ball or roller.

D. Indicator: Counterclockwise opening with arrow, and word OPEN cast on top of handwheel indicating direction for opening.

E. Pull to operate: Maximum 40 pounds pull at most adverse design condition.

F. Stem travel limiting device: Setscrew locked stop nuts above and below lift nut.

G. Grease fittings: Suitable for lubrication of bearings.

2.03 HAND-CRANKED GEARED ACTUATORS

A. Type: Single removable crank; fully enclosed.

B. Teeth on gears, spur pinions, bevel gears, and bevel pinions: Cut.

C. Lift nuts: Cast manganese bronze.

D. Exterior surfaces on cast-iron lift parts: Smooth.


E. Crank rotation indicator: Cast arrow with word OPEN in prominent location readily visible indicating correct rotation of crank to open gate.

F. Hand cranks: requiring maximum 25 pounds pull to operate gate at maximum operating head; with: 1. Revolving brass sleeves. 2. Gears, spur pinions, bevel gears, and bevel pinions with cut teeth. 3. Cast manganese bronze lift nuts. 4. Cast-iron lift parts with smooth exterior surfaces.

G. Indicator: Dial position type mounted on gear actuator; enclosed in cast-iron or aluminum housing with clear plastic cover; marked with fully open, 3/4, 1/2, 1/4, and closed positions.

2.04 ACCESSORY EQUIPMENT

A. Fasteners: Type 316 stainless steel.

B. Geared valve actuators: Provided with cut gears, either spur or worm; sized to operate valves at most adverse design condition; with maximum 40-pound pull at handwheel or chain wheel rim.

C. Geared valve traveling nut actuators: Acceptable only where specified.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install in accordance with manufacturer's instructions.

3.02 SCHEDULES

A. Geared actuators: Provide geared actuators for following valves: 1. Butterfly valves larger than or equal to 6 inches, nominal size, on liquid

service. 2. Butterfly valves larger than 10 inches, nominal size, on gas and air service.

B. Handwheel actuators: Provide handwheel actuators for valves mounted 6 feet or less above floors.

C. Chain wheel actuators: Provide chain wheel actuators for valves mounted more than 6 feet to centerline above floors.

END OF SECTION



SECTION 40_05_57.23

ELECTRIC ACTUATORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Electric motor-driven actuators for valves.




3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents.

1.02 REFERENCES

A. American Water Works Association (AWWA): 1. C504 - AWWA Standard for Rubber-Seated Butterfly Valves. 2. C542 - AWWA Standard for Electric Motor Actuators for Valves and Slide

Gates.

B. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

1.03 DEFINITIONS:

A. NEMA: 1. Type 4X enclosure in accordance with NEMA 250.

1.04 SUBMITTALS

A. Provide a complete list/schedule of all actuators being provided with their associated tag names as indicated on the design drawings and/or specifications, service process area and the size of the valve they are actuating.

B. Clearly identify any exceptions in terms of quantities and/or quality of actuator(s) being submitted.

C. Product data: 1. Electrical ratings:

a. Voltage and number of phases. b. Starting and running current. c. Voltage levels and source for control and status.

2. Description of integral control interface.


3. Environmental ratings, including NEMA enclosure rating and submergence capabilities.

4. Gear ratios for both manual and motorized actuation. 5. Opening and closing directions. 6. Allowable starts per hour. 7. List of all included options and accessories. 8. Full travel times. 9. Gearbox data including gear ratio, and gearbox efficiency. 10. Affidavit in accordance with AWWA C542.

D. Shop drawings: 1. Wiring diagrams:

a. Include all options and expansion cards furnished with each actuator. 2. Dimensioned drawings of each valve and actuator combination. 3. Dimensioned drawings of each valve gearbox. 4. Electric motor data. 5. Interconnection diagrams between actuator and remote control station.

E. Calculations: Submit the following for each valve size and class: 1. Operating torque calculations. 2. Maximum torque calculations for seating and unseating. 3. Maximum operating torque at starting and normal operation.

F. Test reports: 1. Factory test report and certificate. 2. Each actuator must be performance tested with a simulated load at the factory

and individual test certificates and detailed test reports shall be provided: a. The test equipment used should simulate a typical valve load.

G. Manufacturer's instructions: 1. Include manufacturer's instructions, description of system operation, start-up

data, and troubleshooting checklist.

H. Operations and maintenance data: 1. Include manufacturer's literature; cleaning procedures, replacement part lists,

wiring diagrams, and repair data. 2. Include a list of all configurable parameters, and the final values for each. 3. List of recommended spare parts. 4. List of special tools necessary for proper operation and/or maintenance. 5. Exploded view drawings that illustrate all assemblies, sub-assemblies, and

components. 6. Routine test procedures for all electronic and electrical circuits. 7. Troubleshooting chart covering the complete valve and controls/electrical

power systems, showing description of trouble, probable cause, and suggested remedy.

8. Certified factory and field-test results.


A. Obtain required information from the valve supplier, including but not limited to: 1. Interface to valve. 2. Operating range (In degrees). 3. Quarter turn or multi-turn.


4. Required turns for full travel on multi-turn applications. 5. Direction of rotation for opening and closing. 6. Maximum and normal torque requirements.

B. All motorized, intelligent actuators shall be the product of a single manufacturer for all valve and gate applications on this project, regardless of valve type, manufacturer, or supplier.

1.06 SPARE PARTS

A. Provide the following spare parts for each water treatment plant (minimum 10 percent of total number of actuators of each model type furnished, but not less than 1 for each model of actuator furnished): 1. Stem nut. 2. Worm shaft subassembly. 3. Drive sleeve subassembly. 4. Complete actuator seal kit. 5. Actuator gearbox oil (sufficient quantity to fill 4 gearboxes). 6. Encoder. 7. Control module.

B. Provide 1 spare motor for each size motor furnished at each water treatment plant.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Acceptable manufacturers or equal as approved by the Engineer: 1. Rotork Controls Inc.:

a. IQT (Quarter-turn) Series. 2. Limitorque Corporation:

a. Accutronix QX (Quarter-Turn) Series.

2.02 CHARACTERISTICS FOR ACTUATORS

A. Actuators shall comply with AWWA C542 except as modified in this section.

B. Provide actuators complete and operable with all components and accessories required for operation.

C. Power supply: 1. Voltage and phases:

a. Modulating service: 120-volt, 1-phase or 480-volt, 3-phase. b. Open-close service: 120-volt, 1-phase or 480-volt, 3-phase,

2. Valve motion independent of power supply phase rotation. 3. Provide an internal backup power source to maintain settings and track valve

position when main power is off. 4. The actuators shall incorporate all major components such as the motor,

starter, local controls, terminals etc. housed within a self-contained, sealed enclosure.


D. Operating times: 1. Size the actuator to move valves at minimum 12 inches per minute under

maximum load. Measure rate of closure for valves at maximum diameter of disc, plug, or ball.

2. Size actuators so that gear boxes are not required where possible.

E. Control interface: 1. Configuration:

a. Provide a non-intrusive, non-contacting interface for configuring all input and output settings, control values, ranges, torque switch settings, valve positions switch settings, and options: 1) Configurable from a hand-held configuring tool or input devices on

the actuator. 2. Local interface, integral to actuator:

a. Non-intrusive, non-contacting selector switches: 1) LOCAL-STOP-REMOTE:

a) Motor actuator operation is prevented with the switch in STOP. 2) OPEN-CLOSE:

a) Controls the valve when LOCAL-STOP-REMOTE is in LOCAL. b) Spring return to center. c) Configurable between maintained (actuator runs until end of

travel, high torque, or a LOCAL-STOP-REMOTE is switched to STOP) and momentary (actuator stops when lever is released).

b. Local display: 1) Valve fully open and fully closed indicators. 2) Numerical display showing actual valve position in percent of travel.

3. Control inputs: a. Capable of using 120 VAC or 24 VDC inputs. b. Controls the valve when LOCAL-STOP-REMOTE is in REMOTE. c. Isolated inputs capable of operating from external control voltage source

or internal power supply: 1) Furnish 120 VAC and 24 VDC control power supplies within the

actuator. d. Provide the following inputs:

1) OPEN. 2) CLOSE. 3) STOP.

e. OPEN and CLOSE inputs configurable between maintained (actuator runs until end of travel, high torque, or a STOP input) and momentary (actuator stops when command is removed).

4. Status outputs: a. Monitor relay output: Dry contact, normally closed, opens when actuator is

not in REMOTE or in the event of any internal fault or alarm condition. b. Dry contact outputs configured for the functions indicated on the

Drawings. Provide the following outputs for all actuators: 1) Fully closed. 2) Fully open. 3) LOCAL-STOP-REMOTE in REMOTE position.

c. All output contacts rated for 5 amps, 120 VAC and 24 VDC. 5. Analog input:

a. Provide a 4-20 milliampere analog input for analog modulating valves when indicated on the Drawings.


b. Modulate valve to maintain position based on analog input value. c. Maximum input impedance 250 ohms.

6. Analog output: a. Provide an isolated 4-20 milliampere analog output when indicated on the

Drawings: 1) Loop power sourced from the actuator power supply. 2) Capable of driving into a load up to 500 ohms. 3) Valve position.

F. Features: 1. Time delay on reversal: Incorporate time delay between stopping actuator and

starting in opposite direction to limit excessive current, torque, and heating from instantaneous reversal.

2. Data logging: a. Store diagnostic data and reference data:

1) Store reference data (recorded during commissioning) and data from last operation.

3. Provide display of logged data on the actuator, or provisions to download to a personal computer.

G. Materials: 1. Construct motorized actuators of materials suitable for the environment in

which the valve is to be installed.

H. Components: 1. Motors: 2. Specifically designed for valve actuator service with high starting torque, totally

enclosed non-ventilated construction. 3. Torque ratings equal to or greater than that required for valve seating and

dynamic torques with a 50 percent factor of safety: a. Design requirements for rubber-seated AWWA butterfly valves:

1) Design actuators for maximum valve operating torque, in accordance with and using safety factors required in AWWA C504 and AWWA C542: a) Valve actuator torque requirement for open-close service: Not

less than the required valve-seating and dynamic torques under design operating conditions in accordance with AWWA C504.

b) Valve actuator torque requirement for modulating service: Not less than twice the required valve dynamic torque under design operating conditions in accordance with AWWA C504.

4. Capable of being removed and replaced without draining the actuator gear case.

5. Motor bearings shall be amply proportioned of the anti-friction type and permanently lubricated.

6. Rated for operating under the following conditions without exceeding temperature limits with ambient temperature of 40 degrees Celsius: a. Continuous operation for 15 minutes or twice the open-to-close operating

time (whichever is greater) at normal operating torque or 33 percent of maximum torque (whichever is greater).

b. 60 starts per hour for open/close service or 1,200 starts per hour for modulating service.


7. Provide the following motor protection features: a. Jammed valve (no valve motion detected through a time delay). b. High motor temperature (sensed by an embedded thermostats). c. High torque. d. Single phasing protection.

I. Enclosures: 1. Stainless steel external fasteners. 2. Provide 'O' ring seals for each of the following areas:

a. Between the terminal compartment and the internal electrical elements. b. Between the mechanical and electrical portions to protect from the ingress

of oil, and to protect the mechanical components of oil from dust and moisture when the electrical terminal is open.

3. Provide the following minimum enclosure ratings: a. NEMA Type 4X enclosure for general applications.

J. Position sensing: 1. Electronic and adjustable using a solid-state encoder wheel:

a. Mechanical limit switches and potentiometers are not acceptable. 2. Capable of retaining position and monitoring valve motion when valve is

manually actuated and when main power is not present. 3. Valve range and position switch outputs field adjustable.

K. Torque sensing: 1. Torque shutdown setting: 40 percent to 100 percent rated torque:

a. Adjustable in 1 percent increments. 2. Capable of interrupting control circuit during both opening and closing and

when valve torque overload occurs. 3. Electrical or electronic torque sensing. 4. Independent of variations in frequency, voltage, or temperature. 5. Provide a temporary inhibit of the torque sensing system during unseating or

during starting in mid-travel against high inertia loads. 6. Provide visible verification of torque switch status without any housing

disassembly.

L. Manual actuators: 1. Hand wheel for manual operation:

a. Maximum 40 pound pull on rim when operating valve under maximum load.

b. Provide pull chain when motorized actuator is located more than 6 feet above floor surface: 1) Chain shall be of sufficient length to reach approximately 4 feet

above the operating level. 2) Where the chain obstructs an aisle or walkway, provide holdback or

other means to ensure chain does not create a nuisance or hazard to operating personnel.

2. Declutch lever: Padlockable, capable of mechanically disengaging motor and related gearing and freeing hand wheel for manual operation.

M. Gearing: Hardened alloy steel spur or helical gears and self-locking, alloy bronze worm gear set: 1. Accurately cut to assure minimum backlash.


N. Bearings: 1. Anti-friction bearing with caged balls or rollers throughout. 2. Sealed-for-life type thrust bearings housed in a separate thrust base.

O. Drive bushing: 1. Easily detachable for machining to suit the valve stem or gearbox input shaft. 2. Positioned in a detachable base of the actuator.

P. Lubrication: 1. Provide totally enclosed actuator gearing with oil filled gear case suitable for

operation at any angle. 2. Suitable for standard SAE80EP gear oil. 3. Actuators requiring special or exotic lubricants are not acceptable.

Q. Software: 1. Furnish PC-based diagnostic and configuration software to display diagnostic

data and configure actuators. 2. Provide software communications to the valve actuator and hand-held setting

tool using Bluetooth wireless communications: a. Provide all accessories and drivers required for operation and

communications with a standard personal computer running Microsoft Windows.

R. Setting tool: 1. Provide a hand-held setting tool capable of non-intrusive calibration and

interrogation of the actuator: a. Furnish 2 setting tools. b. Capable of communicating with PC-based configuration software, and

transferring the following in either direction between the computer and programmer and setting tool, and between the setting tool and actuator.

c. Actuator configurations: 1) Capable of storing up to 10 different configurations.

d. Diagnostic data: 1) Capable of storing 4 complete sets of diagnostic data.

S. Termination module cover: 1. For actuators on a valve network provide a means to keep the valve network in

service, in the event where the actuator must be removed.


A. Factory test: 1. Test each actuator in the factory, and submit an individual test certificate for

each actuator. 2. Perform a high potential test and record the following information:

a. Test voltage. 3. Simulate a maximum and typical valve loads and record the following

information: a. Current and power factor at maximum and set torque values. b. Torque as measured by the actuator. c. Actuator output speed or operating time.

4. Performance testing: Conduct performance test for each actuator simulating valve operating torque from full-open to full-close and from full-close to


full-open. The following information shall be recorded during each performance test: a. Torque at maximum torque setting. b. Current at maximum torque setting. c. Test voltage and frequency. d. Actuator output speed and operating time for full-open to full-close. e. Amperage draw on motors at breakaway and under normal operation.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install actuators in accordance with manufacturer's instructions.

END OF SECTION


SECTION 40_05_63

BALL VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Metal body ball valves.




3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 09_96_56.05 - High-build Epoxy Coatings. b. Section 40_05_00.01 - Common Work Results for General Piping. c. Section 40_05_57.23 - Electric Motor Actuators.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through 24.

B. ASTM International (ASTM): 1. A 216 - Standard Specification for Steel Castings, Carbon, Suitable for Fusion

Welding, for High-Temperature Service. 2. A 351 - Standard Specification for Castings, Austenitic, for Pressure-

Containing Parts.


A. General: Unless otherwise indicated on the Drawings use: 1. Metal body ball valves on metallic pipelines.

PART 2 PRODUCTS

2.01 METAL BODY BALL VALVES, LESS THAN 6 INCH SIZE

A. Manufacturers: One of the following, or equal as approved by the Engineer: 1. Apollo Valves as manufactured by Conbraco Industries, Inc. 2. Metso Automation/Jamesbury. 3. NIBCO, Inc. 4. Flow-Tek, Inc.


B. General: 1. Type: Non-lubricated, full port and capable of sealing in either direction. 2. End connections:

a. Threaded or solder ends for sizes 1-inch and smaller. b. Class 150 flanged for sizes larger than 1 inch:

1) Flanges: In accordance with ASME B16.1 standards. 3. Stem packing: Manually adjustable while valve is under pressure. 4. Shafts:

a. Rigidly connected to the ball by a positive means: 1) Design connection to transmit torque equivalent to at least

75 percent of the torsional strength of the shaft. 5. Handles: Stainless steel latch lock handle with vinyl grip and stainless steel nut

designed to open and close the valve under operating conditions. 6. Temperature limits: Suitable for operation between minus 20 and 350 degrees

Fahrenheit.

C. Materials: 1. Valves in copper lines: Bronze body. 2. Valves in steel and ductile iron piping: Ductile iron or cast steel body. 3. Valves in stainless steel piping: Stainless steel body, material type to match

piping material as specified in Section 40_05_00.01. 4. Ball: Type 316 stainless steel. 5. Seats: PTFE. 6. Stem seals: PTFE or Viton. 7. Bearings: Self-lubricated, corrosion resistant material that will not contaminate

potable water. 8. Provide a high-solids epoxy coating on all ferrous-metal bodied valves in

accordance with Section 09_96_56.05.

D. Valve actuator: 1. Manually operated valves: Self-locking worm gear type actuator with position

indicator. Permanently lubricate gearing. Provide adjustable screws to stop travel at both open and closed positions.

2. Electric motor operated valves: Provide electric motor operator as specified in Section 40_05_57.23.

PART 3 EXECUTION

3.01 INSTALLATION

A. General: Install each type of valve in accordance with manufacturers' printed instructions.

END OF SECTION


SECTION 40_05_64

BUTTERFLY VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Butterfly valves.




3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 09_96_56.05 High Build Epoxy Coatings. b. Section 40_05_57.13 - Manual Actuators. c. Section 40_05_57.23 - Electric Motor Actuators.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Classes 25, 125 and

250. 2. B16.5 - Pipe Flanges and Flanged Fittings, NPS 1/2 through NPS 24.

B. American Water Works Association (AWWA): 1. C110 - Standard for Ductile-Iron and Gray-Iron Fittings. 2. C504 - Rubber-Seated Butterfly Valves. 3. C540 - Standard for Power-Actuating Devices for Valves and Sluice Gates. 4. C550 - Protective Interior Coatings for Valves & Hydrants.

C. ASTM International (ASTM): 1. A 126 - Standard Specification for Gray Iron Castings for Valves, Flanges, and

Pipe Fittings. 2. A 216 - Standard Specification for Steel Castings, Carbon, Suitable for Fusion

Welding, for Higher-Temperature Service. 3. A 276 - Standard Specification for Stainless Steel Bars and Shapes. 4. A 351 - Standard Specification for Castings, Austenitic, for Pressure-

Containing Parts. 5. A 395 - Standard Specification for Ferritic Ductile Iron Pressure-Retaining

Castings for Use at Elevated Temperatures. 6. A 479 - Standard Specification for Stainless Steel Bars and Shapes for Use in

Boilers and Other Pressure Vessels. 7. A 515 - Standard Specification for Pressure Vessel Plates, Carbon Steel, for

Intermediate - and Higher-Temperature Service.


8. A 516 - Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate - and Lower-Temperature Service.

9. A 536 - Standard Specification for Ductile Iron Castings. 10. A 564 - Standard Specification for Hot-Rolled and Cold-Finished Age-

Hardening Stainless Steel Bars and Shapes. 11. A 582 - Standard Specification for Free-Machining Stainless Steel Bars 12. D 429 - Standard Test Methods for Rubber Property-Adhesion to Rigid

Substrate.

D. Compressed Gas Association (CGA): 1. Standard G-4.1 - Cleaning Equipment for Oxygen Service.

E. NSF International (NSF): 1. Standard 61 - Drinking Water System Components - Health Effects.

F. United States Code of Federal Regulations (CFR): 1. 21 - Food and Drugs.


A. Design requirements: 1. General purpose AWWA butterfly valves:

a. Design standard: Provide valves designed and manufactured in accordance with AWWA C504.

b. Class: 1) Provide butterfly valves in accordance with AWWA Class 150B,

unless otherwise specified. 2. Stainless steel butterfly valves:

a. Stainless steel butterfly valves capable of a minimum of 100 pounds per square inch leak tight shut off and with special cleaning, packaging, and handling.

B. Design requirements for all butterfly valves with power actuating devices: 1. Design valves and actuators for maximum operating torque, in accordance

with and using safety factors required in AWWA C540, using the following values: a. Maximum water velocity: 16 feet per second with valve fully open. b. Maximum pressure differential across the closed valve equal to the

pressure class designation. c. Coefficient for seating and unseating torque, dynamic torque, and bearing

friction in accordance with valve manufacturer's published recommendations.

2. Valve disc: Seat in an angular position of 90 degrees to the pipe axis and rotate an angle of 90 degrees between fully open and fully closed positions: a. Do not supply valves with stops or lugs cast with or mechanically secured

to the body of the valve for limiting the disc travel. 3. Unacceptable thrust bearings: Do not provide valves with thrust bearings

exposed to the fluid in the line and consisting of a metal bearing surface in rubbing contact with an opposing metal bearing surface.

C. Performance requirements: 1. Tight shutoff at the pressure rating of the valve with pressure applied in either

direction.


2. Suitable for the following service conditions: a. Throttling. b. Frequent operation. c. Operation after long periods of inactivity. d. Installation in any position and flow in either direction.

1.04 SUBMITTALS

A. Include the following information: 1. Product data:

a. For general purpose AWWA butterfly valves, include description of the method of attachment of the disc edge to the valve disc.

B. Certificates: 1. Interior epoxy coatings: Affidavit of compliance attesting that epoxy coatings

applied to interior surfaces of butterfly valves comply with all provisions in accordance with AWWA C550.

2. Certification, for all valves and coatings in contact with potable water, that the products used are suitable for contact with drinking water in accordance with NSF Standard 61.

PART 2 PRODUCTS

2.01 GENERAL PURPOSE AWWA BUTTERFLY VALVES

A. Manufacturers: One of the following or equal as approved by the Engineer: 1. DeZurik/Sartell Model BAW. 2. Henry Pratt Company.

B. Valve body: 1. Material: Cast iron, ASTM A 126, Grade B, or ductile iron, ASTM A 536, Grade

65-45-12. 2. Body design:

a. Flanged body valves: 1) Flanges: In accordance with ASME B16.1 Class 125 flanges for

Class 150B valves, in accordance with ASME B16.1 Class 250 flanges for Class 250B valves.

C. Disc: 1. Material: Cast iron or ductile iron with Type 316 stainless steel edge that

matches seat in valve body. 2. Secure valve disc to shaft by means of smooth-sided, taper or dowel pins,

Type 316 stainless steel, or Monel. 3. Extend pins through shaft and mechanically secure in place.

D. Shaft and bearings: 1. Shaft design:

a. 1 piece, through disc design. 2. Shaft seal: Vee type, chevron design. 3. Shaft material for Class 150B valves: Type 316 stainless steel, ASTM A 276. 4. Shaft bearings: Self-lubricating sleeve type:

a. Nylatron.


E. Seats: 1. Seat materials:

a. EPDM. 2. Bond or vulcanize seat into the valve body. 3. Resilient seat: Withstand 75 pound per inch pull when tested in accordance

with ASTM D 429, Method B.

F. Valve packing: 1. Self-adjusting V-type packing or chevron-type packing. NBR or EPDM to

match seat material.

2.02 STAINLESS STEEL BUTTERFLY VALVES FOR OXYGEN AND OZONE SERVICE

A. Manufacturers: One of the following or equal as approved by the Engineer: 1. DeZurik HP. 2. Neles-Jamesbury 815LO. 3. Tyco-Keystone K-LOK Figure 362.

B. Cleaning and handling: Clean, seal, package, and handle valves for oxygen and ozone service in strict accordance with CGA Standard G-4.1.

C. Valve body: 1. Material: Type 316 stainless steel, ASTM A 351, Grade CF8M. 2. Body design: Lugged style body with drilled and tapped boltholes in

accordance with ASME B16.1, Class 125 and Class 150 flange drilling dimensions.

D. Disc: 1. Offset disc. 2. Material: Type 316 stainless steel, ASTM A 351, Grade CF8M.

E. Shaft and bearings: 1. Shaft: Type 316 stainless steel. 2. Shaft bearings: Self-lubricating sleeve type, Teflon with stainless steel or

fiberglass backing.

F. Disc pins: Secure valve disc to shaft by means of solid, smooth-sided, taper or dowel pins, Type 316 stainless steel: 1. Extend pins through shaft and mechanically secure in place.

G. Seats: 1. Material: Teflon, or Teflon with titanium back-up ring. 2. Seat retainer insert: Type 316 stainless steel.

H. Valve shaft packing: 1. Adjustable V-ring Teflon packing with Type 316 stainless steel packing gland.

2.03 BUTTERFLY VALVE ACTUATORS

A. Motorized actuators are specified in Section 40_05_57.23. Additional requirements for manual actuators are specified in Section 40_05_57.13.


B. Manual actuators for aboveground valves, 4 inches in nominal size and smaller for liquid service: 1. For valves operating at pressures up to and including 250 pounds per square

inch, provide hand lever type with locking device so that the valve can be locked in any position with a wing nut: a. Locking device: Rigid, allowing no vibration or chattering of the valve. b. Hand lever: 12 inches long, with handgrip.

C. Manual actuators for aboveground valves in nominal sizes and in service applications other than specified above, except for valves 30 inches and larger: 1. For valves operating at pressures up to and including 250 pounds per square

inch, provide either a totally enclosed worm gear actuator or a totally enclosed traveling nut actuator mounted on the valve.

D. Position indication: 1. For all aboveground worm gear or traveling nut manual actuators, provide

position indication on the actuator enclosure.

2.04 COATING

A. Shop coat interior and exterior metal surfaces of valves, except as follows: 1. Interior machined surfaces. 2. Surfaces of gaskets and elastomeric seats and stem seals. 3. Bearing surfaces. 4. Stainless steel surfaces and components.

B. Coating material for potable water applications: 1. Formulate coating material from materials in accordance with CFR 21.

C. Field applied coatings: 1. Additional coating of the valve exterior will be required to match the epoxy or

epoxy/polyurethane paint system.. a. When shop applied finish coating matches field applied coating on

adjacent piping, touch up shop coating in damaged areas in accordance with instructions recommended by the paint manufacturer.

b. When shop applied coating does not match field coating on adjacent piping, or when damage has occurred to the shop applied coating that requires more than touchup, blast clean valve surfaces or utilize other surface preparation recommended by the manufacturer of the coating material and apply the coating system used for coating adjacent piping.

D. Surface coatings: 1. Interior surfaces: High solids epoxy. 2. Exterior surfaces of valves, actuators, and accessories:

a. High solids epoxy with polyurethane topcoat. 3. Polished and machined surfaces: Apply rust-preventive compound.

E. Coating materials: 1. High solids epoxy:

a. Products: Match the field applied coating on adjacent piping: 1) Coating product in contact with potable water must be in accordance

with AWWA C550 and NSF 61.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install pipe spools or valve spacers in locations where butterfly valve disc travel may be impaired by adjacent pipe lining, pipe fittings, valves, or other equipment:

BUTTERFLY VALVE APPLICATION SCHEDULE Valve Type and Style Acceptable Applications

General Purpose AWWA Butterfly Valves – Flanged Body Design

Aboveground in the following service applications only: - Acceptable in all service applications except

oxygen and ozone service and high-pressure service.

General Purpose AWWA Butterfly Valves – Wafer (not lugged) Body Design

Not allowed.

Stainless Steel Butterfly Valves - Lugged Body Design

Aboveground in the following service applications only: - Oxygen Systems - Ozone Systems

Stainless Steel Butterfly Valves – Wafer (not lugged) Body Design

Not allowed.

END OF SECTION


SECTION 40_05_65.01

GATE, GLOBE, AND ANGLE VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: globe and angle valves.




1.02 REFERENCES

A. American Society of Mechanical Engineers (AMSE).

B. American Water Works Association (AWWA): 1. C515 - Standard for Reduced-Wall, Resilient-Seated Gate Valves for Water

Supply Services. 2. C 550 - Protective Interior Coatings for Valves and Hydrants.

C. ASTM International (ASTM): 1. B 98 - Standard Specification for Copper-Silicon Alloy Rod, Bar, and Shapes.

PART 2 PRODUCTS

2.01 GLOBE AND ANGLE VALVES

A. General purpose globe and angle valves: 1. Valves 3 inches and smaller:

a. Manufacturers: One of the following or equal as approved by the Engineer: 1) Except in welded steel piping:

a) Crane, No. 1 Globe or No. 2 Angle. b) Lunkenheimer Company Figure No. 2140 Globe or No. 2141

Angle. 2) In Welded steel piping:

a) Crane, No. 351. b) Lunkenheimer Company, Figure No. 1123; or equal as approved

by the Engineer with flanged ends. b. Design:

1) Size and configuration: Indicated on the Drawings. 2) Valve: Class 125 threaded ends, rated for 250 degrees Fahrenheit at

pressure of 170 pounds per square inch.


2. Valves larger than 3 inches: a. Manufacturers: One of the following or equal as approved by the

Engineer: 1) Crane, No. 351. 2) Lunkenheimer Company, Figure No. 1123.

b. Design: 1) Size and configuration: Indicated on the Drawings.

2.02 NEEDLE VALVES

A. Manufacturers: One of the following or equal as approved by the Engineer: 1. Powell, Figure No. 180. 2. Lunkenheimer Company, Figure No. 906-BS or No. 907-BS. 3. Crane No. 88 or No. 89.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install valves as specified in manufacturer’s instructions.

END OF SECTION


SECTION 40_05_67.37

PRESSURE REDUCING AND PRESSURE RELIEF VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Pressure reducing and pressure relief valves for water and oxygen service.




1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.42 - Ductile Iron Pipe Flanges and Flanged Fittings: Classes 150 and 300.

B. ASTM International (ASTM): 1. A 48 - Standard Specification for Gray Iron Castings. 2. A 536 - Standard Specification for Ductile Iron Castings.

C. Compressed Gas Association (CGA): 1. Standard G-4.1 - Cleaning Equipment for Oxygen Service.

D. Underwriters Laboratories, Inc. (UL).

1.03 SUBMITTALS

A. Manufacturer's installation instructions, description of operation, and shop drawings for all valves provided in this section.

PART 2 PRODUCTS

2.01 WATER PRESSURE RELIEF VALVES

A. Water pressure relief valves: 1. Manufacturers: The following, or equal:

a. Kunkle Valve, Model 911. 2. Design:

a. Direct spring operated, threaded cap for ASME Section VIII code applications.

b. Rated for 500 pounds per square inch gauge, minimum. c. End connections:

1) Smaller than 1 inch: threaded.


2) 1 inch and larger: 150 pound rated flanges in accordance with ASME B16.42.

3. Materials: a. Body and cover: 316 Stainless Steel. b. Valve trim and spring: 316 Stainless Steel.

2.02 OXYGEN/OZONE PRESSURE RELIEF VALVES

A. Oxygen/ozone pressure relief valves: 1. Manufacturers: One of the following, or equal as approved by the Engineer:

a. Anderson Greenwood and Company. b. Kunkle.

B. Cleaning and handling: Clean, seal, package, and handle valves for oxygen and ozone service in strict accordance with CGA Standard G-4.1.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install in accordance with the manufacturer's instructions.

END OF SECTION


SECTION 40_61_00

COMMON WORK RESULTS FOR PROCESS CONTROL AND INSTRUMENTATION SYSTEMS

PART 1 GENERAL

1.01 DESCRIPTION

A. Work included: This section covers instrumentation and controls work by the Ozone System Supplier, necessary for the Procurement Contract, including furnishing, calibrating, adjusting, testing, documenting, and starting up the new ozone system. The furnished ozone system shall be suitable for integration into the plant's new Honeywell Experion DCS for plant process control.

B. Major Constituents: Major constituents of this system shall include all materials, equipment, and work required to implement a complete and operating ozone system and shall include furnishing the following: 1. Primary elements and transmitters, analog display and control elements,

discrete primary elements, discrete display and control elements, control panels and panel mounted devices as shown, and associated ancillary devices.

2. Programmable logic controllers (PLC), and local operator interfaces (LOI). The ozone system supplier shall provide all required hardware, software, networking equipment, and all PLC and LOI programming for a complete, and operational stand-alone ozone system.

C. Related work specified elsewhere: 1. Section 01_11_00 - Summary of Work. 2. Section 01_33_00 - Submittal Procedures. 3. Section 01_41_00 - Regulatory Requirements. 4. Section 01_75_17 - Commissioning and Process Start-Up. 5. Section 01_78_23 - Operation and Maintenance Data. 6. Section 01_81_01 - Project Design Criteria. 7. Section 01_81_02 - Seismic Design Criteria. 8. Section 26_05_19 – Low- Voltage Electrical Power Conductors and Cables. 9. Section 26_05_53 - Identification for Electrical Systems. 10. Section 26_05_83 - Low Voltage Motors. 11. Section 26_29_23 - Low Voltage Variable Frequency Drives. 12. Section 40_61_05 - Packaged Control System. 13. Section 40_61_16 - Specific Control Strategies. 14. Section 40_71_13 - Flow Measurement: Magnetic Flowmeters. 15. Section 40_71_23.21 - Flow Measurement: Orifice Plate. 16. Section 40_71_79 - Flow Measurement: Switches. 17. Section 40_73_13 - Pressure/Vacuum Measurement: Gauges. 18. Section 40_73_23 - Pressure/Vacuum Measurement: Direct. 19. Section 40_73_29 - Pressure/Vacuum Measurement: Differential. 20. Section 40_73_36 - Pressure/Vacuum Measurement: Switches.


21. Section 40_73_63 - Pressure/Vacuum Measurement: Diaphragm and Annular Seals.

22. Section 40_73_64 - Pressure/Vacuum Measurement: Instrument Valves. 23. Section 40_74_13 - Temperature Measurement: RTD. 24. Section 40_74_43 - Temperature Measurement: Temperature Gauge. 25. Section 40_74_66 - Temperature Measurement: Temperature Switch. 26. Section 40_75_85 - Analyzers: Dew Point. 27. Section 40_76_13 - Analyzers: Gas Monitors. 28. Section 40_80_01 - Testing, Calibration, and Commissioning. 29. Section 40_94_33 - Local Operator Interfaces (LOIs). 30. Section 40_94_43 - Programmable Logic Process Controllers. 31. Section 40_95_13 - Process Control Panels and Hardware. 32. Section 46_31_52 - Ozone Systems: General. 33. Section 46_31_54 - Supplemental Nitrogen Equipment. 34. Section 46_31_55 - Ozone Generating Equipment. 35. Section 46_31_57 - Ozone Destruction Equipment. 36. Section 46_31_58 - Cleaning for Oxygen and Ozone Service. 37. Section 46_31_59 - Ozone System Testing.

1.02 DIVISION OF WORK

A. OSS: The OSS shall have overall ozone system responsibility and shall provide all materials and work necessary satisfy all requirements of this Division 40.

B. Minimum OSS Scope: The selected pre-purchase OSS shall provide the following minimum scope of work: 1. For control panels, components, and ancillaries specified under the pre-

purchase contract provide the following: a. Coordinating to ensure that:

1) The proper type, size, and number of signal wires with their raceways are provided and installed.

2) The proper electrical power circuits with their raceways are provided and installed.

3) The proper size, type, materials of construction, and connections of process mechanical piping are provided and installed for in-line primary elements.

2. Provide panels, components, and ancillaries. 3. Provide and install all skid mounted instrumentation. 4. Provide and install PLCs, and OIUs. 5. Provide the specified submittals. 6. Provide instructions, details, and advice to, and coordinating with, the future

installing Contractor to ensure proper installation. 7. Certify correctness of installations. 8. Verify final power and signal connections and labeling (lugging and

connecting). 9. Adjust and calibrate instruments and components. 10. Startup and testing support.


1.03 COORDINATION MEETINGS

A. Coordination meetings shall be held periodically during the course of the separate ozone system installation project. The OSS shall participate in all required coordination meetings and shall summarize resolutions reached in each coordination meeting and send a copy to the Owner and Engineer. The OSS shall provide for a minimum of four such meetings.


A. Codes and Standards: Unless otherwise specified herein, or shown on the drawings, work under this specification shall be performed in accordance with the following codes, standards and publications to the extent indicated by the references herein. The date of issue or version shall be the current version at time of bid. Any conflict among these standards shall be brought to the attention of the Engineer for clarification and final ruling. 1. NFPA Standard 70 National Electrical Code 2. IEEE Standard 472 Electrical Surge Protection 3. EIA Standard RS-232-C Interface between data terminal equipment and data

communication equipment employing serial binary data interchange 4. EIA Standard RS-485 Electrical characteristics of balanced voltage digital

interface circuits 5. NEMA ICS6 Enclosures for Industrial Controls and Systems 6. SAMA PMC-33.1 Electromagnetic Susceptibility of Process Control

Instrumentation 7. IEEE 472 Electrical Surge Protection 8. ISA S5.1 Instrumentation Symbols and Identification 9. ISA S20 Specification Forms for Process Measurement and Control

Instruments, Primary Elements and Control Valves

B. Underwriters Laboratories Inc.: Unless otherwise specified, electrical equipment and material shall be listed and labeled for the purpose for which it is used by the Underwriters Laboratories Inc. (UL). All control panels provided under this Division 40 shall have a UL stamp and be constructed by a UL approved panel fabrication shop.

C. Seismic design requirements: See Section 01_81_02, Seismic Design Criteria for seismic requirements, including structural integrity, anchorage, and proof of compliance.

D. All components shall be new and of the specified quality, constructed of durable materials, and designed for long life in continuous service with a minimum of maintenance.

E. All mechanisms shall be enclosed in such a manner that they shall be protected against damage from dust, moisture, or striking by external objects.

F. Where shown in the specifications or on the drawings, components shall comply with the referenced codes and standards.

G. All freestanding or floor-mounted equipment shall be front aligned


1.05 SUBMITTALS

A. General: In addition to the requirements of Section 01_33_00 Submittals Procedures, the following requirements shall be satisfied for submittals relating to work provided under Division 40 and for all vendor submittals: 1. All submittals shall be complete, neat, orderly, indexed with labeled tab

dividers. Partial submittals shall not be accepted. Submittals shall either be bound in a three-ring binder or provided in an electronic format as specified in Section 01_31_23.10.

2. The number of final copies for each submittal shall be in accordance with Section 01_33_00 unless otherwise noted. Submittals may be broken down into smaller packages with the approval of the Engineer.

B. Design-Related Submittals: 1. Design. 2. Hardware. 3. Application Software.

C. Spares, Expendables, and Test Equipment Lists: 1. Before any components are fabricated, and/or integrated into assemblies, or

shipped to the site, furnish to the District, and receive for review of full details, shop drawings, catalog cuts, and such other descriptive matter and documentation as may be required to fully describe the equipment and options proposed and to demonstrate its conformity to these specifications. The decision of the District upon the acceptability of any submittal shall be final. Catalog information shall be submitted for all equipment, regardless of whether or not it is of the same manufacture as that listed in the specifications.

2. All submittals shall be complete, neat, orderly, and tabbed. Partial submittals shall not be accepted. All components shall be referenced by the instrument tag name designations shown. List proposed exceptions and/or deviations to these Contract Documents contained in each submittal.

3. If, in the opinion of the District, a submittal is not clear, it will be returned to the OSS and it shall be revised and resubmitted.

D. Design-Related Submittals: 1. Design:

a. Submit full details, panel fabrication drawings, panel power distribution drawings, wiring diagrams, panel arrangement drawings, catalog cuts, and such descriptive literature and documentation as may be required to demonstrate conformance to these drawing and specifications. These submittals shall clearly identify specific items and options proposed to be provided. In addition, these submittals shall clearly identify installed spares and other provisions for future work (e.g., reserved panel space; unused components, wiring, terminals, etc.).

b. All design drawings, panel drawings, wiring diagrams, loop diagrams, and interconnection diagrams shall be drafted using the latest version of AutoCAD or MicroStation. Drawings shall be developed in accordance with the District's procedures and standards, copies of which are available on request.

c. Legends and Abbreviations Lists: As part of the first Design-Related Submittals for each subsystem, submit a complete definition of symbols


and abbreviations used on this project. For example: engineering units, flow streams, instruments, structures, and other process items used in nameplates, legends, data sheets, and point descriptions. The same abbreviations shall be used through the design subsystems. Submit updated versions with subsequent submittals and a final version with the O&M Manuals.

d. Submit complete, detailed panel elementary diagrams of all pre-wired panels. Diagrams shall be similar to those typical diagrams shown on the drawings, but with the addition of all the auxiliary devices such as relays, alarms, fuses, circuit breakers, lights, fans, heaters, etc. Provide panel control diagrams for all discrete control and power circuits. Diagrams shall be ladder type schematic diagrams similar to the typical diagrams shown in the drawings, but shall include all devices requiring electrical connections. Panel control diagrams shall identify all wire numbers and types, terminal numbers, tag numbers, and PLC input/output I/O identification (rack and slot) numbers. Control diagrams shall show all circuits individually; no common diagrams will be allowed. Line numbers and sheet numbers shall reference relay contacts. Where multiple relays are required, their coils shall be wired parallel. All discrete devices shall be labeled to define their switching action (close on rising or close on falling process variable.

e. Submit interconnecting wiring diagrams showing all component and panel terminal board identification numbers and external wire numbers in the same format as shown on the drawings. Wiring tables or wire lists will not be considered as a suitable substitute for these drawings unless approved by the District. These diagrams shall include all intermediate terminations between field elements and panels (e.g., terminal junction boxes, motor control centers, etc.). These diagrams shall be coordinated with the installing Contractor and shall bear a statement that this has been done. Reference the drawings for a typical interconnecting wiring diagram showing the format to be used. These drawings shall be provided to the installing Contractor for wiring system coordination and shall be used to provide wire numbers on the field wiring that is identical to the panel wire number. When wire numbers are not shown on the drawings, the OSS shall contact the District to obtain wire numbers.

f. Submit power requirement and heat dissipation summary for all control panels. Power requirements shall state required voltages, currents, and phases(s). Heat dissipations shall be maximums and shall be given in Btu/hr. Summaries shall be supplemented with calculations. Provide complete panel power distribution wiring diagrams for each control panel.

g. Panel Construction Drawings: Submit shop drawings and catalog material for all control and field panels, instrument racks, and enclosures. Drawings shall be to scale and shall show the location of all panel mounted devices as well as doors, louvers, and sub-panels. Drawings shall include a panel legend and a bill of materials. The panel legend shall list and identify all front of panel devices by their assigned tag numbers, all nameplate inscriptions, service legends, and annunciator inscriptions. The bill of materials shall list all devices mounted within the panel that are not listed in the panel legend, and shall include the tag number, description, manufacturer, and model number for each.


h. Panel Plumbing Diagrams: Diagrams for each panel containing piping and/or tubing shall be submitted showing pipes/tubes (size and materials); components (type, size, and materials); connections to panel mounted devices (size and type); and panel interface connections (size and type).

i. Submit drawings showing any modifications or additional details as may be required to supplement the Contract Documents and adequately define the installation of the ozone system elements.

j. Submit seismic calculations In accordance with Section 01_81_02. 2. Hardware:

a. Bill of Materials: Submit a listing of all the panels, racks, instruments, PLCs, LOIs, and equipment supplied as a part of the ozone system. All components shall be grouped by component type. Submit the list in electronic format in a Microsoft Access compatible file and contain, as a minimum, the following: 1) Tag number. 2) Instrument, panel, rack or device, tag number. 3) Description. 4) Quantity supplied. 5) Reference to component data sheet and catalog cut. 6) Component type. 7) Manufacturer. 8) Model number. 9) Part number. 10) Calibration information. 11) Wiring diagram sheet or drawing number. 12) Electrical, and process drawing sheet or drawing number.

E. Submit catalog information, descriptive literature, wiring diagrams (showing internal wiring and external connections for power and signal), and shop drawings for all recorders, indicators, transmitters, primary elements, flowmeters, PLCs, I/O modules, LOIs, networking equipment and appurtenances, and all other components of the ozone system. Also, provide catalog information on all electrical devices furnished under this Division 40 (for example: power supplies, relays, surge suppressors, terminal blocks, circuit breakers, heaters, thermostats, lighting, enclosures and electrical cabinets, fans, louver kits, etc.).

F. Individual data sheet (or specification) listing shall be provided for all components provided under this Division 40 and by the ozone system supplier. The purpose of these data sheets is to supplement the generalized catalog information provided by citing all specific features for each specific component (e.g.: manufacturer, model number, scale range, set point, materials of construction, special options included, etc.). Each component data sheet shall bear the component name and instrument tag number designation shown in the drawings and Specifications. All data sheets shall use the ISA format and shall be done using Microsoft Word, Excel, or Access with two copies of the disk files delivered to the District at the end of the project.

G. Submit catalog information on all electrical devices furnished under this Division 40 and for all ozone system components.


H. Submit shop drawings and catalog material for all control panels and enclosures. Provide control panels sized as shown on the drawings. Where control panel dimensions have not been shown, size panels with a minimum of 30 percent spare usable space horizontally and vertically on all internal and external panel surfaces and mounting panels. Drawings shall be to scale and shall show the location of all panel mounted devices (such as terminal blocks, relays, wire ducts, power supplies, color coding of terminal strips, nameplates, etc.) as well as doors, louvers, and subpanels. Drawings shall include a panel legend and a bill of materials. The panel legend shall list and identify all front of panel devices by their assigned tag numbers, all nameplate inscriptions, service legends, and annunciator inscriptions. The bill of materials shall list all devices mounted within the panel that are not listed in the panel legend, and shall include the tag number, description, manufacturer, and model number for each.

I. O&M Manual Submittals: 1. O&M manuals shall be submitted in accordance with Section 01_33_00.

1.06 TESTING

A. Testing shall be performed in accordance with Section 01_75_17 and Section 40_80_01 Testing, Calibration, and Commissioning.

1.07 TRAINING

A. Training shall be performed in accordance with Section 01_75_17 and Part 3 below.

1.08 TECHNICAL REQUIREMENTS

A. General: 1. The OSS shall furnish the ozone system which shall be capable of performing

the following functions: a. Measure and monitor discrete and continuous process and process

equipment variables for the ozone system. b. Effectively present the process and process equipment variables to the

operators to allow them to accurately monitor and change the status of the plant's processes for the ozone system.

B. Control, status, alarm, and indication functions are shown on the drawings in Process and Instrumentation Diagram (P & ID) form in accordance with the Instrumentation Society of America (ISA), Standard S5.1, except as noted. These drawings show the functional requirements and general location of each function to be provided.

C. Like items of equipment of the ozone system shall be the end products of one manufacturer and of the same series or family of models in order to achieve standardization for appearance, operation, maintenance, spare parts, and manufacturer's services. All same or similar functions shall be implemented in the same or similar manner. For example, control logic, sequence controls, display layouts, etc.


1.09 DEFINITIONS

A. Signal Characteristics: 1. Analog signals are 4 to 20 mA dc and shall conform to the compatibility

requirements of ISA S50.1. Unless otherwise noted, circuits shall be ISA S50.1, Type 2, two-wire. Transmitters shall have a load resistance capability conforming to Class L. Transmitters and receivers shall be fully isolated. Within panels where a common 1 percent dropping resistor is used, analog signals are 1 to 5 Vdc.

2. Discrete signals are two-state logic signals and shall use 24VDC or 120 VAC sources as noted.

3. Digital signals are binary coded signals.

B. Definitions of terms and other electrical and instrumentation considerations as set forth in the: 1. Factory Mutual or FM Global (FM). 2. Institute of Electrical and Electronic Engineers (IEEE). 3. InterNational Electrical Testing Association (NETA). 4. International Electrotechnical Commission (IEC). 5. International Organization for Standardization (ISO). 6. International Society of Automation (ISA). 7. National Electrical Code (NEC). 8. National Fire Protection Association (NFPA). 9. National Institute of Standards and Technology (NIST). 10. Underwriter Laboratories (UL).

C. NEMA: 1. Type 1 enclosure in accordance with NEMA 250. 2. Type 3R enclosure in accordance with NEMA 250. 3. Type 4 enclosure in accordance with NEMA 250. 4. Type 4X enclosure in accordance with NEMA 250. 5. Type 6 enclosure in accordance with NEMA 250. 6. Type 6P enclosure in accordance with NEMA 250. 7. Type 12 enclosure in accordance with NEMA 250.

D. Specific definitions: 1. Control circuit: Any circuit operating at 120 volts alternating current (AC) or

direct current (DC) or less, whose principal purpose is the conveyance of information (including performing logic) and not the conveyance of energy for the operation of an electrically powered device.

2. Panel: An instrument support system that may be either a flat surface, a partial enclosure, or a complete enclosure for instruments and other devices used in process control systems. Unless otherwise specified or clearly indicated by the context, the term “panel” in these Contract Documents is interpreted as a general term, which includes flat surfaces, enclosures, cabinets and consoles.

3. Power circuit: Any circuit operating at 90 volts (AC or DC) or more, whose principal purpose is the conveyance of energy for the operation of an electrically powered device.

4. Signal circuit: Any circuit operating at less than 50 volts AC or DC, which conveys analog information or digital communications information.


5. Digital Bus: A communication network, such as Profibus, Foundation Fieldbus, or DeviceNet, allowing instruments and devices to transmit data, control functions, and diagnostic information.

6. 2-Wire transmitter (loop powered): A transmitter that derives its operating power supply from the signal transmission circuit and requires no separate power supply connections. As used in this Section, 2-wire transmitter refers to a transmitter that provides 4 to 20 mA current regulation of a signal in a series circuit with an external 24 VDC driving potential: a. Field Bus Communications signal or both.

7. Powered transmitters: A transmitter that requires a separate power source (120 VAC, 240 VAC, etc.) in order for the transmitter to develop its signal. As used in this Section, the produced signal may either be a 4 to 20 mA current signal, a Digital Bus communications signal or both.

8. Hardwired control: Control circuitry that does not utilize software to initiate functionality.

9. Hardwired interlocks: A safety or protective feature that will interrupt operation of the equipment in all operating modes with no required operator intervention.

10. Software interlocks: A safety or protective feature that will interrupt operation of the equipment when the RTU has control.

11. The term “panel” in this Section is interchangeable with the term “enclosure.”

E. Acronym definitions: 1. CCS: The PCS central computer system (CCS) consisting of computers and

software. The personal computer-based hardware and software system that includes the operator interface, data storage, data retrieval, archiving, alarming, historian, reports, trending, and other higher level control system software and functions.

2. DCS: Distributed Control System. 3. DPDT: Double-pole, double-throw. 4. ES: Enterprise system: Computer based communications or data sharing

system utilized for non-process control functions such as E-mail, sharing files, creating documents, etc.

5. FAT: Factory acceptance test also known as Source Test. 6. HART: Highway addressable remote transducer. 7. HOA: Hand-Off-Auto control function that is totally PLC based. In the Hand

mode, equipment is started or stopped, valves are opened or closed through operator direction under the control of the PLC software. In the Auto mode, equipment is started or stopped and valves are opened or closed through a control algorithm within the PLC software. In the Off mode, the equipment is prohibited from responding from the PLC control.

8. HMI: Human machine interface is a software application that presents information to an operator or user about the state of a process, and to accept and implement the operators control instructions. Typically information is displayed in a graphical format.

9. ICSC: Instrumentation and control system contractor: Subcontractor who specializes in the design, construction, fabrication, software development, installation, testing, and commissioning of industrial instrumentation and control systems.

10. IJB: Instrument junction boxes: A panel designed with cord sets to easily remove, replace or relocate instrument signals.

11. I/O: Input/Output.


12. IP: Internet protocol or ingress protection. 13. LCP: Local control panel: Operator interface panel that may contain an HMI,

pilot type control devices, operator interface devices, control relays, etc. and does not contain a PLC or RIO.

14. LAN: Local area network: A control or communications network that is limited to the physical boundaries of the facility.

15. LOI: Local Operator Interface is an operator interface device consisting of an alphanumeric or graphic display with operator input functionality. The LOI is typically a flat panel type of display mounted on the front of an enclosure with either a touch screen or tactile button interface.

16. LOR: Local-Off-Remote control function. In the Remote mode, equipment is started or stopped, and valves are opened or closed through the PLC based upon the selection of the HOA. In the Local mode, equipment is started or stopped, valves are opened or closed based upon hardwired control circuits completely independent of the PLC with minimum interlocks and permissive conditions. In the Off mode, the equipment is prohibited from responding to any control commands.

17. NJB: Network junction box. An enclosure that contains multiple access points to various networks within the facility. Networks could be Ethernet, Ethernet/IP, Fieldbus, RIO etc.

18. P&ID: Process and instrumentation diagram. 19. PC: Personal computer. 20. PCIS: Process control and instrumentation system: Includes the entire

instrumentation system, the entire control system, and all of the Work specified in the Instrumentation and Control Specifications and depicted on the Instrumentation Drawings.

21. PCM: Process control module: An enclosure containing any of the following devices: DCS Controller, PLC, RTU, or RIO.

22. PCS: Process Control System: A general name for the computerized system that gathers and processes data from equipment and sensors and applies operational controls to the process equipment. It includes the DCS controllers, PLCs and/or RIOs, LOIs, HMIs, both LCPs, VCPs and all data management systems accessible to staff.

23. PJB: Power junction box: An enclosure with terminal blocks that distribute power to multiple instruments.

24. PLC: Programmable logic controller. 25. RIO: Remote I/O device for the PLC consisting of remote I/O racks, or remote

I/O blocks. 26. RTU: Remote telemetry unit: A controller typically consisting of a PLC, and a

means for remote communications. The remote communications devices typically are radios, modems, etc.

27. SCADA: Supervisory control and data acquisition system: A general name for the computerized system that gathers and processes data from sensors and equipment located outside of the facility, such as wells, lift stations, metering stations etc.

28. SPDT: Single-pole, double-throw. 29. SPST: Single-pole, single-throw. 30. UPS: Uninterruptible power supply.


31. VCP: Vendor control panel: Control panels that are furnished with particular equipment by a vendor other than the ICSC. These panels may contain PLCs, RIO, LOI, HMI, etc.

32. WAN: Wide area network: A control or communications network that extends beyond the physical boundaries of the facility.

1.10 NAMETAGS

A. All components provided under this Division 40, both field and panel mounted, shall be tagged, and identified in accordance with Section 26 05 53 Identification for Electrical Systems.

1.11 GENERAL

A. Install materials and equipment in a workmanlike manner utilizing craftsmen skilled in the particular trade. Provide work that has a neat and finished appearance.

1.12 EQUIPMENT FINISH

A. Provide materials and equipment with manufacturer's standard finish. Provide manufacturer's standard finish color, except where specific color is indicated or specified. If manufacturer has no standard color, finish equipment with light gray color.

1.13 PANELS AND PANEL MOUNTED EQUIPMENT

A. Panels and panel-mounted equipment shall be assembled as far as possible at the OSS's panel shop or supplier. No work, other than correction of minor defects or minor transit damage, shall be done on the panels at the jobsite.

1.14 SPECIALTY EQUIPMENT

A. For ozone system components furnished by the OSS, the services of qualified manufacturer's representative shall be provided during installation, startup, and demonstration testing and District training.

1.15 WIRING

A. Plastic ducts or ties shall restrain all wiring within OSS panels and enclosures. Major runs of wiring inside panels shall be installed in plastic ducts. Hinge wiring shall be secured at each end so that any bending or twisting will be around the longitudinal axis of the wire and the bend area shall be protected with a sleeve. 1. Arrange wiring neatly, cut to proper length, and remove surplus wire. All panel

wires shall be terminated with ferrules of proper size. Provide abrasion protection for any wire bundles that pass through holes or across edges of sheet metal.

2. No more than two wires may be installed on a single screw terminal. Where crimp connections are used, crimper shall be the ratchet type.

3. For connections to compression clamp type terminals; strip, prepare, and install wires in accordance with the terminal manufacturer's recommendations. No more than one wire shall be installed in each compression screw and yoke.


4. Wiring shall not be spliced or tapped except at device terminals or terminal blocks. All wiring connections shall be made by terminal blocks, including signal ground shields.

5. 24 Vdc and analog signal circuits shall be terminated on color coded terminal blocks separate from color coded ac circuit terminal blocks.

6. Separate all analog and other dc circuits at least 6 inches from any ac power and control wiring, except at unavoidable crossover points and at device terminations. Where crossover points exist, they shall cross at right angles.

7. Conductor tags shall be provided as specified in Section 26_05_19 and Section 26_05_53 and as shown on the drawings.

1.16 INSPECTIONS

A. All materials, equipment, and workmanship shall be subject to inspection at any time by the District. Correct any work, materials, or equipment not in accordance with these Contract Documents or found to be deficient or defective in a manner satisfactory to the District at no additional cost to the District.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Provide similar items from a single manufacturer throughout the ozone system.

B. Allowable manufacturers are specified in individual instrument and equipment specifications.


2.03 MATERIALS

A. Furnish all materials under this Contract that are new, free from defects, and standard products produced by manufacturers regularly engaged in the production of these devices and that bear all approvals and labels as required by the Specifications.

B. Provide materials complying with the applicable industrial standard as specified in the Contract Documents.



2.06 COMPONENTS

A. Furnish all meters, instruments, and other components that are the most recent field proven models marketed by their manufacturers at the time of submittal of the shop drawings unless otherwise specified to match existing equipment.


B. Unless otherwise specified, furnish individual instruments that have a minimum accuracy of within 0.5 percent of full scale and a minimum repeatability of within 0.25 percent of full scale.

C. Signal transmission: 1. Analog signals:

a. Furnish analog measurements and control signals that vary in direct linear proportion to the measured variable, unless otherwise indicated.

b. Furnish electrical analog signals outside control panels that are 4 to 20 milliamperes 24 VDC, except as indicated.

c. Analog signals within enclosures may be 1 to 5 VDC. d. Electrically or optically isolate all analog signals from other signals. e. Furnish regulated analog signals that are not affected by changes in

supply voltage or load resistance within the unit’s rating. f. Maintain the total 4 to 20 milliamperes loop impedance to 10 percent

below the published value at the loop operating voltage. g. Where necessary, reduce loop impedance by providing current-to-current

(I/I) isolation amplifiers for signal re-transmission. 2. Discrete input Signals:

a. As indicated in the controller hardware specification. 3. Discrete output signals:

a. Dry contacts or TRIAC outputs (with express written approval by the Engineer) as needed to coordinate with the field device.

b. Provide external terminal block mounted fuse with blown fuse indication for all discrete outputs.

c. Provide interposing relays for all discrete outputs for voltage and/or current compatibilities.

d. Provide interposing relays as required for functionality of the control circuit.

4. Signal Performance and Design Criteria: a. Stability:

1) After Control have taken corrective action, oscillation of the final control element shall not exceed 2 cycles per minute or a magnitude of motion of 0.5 percent of full travel.

b. Response: 1) Any change in setpoint or controlled variable shall produce a

corrective change in position of the final control element and stabilized within 30 seconds.

c. Agreement: 1) Setpoint indication of controlled variable and measured indication of

controlled variable shall agree within 3 percent of full scale over a 6:1 operating range.

d. Repeatability: 1) For any repeated magnitude of control signal, from either an

increasing or decreasing direction, the final control element shall take a repeated position within 0.5 percent of full travel regardless of force required to position the final element.

e. Sensitivity: 1) Controls shall respond to a setpoint deviations and measured

variable deviations within 1.0 percent of full scale.


f. Performance: 1) All instruments and control devices shall perform in accordance with

the manufacturers’ specifications.

D. Discrete circuit configuration: 1. Configure discrete control circuits to fail safe, on loss of continuity or loss of

power. 2. Alarm contacts: Fail to the alarm condition. 3. Control contacts fail to the inoperative condition unless otherwise indicated on

the Drawings.

2.07 ACCESSORIES

A. Provide flow conditioning devices or other required accessories if necessary to meet the accuracy requirements in the Contract Documents.

B. Nameplates: 1. Provide a nameplate for each controller, instrument transducer, instrument

power supply, solenoid, or any other control device located either in the field or within panels.

2. All nameplates shall be of identical style, color, and material throughout the facility.

3. Device nameplates shall include: a. Designations as indicated on the Drawings and identified on the Process

and Instrumentation Drawings: 1) Device tag and loop number ID. 2) PLC ID. 3) Power information.

b. White lettering on a black background, laminated plastic. 4. All instruments shall be equipped with Type 316 stainless steel nameplate with

the instrument tag stamped in 3/8-inch letters and connected to the instrument using Type 316 stainless steel wire.





A. Provide all equipment that is new, free from defects, and standard products produced by manufacturers regularly engaged in the production of these products that bear all approvals and labels as required by the Specifications.

B. Arrange with all manufacturers of the equipment and fabricators of panels and cabinets, to allow the Owner and Engineer to inspect and witness the testing of the equipment at the site of fabrication: 1. Equipment includes the cabinets, special control systems, flow measuring

devices, and other pertinent systems and devices.


C. Source Test is specified in Section 40_80_01.

PART 3 EXECUTION



3.03 INSTALLATION (NOT USED)






B. Owner Training: 1. Demonstration requirements are specified in Section 40_80_01. 2. Training specified in this Section shall be included as part of the training

services specified in Section 46_31_52. 3. General:

a. Provide system maintenance and operator training courses for the ozone instrumentation and ozone control systems furnished.

b. Tailor training classes to the specific needs of the class participants: 1) Develop separate courses for operators, maintenance staff, and

supervisors. c. Schedule individual training classes per Section 01_75_17 d. Instructor qualifications per Section 01_75_17

4. Training course requirements: a. Operator training:

1) Furnish training courses that instruct system operators in the efficient operation of OSS-provided aspects of the ozone control system that include not only the general operation of each control system but also the operation of specific system features.

2) Operator’s training shall include the following for each vendor package and programmable device: a) Control system overview: Architecture, equipment functions,

software components, etc. including flow charts for all programming and controls.

b) Display navigation, overview, and types of displays. c) Process and equipment monitoring and control: Basic principles

and operation. d) Logging ON and OFF the system and description of the security

and access system. e) Alarm subsystem.


f) Trending: Provide a thorough session on how to use all trending functions.

g) Reports: How to access, print, and review content. h) Control strategies: Present an average 15-minute review of

each control strategy, including a hands-on demonstration of screens and operator functions for each.

b. PLC and LOI software training: 1) Furnish a minimum of 8 hours training on project specific PLC

software: a) Project-specific PLC software training covers the programming

conventions, new standardized software modules, specific control strategy programs, and documentation created for the Work performed under this Contract. This training includes the specific knowledge needed to modify, expand, duplicate, troubleshoot, and repair the PLC and LOI programs provided under this Contract, provided by a qualified individual who is thoroughly familiar with the delivered system, and is one of the senior programmers who programmed the PLCs and LOIs for this Project.

c. Follow-up training: 1) Provide a series of on-site follow-up training classes beginning after

process start-up of the ozone system. The intent for these classes is to provide the Owner’s personnel the opportunity for a review and “refresher” of the training topics and material after they have had some experience using the system.

2) Mutually schedule and develop the content of these classes with the Owner no later than 1 month before the beginning of the first session: a) Schedule at the Owner’s discretion on non-consecutive days

spaced out over the process start-up and warranty period. d. Instrumentation training:

1) Furnish training covering all instruments and control panels. 2) Train maintenance staff in the use, cleaning, calibration,

maintenance, and troubleshooting of all the instruments furnished within this Project.

3) Furnish training on the operation of new hardwired controls. e. Analytical instrument training:

1) Furnish training covering all analytical instruments. 2) Train maintenance staff in the use, cleaning, calibration,

maintenance, and troubleshooting of all the analytical instruments furnished within this Project.

3) Provide training by manufacturer.


3.09 ADJUSTING

A. Control valves: 1. Stroke all control valves, cylinders, drives and connecting linkages from the

control system as well as local control devices and adjust to verify proper


control action, hand switch action, limit switch settings, torque settings, remote control actions, and remote feedback of valve status and position.

2. Check control valve actions and positioner settings with the valves in place to ensure that no changes have occurred since the bench calibration.

B. Make all revisions necessary to the ozone control system software, as directed by the Engineer: 1. It is understood that the Contractor knows and agrees that changes will be

required in the control system software during the Source Testing, Functional Testing, Process Operational Period, Process Start-up and during the Project Correction Period.

3.10 CLEANING

A. All oxygen service devices including piping, valves and all appurtenances shall be cleaned for oxygen service and certified by a qualified inspector prior to placing into service. For additional requirements refer to Specifications Section 46_31_58.

B. Vacuum clean all control panels and enclosures before process start-up and again after final completion of the project.

C. Clean all panel surfaces.

D. Return to new condition any scratches and/or defects.

E. Wipe all instrument faces and enclosures clean.

F. Leave wiring in panels, manholes, boxes, and other locations in a neat, clean, and organized manner: 1. Neatly coil and label all spare wiring lengths. 2. Shorten, re-terminate, and re-label excessive spare wire and cable lengths, as

determined by the Engineer.

G. As specified in other sections of the Contract Documents.

3.11 PROTECTION

A. Protect all Work from damage or degradation until date of Substantial Completion.


A. The provided information does not necessarily include all required instruments. Furnish all instruments identified on the Contract Drawings or in the Contract Specifications. If an instrument is shown on one of these documents, it shall be considered to be shown on all.

B. Produce completed Instrument data sheets for all instruments required under this Contract: 1. Submit all instrument data sheets for review. 2. Furnish instrument data sheets in both hard copy and electronic format.


C. The instrument data sheets are included as a guideline for the supply of instruments. The data sheets are not complete; some information needed to order and specify the required instruments is not included.

D. The P&IDs are intended as a guideline for the supply of instruments. Some information needed to order and specify the required instruments is not included.

END OF SECTION


SECTION 40_61_05

PACKAGED CONTROL SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. General requirements for a Master Ozone Control Panel (MOCP), designed to

monitor and control all skids and ancillary equipment furnished for each skid, local vendor control panels at each skid, local vendor control panels for other furnished equipment, and field instruments required for a complete package ozone control system.




3. The following Sections are related to the Work described in this Section. This list of related sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 01_41_00 - Regulatory Requirements. c. Section 01_75_17 - Commissioning and Process Start-Up. d. Section 01_81_02 - Seismic Design Criteria. e. Section 26_05_53 - Identification for Electrical Systems. f. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. g. Section 40_80_01 - Testing, Calibration, and Commissioning. h. Section 40_94_33 - Local Operator Interfaces. i. Section 40_94_43 - Programmable Logic Process Controllers. j. Section 40_95_13 - Process Control Panels and Hardware.

1.02 REFERENCES

A. Code compliance: 1. As specified in Section 01_41_00:

a. The publications are referred to in the text by basic designation only. The latest edition accepted by the Authority Having Jurisdiction of referenced publications in effect at the time of Bid governs.

2. The following codes and standards are hereby incorporated into these Specifications: a. Institute of Electrical and Electronics Engineers:

1) C62.41.1 - IEEE Guide on the Surge Environment in Low-Voltage (1000V and less) AC Power Circuits.

b. International Society of Automation (ISA): 1) 5.4 - Instrument Loop Diagrams.


2) 20 - Specification Forms for Process Measurement and Control Instruments, Primary Elements, and Control Valves.

c. National Electrical Manufacturer's Association (NEMA): 1) 250 - Enclosures for Electrical Equipment (1,000 Volts Maximum).

d. National Fire Protection Association (NFPA). e. Underwriters Laboratories Inc. (UL):

1) 508C - Power Conversion Equipment. 2) 489 - Molded-Case Circuit Breakers, Molded-Case Switches, and

Circuit-Breaker Enclosures. 3) 913 - Standard for Intrinsically Safe Apparatus and Associated

Apparatus for Use in Class I, II, III, Division 1, Hazardous (Classified) Locations.

4) 1283 - Standard for Electromagnetic Interference Filters. 5) 1449 - Transient Voltage Surge Suppressors.

1.03 DEFINITIONS



A. Master Ozone control panel (MOCP): 1. PLC processors, power supplies, I/O backplanes, I/O modules and

communications modules sized for connected I/O and required spares. 2. Main and Hot standby PLC processors with all required modules, software,

and cables. 3. LOI on the face of the MOCP enclosure for monitoring and control of the

ozone control system. 4. Ethernet IP communication equipment to provide communications with existing

plant Honeywell DCS. 5. Uninterruptable power supply connections to interface with UPS provided by

others. 6. The MOCP shall exercise control over all aspects of the ozone control system. 7. All PLC and LOI programming required for fully functional ozone control

system.

B. Other ozone control panels: 1. Provide each ozone skid with a power supply unit control panel. 2. Provide LOX and ozone destruct units' remote I/O control panels. 3. PLCs, I/O modules, and all equipment necessary to interface with the MOCP.

C. Field instruments for process and equipment monitoring.

1.05 SUBMITTALS

A. General: 1. All control panel hardware submittals shall be as specified in Section

01_33_00 and Section 40_61_00.


B. Process control and LOI software submittal: 1. A complete listing of the PLC system point I/O database:

a. Include for each data point, relevant parameters such as range, contact orientation, limits, incremental limits, I/O card byte, I/O hardware address, and PLC assignment.

b. Organize on a site-by-site basis, separate by point type. c. In addition to the active l/O points, list the implemented spare l/O points

and the available l/O points remaining on each card, as well as other defined future points specified or shown.

2. Preliminary LOI screens, including pop-ups, trends, and alarm screens. Provide electronic and hard copy.

3. Final LOI screens for use by the DCS Programmer in developing graphic screens for Honeywell DCS. Provide electronic and hard copy.

4. Provide a complete, documented listing of all PLC codes.

C. Testing submittal: 1. For each test specified in this Section, prepare and submit complete test

plans, test procedures, test forms, test binders, and test reports, and other submittals, as specified below.

2. Submit manufacturer’s certifications and manufacturer’s field reports where required.

3. Submit Test plans, procedures, forms, and binders for approval by the Engineer before scheduling or performing tests.

4. Additional test form and test procedure requirements are specified with individual test requirements.


A. Quality assurance requirements shall be as specified in Section 46_61_00.


A. Shipping precautions: 1. After completion of shop assembly and successful Source Testing, pack all

equipment, cabinets, panels, and consoles in protective crates and enclose in heavy duty polyethylene envelopes or secured sheeting to provide complete protection from damage, dust, and moisture.

2. Place dehumidifiers when required, inside the polyethylene coverings. 3. Skid-mount the equipment for final transport. 4. Provide lifting rings for moving without removing protective covering. 5. Display boxed weight on shipping tags together with instructions for unloading,

transporting, storing, and handling at the job site.

B. Tagging: 1. Tag each component and/or instrument to identify its location, instrument tag

number, and function in the system. 2. Firmly attach a permanent tag indelibly machine marked with the instrument

tag number, as given in the tabulation, on each piece of equipment provided as part of this Section.

3. Tag instruments immediately upon receipt in the field. 4. Prominently display identification on the outside of the package.


1.08 PROJECT OR SITE CONDITIONS

A. Provide instruments suitable for the installed site conditions including, but not limited to, material compatibility, site altitude, site seismic conditions, humidity, and process and ambient temperatures.


1.10 SCHEDULING

A. The ozone supplier shall participate in coordination meetings with the Owner, installation Contractor, and Engineer: 1. The meeting shall take place before installation of control systems equipment. 2. These meetings are part of the four minimum meetings identified in

specification section 40_61_00, item 1.03. 3. The ozone supplier shall bring sample LOI graphic screens, including pop-up,

trends, and alarm screens. 4. Sample LOI graphic screens shall be reviewed and discussed. 5. Discuss Ethernet communications between the MCP and connected devices

provided by others, including the plant's Honeywell DCS. 6. Data transfer between the MCP and connected devices shall be discussed,

including PLC data register addresses.

1.11 WARRANTY


1.12 SYSTEM STARTUP (NOT USED)


1.14 COMMISSIONING (NOT USED)

1.15 MAINTENANCE

A. Provide 5 spare fuses of each type and rating furnished for each water treatment plant.

PART 2 PRODUCTS

2.01 GENERAL

A. Provide the ozone control system as indicated on the drawings.

B. Signal transmission: 1. Analog signals:

a. Furnish analog measurements and control signals that vary in direct linear proportion to the measured variable, unless otherwise indicated.

b. Furnish electrical analog signals outside control panels that are 4 to 20 mA 24 VDC, except as indicated.

c. Analog signals within enclosures may be 1 to 5 VDC. d. Electrically or optically isolate all analog signals from other signals.


e. Discrete input signal: 24 VDC. f. Discrete output signals:

1) Outputs shall be 24 VDC, except as indicated. 2) Provide external terminal block mounted fuse with blown fuse

indication for all discrete outputs. 3) Interposing relays:

a) Provide interposing relays as required. g. Furnish regulated analog signals that are not affected by changes in

supply voltage or load resistance within the unit’s rating. h. Maintain the total 4 to 20 mA loop impedance to 10 percent below the

published value at the loop operating voltage. i. Where necessary, reduce loop impedance by providing current-to-current

(I/I) isolation amplifiers for signal re-transmission.

C. Discrete circuit configuration: 1. Configure discrete control circuits to fail safe, on loss of continuity or loss of

power. 2. Alarm contacts: Fail to the alarm condition. 3. Control contacts fail to the inoperative condition unless otherwise indicated on

the Drawings.

D. Grounding: 1. As specified in Section 40_95_13.

2.02 CONTROL PANEL

A. General: 1. All project control panels shall be provided in accordance with the

requirements of Section 40_95_13. 2. PLC processor, power supply, I/O backplanes, and modules shall be sized for

connected I/O and required spares. 3. Hot standby PLC processors shall be provided for the MOCP with all required

modules, software, and cables. 4. A LOI shall be provided on the face of the MOCP enclosure for monitoring and

control of the system. Additional LOIs may be provided on individual units local control panels as indicated on the Drawings.

5. The MOCP shall exercise control over all aspects of the ozone control system. Each unit shall be equipped with a control panel containing I/O modules and necessary interface with the MOCP.

6. Ethernet IP communication equipment to provide communications with the plant Honeywell DCS.

7. The MOCP shall continuously monitor all operating parameters, and shall respond to alarms and emergency conditions by shutting down or activating system components. The MOCP shall indicate alarm conditions locally at the LOI, and remotely for monitoring by the Honeywell DCS.

8. The MOCP shall be integrated into the plant Honeywell DCS via Ethernet IP. 9. The MOCP shall be capable of sending and receiving equipment status

signals, analog data and alarms, and receiving both discrete and analog control signals from the plant Honeywell DCS via Ethernet IP.

10. The plant Honeywell DCS shall be configured to store data for the system for reports and alarm generation. The Ozone System Supplier shall provide


information on register addresses on all data, which are to be transmitted. The data register shall be contiguous for each data type.

11. Uninterruptible power supply connections to interface with UPS provided by others.

12. All PLC and LOI programming required for fully functional package ozone control system.

2.03 PROGRAMMABLE LOGIC CONTROLLERS (PLC) HARDWARE

A. General: 1. As specified in Section 40_94_43.

2.04 LOCAL OPERATOR INTERFACE (LOI) HARDWARE


2.05 PLC AND LOI PROGRAMMING

A. General: 1. The PLC programming software system shall be manufactured by the PLC

hardware manufacturer. 2. Provide one licensed copy of PLC programming software to the Owner. 3. The LOI programming software system shall be manufactured by LOI

hardware manufacturer. 4. Provide one licensed copy of LOI programming software to the Owner.

B. PLC programming software shall be: 1. As specified in Section 40_94_43.

C. LOI programming software shall be: 1. As specified in Section 40_94_33.

D. Coordination with plant Honeywell DCS: 1. Coordinate with the Owner to determine the requirements for data transfer

between the packaged system controls and the plant process control system. 2. Supplier shall program MOCP to aggregate the data into contiguous registers

for efficient transfer to the plant DCS. 3. Minimum data transfer shall be as indicated on the P&IDs, in the software I/O

lists, or in the control strategies. Supplier shall supplement the I/O requirements with setpoints and virtual I/O required to implement the control strategies as specified in this Section and in Section 40_61_16.

4. Unless otherwise stated, the packaged control system shall provide data to the Honeywell DCS with data in engineering units.

5. In addition to the supplier provided equipment, the following systems shall be monitored and controlled by supplier provided PLCs as indicated on the P&IDs, in the software I/O lists, or in the control strategies.


E. General programming requirements: 1. Use variable names or aliases derived from tag and loop identification on the

P&IDs for all process values. 2. All programming shall be configured to allow bumpless transfer between the

MOCP and the plant Honeywell DCS. 3. Program slew rates for all setpoints to limit the effect of updated setpoints on

the process: a. Provide for control setpoints and manual speed and position selections. b. Store new setpoints in one register, and gradually ramp the actual

setpoint register at the slew rate until it reaches the new value. c. Provide operator access to change slew rates through the controls

system. 4. Saved setpoints:

a. Provide an operator selection to save all setpoint values. b. Provide an operator selection to restore all setpoints to the last saved

value. 5. Calculated values:

a. Program calculations such that division by zero errors cannot occur. b. Prevent calculations from generating values that exceed the limits of the

equipment or data type structures (integers) internal to the PLC. c. Configure counting functions (start counts and operation counts) to allow

a minimum of 10,000 counts and to rollover to zero at an even decimal interval (1 followed by 4 or more zeros).

6. Timers: a. Provide programmable settling and proving timers in all control sequences

for starting and stopping of equipment to allow the process to settle down before proceeding with any additional control functions.

7. PLC status: a. Furnish all information that depicts the status of all enclosures containing

PLC or I/O in the control system, including but not limited to the following: 1) PLC cabinet over-temperatures from high temperature switch. 2) Intrusion status on all enclosures equipped with intrusion switches. 3) AC power failure. 4) DC power supply failure.

8. PLC system communication status: a. Furnish a minimum of 1 screen to display all communication errors and

status within the ozone control system network: 1) Communication between the Honeywell DCS and Master Ozone

PLC. 2) PLC to PLC and PLC to RIO. 3) Display status of each node, and summary of failures over the past

60 minutes. b. Generate a communications alarm if any communication fault is detected. c. In the event of communications loss:

1) Continue normal operation at each PLC with last known shared values.

F. Common control functions: 1. Incorporate common control functions into all control loops and devices and

into the control programming, whether or not specifically specified in the specific control descriptions or elsewhere in the Contract Documents.


2. Alarms: a. Generate alarms within the PLC logic. b. Indicate alarms at the DCS and the LOI. Enable acknowledgement from

either the DCS or the LOI. c. Once the alarm is acknowledged by an operator, display alarm conditions

in a steady state (not flashing) while the alarm condition is still present. d. Use interlocks and proving timers to prevent alarms from operating due to

power loss, except for loss of power alarms. 3. Where run time accumulation is required, integrate accumulated run time to

the nearest 0.1 hours whenever the running status input indicates that the equipment is running: a. Display total run time in hours.

4. For all monitored analog values: a. Maintain trends in the DCS. b. Totalize flows:

1) Display totals on the HMI and LOI. 5. Analog data processing:

a. Engineering units conversion: 1) Use engineering units for all analog point values. Convert analog

inputs to engineering units. b. Analog magnitude checking:

1) Provide clamps to prevent operator-entered values (setpoints, etc.) that fall outside acceptable limits.

6. Tank and vessel levels: a. Display all tank and vessel levels as both a level (typically in feet) and a

volume (typically in gallons): 1) Some individual displays may be only level or volume, when agreed

to by the Owner and Engineer during the submittal phase. b. Monitor rate of change of volume on all tanks and vessel:

1) Establish the maximum rate at which the volume should decrease (all pumps or feeders operating at maximum output). Generate an alarm whenever the volume decreases faster than this rate.

7. I/O filtering and processing: a. Analog input filtering:

1) Provide PLC programming for each analog input to implement an adjustable first order filter, for the purpose of smoothing out spikes and other noise for analog transmitter input signals. By default, shall configure analog inputs with no filtering affect.

2) Monitor analog input signal quality: a) Over range: The input value is above the normal range (typically

over 21 mA). b) Under range: The input value is below the normal range

(typically under 3 mA, indicating a probable broken connection). c) Generate alarms for over or under range inputs. d) Do not use over- or under-range values for control or calculation

purposes: (1) Where a second instrument is provided to monitor the same

condition (a redundant instrument, or additional instruments furnished for averaging or different operating modes), and has a valid signal, use that input for control.

(2) Otherwise, hold all outputs affected by the signal at their last values before the signal went out of range.


3) Digital input filtering (proving timer): a) Provide an adjustable time delay function (0-10 seconds) on

discrete input for the purpose of de-bouncing. By default, discrete inputs shall be configured with de-bounce timers set to zero seconds.

8. LOI HAND-OFF-AUTO: a. Where indicated, provide HAND-OFF-AUTO and START-STOP

selections accessed from an LOI for operators with sufficient security, to provide the following operating modes: 1) AUTO: The normal, Automatic control mode of the strategy which

allows full PLC control in response to process conditions and programmed sequences.

2) HAND: Enables Manual control where control decisions are made by an operator through the START-STOP, OPEN/CLOSE, or other selections as indicated.

3) OFF: Automated control is disabled and PLC calls for all associated equipment to stop and valves to close or go to their identified safe state.

9. Display the current status of all operator selections (HAND/AUTO, START/STOP, etc.) on the LOI.

10. Motor control: a. Display current REMOTE status on the screens. b. Monitor the device’s running status. c. Display the current status (running or stopped) on the screens.

G. Refer to Specifications Section 40_61_16 for project specific ozone system control strategies.

2.06 PANELS, ENCLOSURES, AND PANEL COMPONENTS


2.07 CONTROL PANEL MOUNTED ETHERNET SWITCHES

A. Ethernet Switches: The Ethernet switches shall have the following features and characteristics: 1. Managed Ethernet switches:

a. Manufacturers: The following, no equal: 1) Allen Bradley Stratix Series.

b. Properties: 1) Hardware:

a) Power supply: (1) Provide redundant power supplies. (2) 24 VDC, 350 Watts per power supply.

b) No fans or moving parts. 2) Performance:

a) Switch fabric speed: 8 Gbps, minimum. b) Gigabit throughput. c) Latency 2.9 microseconds. d) Enclosure:

(1) All metal hardened housing.


(2) 15g Shock for 10ms minimum. (3) Cat 6 grounding for shield drains.

e) 10/100Base-TX RJ-45 Copper Ports (quantity as indicated on the Drawings).

f) 100Base-FX Full Duplex Fiber Optic Ports (quantity as indicated on the Drawings).

g) 1,000Base-T Mini GBIC Full Duplex (quantity as indicated on the Drawings).

h) Ports will auto negotiate speed duplex and MDIX. i) MTBF of 2M Hours. j) Capable of performing basic switching without special

programming or configurations. Additional features available through software setup includes but not limited to: (1) Full SNMP and Web Browser Management. (2) Detailed Ring Map and Fault Location Charting Web

Browser display. (3) VLAN. (4) QoS. (5) Trunking. (6) CIP Messaging. (7) Port Mirroring. (8) DHCP Server with Option 61, Option 82 Relay Agent and

Local IP Addressing. k) OPC 2.0 Compliant Monitoring. l) IGMP Snooping with Ethernet I/P plug & play compatibility. m) RJ-45 Copper Ports Auto Negotiates Speed, Duplex, and MDIX. n) Store-and-forward technology. o) Redundant Power Inputs (10-30 VDC). p) 802.1d, 802.1w, 802.1D RSTP. q) Rapid Spanning Tree protocol. r) Ring Management with 30ms heal times.

3) Environment: a) Operating temperature range: 32 to 140 Degrees Fahrenheit. b) Humidity: 15 to 95 percent, non-condensing.

4) Connector type: a) Fiber: SC. b) Copper: RJ-45.

(1) Quantity of copper and fiber ports as required to provide connections as indicated on the Drawings: As required to provide the number of connections required plus 15 percent spare ports of each type used.

5) Mounting: a) DIN Rail mounting.

2. Unmanaged Ethernet switches: a. Manufacturers: The following, no equal:

1) Allen Bradley Stratix Series. b. Properties:

1) Hardware: a) 10/100 BaseFX. b) 100Base-FX. c) Power supply:

(1) Provide redundant power supplies.


(2) 24 VDC, 200 Watts/per power supply. (3) Store and forward.

d) No fans or moving parts. 2) Performance:

a) Full/half-Duplex. b) MDI/MDI-X Auto-sensing.

3) Environment: a) Operating temperature range: 32 to 140 Degrees Fahrenheit. b) Humidity: 5 to 95 percent, non-condensing.

4) The Ethernet switch shall be capable of performing basic switching without special programming or configurations.

5) Ports: a) As required to provide the number of connections required plus

10 percent spare of each type used. 6) Connector type:

a) Fiber: SC. b) Copper: RJ-45.

7) Mounting: Din Rail.

2.08 PATCH PANELS

A. Located in Control Panels – TYPE A 1. Single panel housing suitable for wall mount installation in small closets or

PLC control panel enclosures. 2. Used for protection and termination of fiber optic cables. 3. Includes a 6-slot, 0.4 inch splice holder to accommodate up to 12 heat shrink

fiber splices. 4. Connector panels shall be included and be compatible with ST type fiber

connectors. Number of fiber connectors as required by cable type. 5. Top and bottom cable entry grommets for access and sealing of fiber cables. 6. Metal housing. 7. Provide mounting accessories. 8. Acceptable manufactures:

a. Corning, LANscape Solutions SPH-01P Series. b. Or equal as approved by the Engineer.

2.09 FIELD INSTRUMENTS

A. General: 1. Instrument housing shall be rated NEMA Type 4X. 2. Wetted materials shall be compatible with process fluid and manufacturer’s

recommendations for the intended service. 3. For analog field instruments, provide local LCD display. 4. Provide all hardware for instrument mounting. 5. Factory calibrate each instrument at a facility that is traceable to the NIST. 6. Analog instrument outputs:

a. Isolated 4-20 mA DC with HART communication protocol.


2.10 ACCESSORIES (NOT USED)

2.11 CONTROL SYSTEM SOURCE TEST

A. Source Test - General: 1. Right of observation: The Owner retains the right to observe all Source test

activities including any and all subsystem preparation, pretests, troubleshooting, retests, warm-up, and software modification and/or update.

2. The Owner reserves the right to test any specified function, whether or not explicitly stated in the test submittal.

3. Costs for repeating testing: The supplier shall pay for Engineer’s and other Owner’s representatives’ travel, subsistence for witnessing the repetition of failed tests.

4. Correction of deficiencies: Any deficiencies observed during the test shall be corrected and retested before completion of the test.

5. Any changes and/or corrections shall be noted on the test forms. Engineer shall witness the revisions and/or corrections prior to leaving the test site.

6. If the corrections and/or revisions are too extensive to be made while the Engineer is scheduled to be at the Source test site, the Source Test shall be, at the Engineer’s sole discretion, considered failed, and the test shall be restarted at a later date. All costs for the re-test shall be borne by the supplier.

B. Testing simulation: 1. The Source shall make use of hardware simulators that contain switches, pilot

lights, variable analog signal generators, and analog signal level displays, which shall be connected to the I/O points of the PLCs and controllers provided. All inputs and outputs shall be simulated and proper control and system operation shall be validated.

C. Panel inspections: 1. The Engineer to inspect each control panel for completeness, workmanship, fit

and finish, and compliance with the Contract Documents and the approved shop drawings.

2. Inspection to include, as a minimum: Layout, mounting, wire and data cable routing, wire tags, power supply, components and wiring, I/O components layout (including terminals, wiring and relays), device layout on doors and front panels, and proper ventilation operation.

D. I/O test: 1. Verify that I/O is properly wired to field terminals and is properly mapped into

the PLC and operator displays. 2. Test forms to include, but not be limited to:

a. PLC and panel number. b. I/O type. c. I/O tag name. d. Panel terminal block numbers. e. Rack/slot/number of I/O point. f. Check-off for correct response for each I/O point. g. Space for comments. h. Initials of individual performing test. i. Date test was performed. j. Witness’ signature lines.


E. Control logic test: 1. The purpose of this test is to verify that all software functions and logic work as

specified, along with any hardwired logic or functions in the tested control panels.

2. Testing requirements: a. Demonstrate each function described in the general and specific control

description. Demonstrate in detail how each function operates under a variety of operating scenarios. Test to verify the application of each general control strategy function to each specific control strategy or loop description.

b. Demonstrate the proper operation of the programming and configuration for each control strategy or loop description. Test each strategy or loop description on a sentence-by-sentence and function-by-function basis. Loops with similar or identical logic must each be tested individually.

3. Test forms: a. Include the fully revised and approved for the loop being tested. b. Identify the cause and effect as each I/O point is toggled through the

simulator. Check boxes shall be provided to track proper and/or improper operation of the loop.

c. Any deficiencies or operational changes shall be noted on the forms for correction and documentation.

d. Include signature and date lines.

PART 3 EXECUTION



3.03 INSTALLATION

A. Field instruments installation: 1. Install field instruments as specified in the Contract Documents and in

accordance with API 550 and 551 and the manufacturer’s instructions. 2. Mount field instruments so that they can be easily read, readily approached,

and easily serviced, and so they do not restrict access to mechanical equipment: a. Mount field instruments on a pipe stand or local panel, if they are not

directly mounted. 3. Make connections from rigid conduit systems to field instruments with PVC

coated flexible conduit: a. Type of flexible conduit required for the area classification. b. Maximum length of 18 inches.

4. Connect field instruments with cable as specified in the Electrical Specifications, except when the manufacturer requires the use of special cable, or otherwise specified in this Section: a. Special cable applications shall be in accordance with the NEC.

5. Verify the correctness of each installation: a. Polarity of electric power and signal connections. b. Ensure all process connections are free of leaks.


B. Process sensing lines and air tubing: 1. Install individual tubes parallel and/or perpendicular to and near the surfaces

from which they are supported. 2. Provide supports for rigid tubing at intervals of not more than 3 feet. 3. Slope horizontal runs of instrument tubing at a minimum of 1/16th-inch per foot

to allow for draining of any condensate. 4. Bends:

a. Use proper tool. b. Make bends for parallel lines symmetrical. c. Make bends without deforming or thinning the walls of the tubing.

5. Square-cut and clean all ends of tubing before being inserted in the fittings. 6. Provide bulkhead fittings at all panels requiring pipe and/or tubing entries. 7. Use stainless steel tubing for all piping hard piped from the air header, unless

otherwise indicated on the Drawings or not compatible with the fluids or atmosphere in the area: a. Use flexible connections only on moving equipment and under the

constraint that the length shall be less than 1.5 times maximum travel of the equipment.

C. Equipment tie-downs: 1. Anchor all instruments, control panels, and equipment by methods that comply

with seismic and wind bracing requirements, which apply to the site. 2. All control panels shall be permanently mounted and tied down to structures.

D. Instrument tagging: 1. Provide all field-mounted instruments with nameplates:

a. Nameplates engraved with the instrument’s full tag number as indicated on the Drawings: 1) Affix tags with stainless steel wire fasteners.

2. Provide all back of panel instruments with nameplates: a. Engraved with the instrument’s full tag number.

3. Provide all front of panel instruments with a nameplate: a. Engraving to include the following:

1) Instrument’s full tag number. 2) Service description.

b. Nameplates: 1) Secure nameplates to the panel with stainless steel screws. 2) Use an approved adhesive if screws would violate the NEMA or other

ratings of the enclosure.

E. Cable and conductor termination: 1. Terminate all cables and conductors on terminal blocks. 2. Terminal block enclosures:

a. Suitable for the area classification.

F. Surge protection: 1. Provide outdoor field instrument loops with voltage surge protection units

installed on the instruments. 2. Individually fuse each 4-20 mA DC loop with a 1/16 ampere fuse between

power supplies and receiver surge protectors. 3. Provide voltage surge protection for 4-wire transmitters and analyzers:

a. Protect both power source and signal loop.


G. Control panel installation: 1. Install enclosures so that their surfaces are plumb and level within 1/8 inch

over the entire surface of the panel; anchor securely to wall and structural supports at each corner, minimum. Direct attachment to drywall is not permitted.

2. Provide floor stand kits for wall-mount enclosures larger than 48-inches high. 3. Provide a full-size equipment-grounding conductor in accordance with NEC

included with the power feeder. Terminate to the incoming power circuit-grounding terminal.





A. General: 1. Failure testing:

a. In addition to demonstrating correct operation of all specified features, demonstrate how the system reacts and recovers from abnormal conditions including, but not limited to: 1) Equipment failure. 2) Operator error. 3) Communications sub-system error. 4) Power failure. 5) Process equipment failure. 6) High system loading conditions.

B. Loop check/validation: 1. Check all control loops under simulated operating conditions. 2. Provide “end-to-end” tests:

a. Test PLC/controller inputs and outputs from field device to all operator displays and pilot devices.

C. Pre-commissioning (functional) test: 1. General:

a. Commence pre-commissioning tests after completion of all loop check/validation tests.

b. Pre-commissioning to demonstrate proper operation of all systems with process equipment operating over full operating ranges under conditions as closely resembling actual operating conditions as possible.

2. Control logic operational validation: a. The purpose of control logic validation is to field test the operation of the

complete control system, including all parts of the system, all control panels (including vendor control panels), all control circuits, all control stations, all monitored/controlled equipment, and final control elements.

3. Loop tuning: a. Optimally tune all electronic control stations and software control logic

incorporating proportional, integral, or derivative control. Apply control signal disturbances at various process variable levels and adjusting the gain, reset, or rate settings as required to achieve proper response.


4. Commissioning validation sheets: a. Document each pre-commissioning test on an approved test form. b. Document loop tuning with a report for each loop, including two-pen chart

recordings showing the responses to step disturbance at a minimum of 3 setpoints or process rates approved by the Engineer. Show tuning parameters on the charts, along with time, date, and sign-off by supplier and Engineer.

5. Commissioning certification: a. Document via a certified report the completion of all pre-commissioning

and test activities: 1) Including all test forms with test data entered, submitted to the

Engineer with a clear and unequivocal statement that all pre-commissioning test requirements have been satisfied.

D. Performance tests: 1. After successful completion of the commissioning tests as accepted by the

Engineer and Owner, the Instrumentation and Control Performance Test can proceed.

E. The Instrumentation and Control Performance Test may be performed concurrently with the Process Operational Test specified in Section 01_75_17.

3.08 ADJUSTING


3.09 CLEANING


3.10 DEMONSTRATION AND TRAINING


3.11 PROTECTION


B. Fully protect all instruments after installation and before commissioning. The Contractor shall replace any instruments damaged before commissioning: 1. The sole party responsible for determining the corrective measures is the

Engineer.

3.12 SCHEDULES


END OF SECTION


SECTION 40_61_16

SPECIFIC CONTROL STRATEGIES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Loop descriptions:

a. Specific control requirements and functional descriptions for individual control loops.




3. The following sections are related to the Work described in this Section. This list of related sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems.

1.02 REFERENCES


1.03 DEFINITIONS


1.04 SYSTEM DESCRIPTION (NOT USED)

1.05 SUBMITTALS

A. Develop detailed loop descriptions based on the information in the Contract Documents, and submit as specified in Sections 01_33_00 and 40_61_00: 1. For each control loop, provide a detailed functional description of the operation

of the equipment, signals, and controls shown on the P&IDs and controls described herein but not presented on P&IDs: a. Include all functions depicted or described in the Contract Documents. b. Include the following within each loop description:

1) All requirements specific to that loop. 2) Common control requirements applicable to that loop. 3) List of all ranges, setpoints, timers, values, counters, etc.


2. Where there are similar loops with identical control, such as multiple loops for individual pumps, only 1 loop description need be developed and the remaining loops may reference that loop description.

B. Loop description format - Loop number and title: 1. References:

a. List P&IDs that are specifically referenced. 2. Abstract:

a. General description of how the loop works, what devices are involved, and how the process will be controlled.

b. Process values, setpoints, and limits, including units and ranges: 1) Show span and range values for analog inputs and outputs, and

operating point and deadband for discrete inputs. 3. Hardwired control:

a. Detailed description of the control functions at the local level. b. Function of local operator interfaces. c. Operation of hardwired field pilot controls:

1) Pushbuttons. 2) Selector switches. 3) Potentiometers. 4) Pilot lights, indicators, and other displays.

4. Hardwired interlocks: a. Explanation of the operation of system interlocks and hardwired

permissive conditions. 5. MOCP PLC control:

a. Detailed description of the control functions that are under control of the MOCP PLC.

b. Operator controls and automatic controls. c. Setpoints, alarms, etc.:

1) Include units and ranges for analog values. 2) Include span and range for analog inputs and outputs. 3) Include operating point and deadband for discrete inputs, and identify

conditions where contacts are open, and when they close. d. Control sequences.

6. Software interlocks: a. Operation of system software interlocks.

7. MOCP LOI control: a. Detailed description of the operator controls at the MOCP.

8. DCS HMI control: a. Detailed description of the operator controls at the DCS. b. Setpoints, alarms, etc.

9. Indicators and alarms: a. List any indicators and alarms specific to the loop that are not covered in

the common control strategies. 10. Failure modes:

a. List any failure modes specific to the loop that are not covered in the common control strategies.

1.06 QUALITY ASSURANCE (NOT USED)

1.07 DELIVERY, STORAGE, AND HANDLING (NOT USED)


1.08 PROJECT OR SITE CONDITIONS (NOT USED)


1.10 SCHEDULING (NOT USED)


1.12 SYSTEM START-UP (NOT USED)


1.14 COMMISSIONING (NOT USED)


PART 2 PRODUCTS

2.01 MANUFACTURERS (NOT USED)


2.03 MATERIALS (NOT USED)









PART 3 EXECUTION



3.03 INSTALLATION (NOT USED)


3.04 ERECTION, INSTALLATION, APPLICATION, CONSTRUCTION

A. LOX Storage and Vaporization: 1. Summary:

a. The equipment and instrumentation described in Paragraphs A-J will be supplied by the Contractor. The Ozone System Supplier shall provide the programming for this equipment as described herein. Tag numbers shown herein are preliminary and are subject to change.

b. General Description: 1) Two LOX tanks will be provided. 2) Liquid oxygen is evaporated in two static ambient vaporizers;

typically one will be in service, one in stand-by. Each ambient vaporizer is able to handle 100 percent of the design oxygen flow. Each vaporizer consists of the vaporizer itself and a motorized outlet valve.

3) One oxygen particulate filter will be provided.

B. LOX Storage Tank Level Transmitter: 1. References:

a. In the General Contract Set of Drawings. 2. Abstract:

a. The LOX storage tank level transmitter measures the level of LOX inside each horizontal tank by using differential pressure measured between the top and bottom.

b. This equipment will be provided by the Contractor. c. There is one level transmitter on each of two LOX tanks at each WTP.

3. Hardwired control: a. None.

4. Hardwired interlocks: a. None.

5. MOCP PLC control: a. None.

6. Software interlocks: a. None.

7. MOCP LOI control: a. Low LOX tank level alarm setpoint. (Administrator only). b. High LOX tank level alarm setpoint. (Administrator only).

8. DCS HMI control: a. Low LOX tank level alarm setpoint. (Administrator only). b. High LOX tank level alarm setpoint. (Administrator only).

9. Indicators and alarms for each storage tank: a. The differential pressure transmitter shall have an input 4-20 mA signal to

the LOX Area RIO for transmittal to the MOCP. The MOCP PLC shall calculate a volume in gallons of LOX based on the level reading, the geometry of the LOX tank, and the specific gravity of LOX (0 to 20,000 gallons range). The calculated volume shall be transmitted to the MOCP LOI and DCS HMI.

b. The MOCP shall generate low and high level alarms based on the calculated volume above and below operator-adjustable setpoints (0 to 20,000 gallons range; initial low setpoint = 2,000 gallons, initial high setpoint = 19,500 gallons). The alarms shall be annunciated at the MOCP LOI and the DCS HMI.


10. Failure Modes: a. None.

C. LOX Storage Tank Pressure Transmitter: 1. References:


a. The LOX Storage Tank pressure transmitter measures the pressure inside each LOX tank.

b. This equipment will be provided by the Contractor. c. There is one pressure transmitter on each of two LOX tanks at each WTP.





7. MOCP LOI control: a. Low LOX tank pressure alarm setpoint. (Administrator only) b. High LOX tank pressure alarm setpoint. (Administrator only)

8. DCS HMI control: a. Low LOX tank pressure alarm setpoint. (Administrator only) b. High LOX tank pressure alarm setpoint. (Administrator only)

9. Indicators and alarms for each storage tank: a. The pressure transmitter shall have an input to the LOX Area RIO for

transmittal to the MOCP (0 to 120 psig range). This signal shall be indicated in the MOCP LOI and the DCS HMI. The MOCP shall generate low (30 to 70 psig range, initial setting = 50 psig) and high (80 to 100 psig range, initial setting = 90 psig) pressure alarms. The alarms shall be annunciated at the MOCP LOI and the DCS HMI.


D. LOX Vaporizer Outlet Valves: 1. References:


a. The LOX vaporizer outlet valves are motorized and are used to bring a specific vaporizer on and off line.

b. This equipment will be provided by the Contractor. c. There is one outlet valve on each of two LOX vaporizers at each WTP.

3. Hardwired control: a. Local-off-remote selector switch on the actuator. b. Local open-stop-close selector switch on the actuator.


5. MOCP PLC control: a. The LOX vaporizer outlet valves shall be able to be opened and closed

from the MOCP LOI as described herein.


b. The auto ozone system start sequence shall open the lead outlet valve if the lead outlet valve is not already open


7. MOCP LOI control: a. In the MOCP LOI, the operator shall be able to select remote-MOCP or

remote-DCS for each outlet valve if 'remote' is selected at the actuator. b. In the MOCP LOI, the operator shall be able select a lead and lag outlet

valve with a Lead-Lag selector switch. c. In remote-MOCP, the valves shall be controlled by the MOCP LOI. d. In remote-DCS, the valves shall be controlled by the DCS HMI.

8. DCS HMI control: a. The LOX vaporizer outlet valves shall be able to be selected between lead

and lag manually if 'remote-DCS' is selected at the MOCP LOI and 'remote' is selected at the actuator.

9. Indicators and alarms for each outlet valve: a. At the MOCP LOI:

1) Open-closed status. 2) Lead-lag control. 3) Remote-MOCP control status based on the local-remote switch

contact on the valve actuator. b. At the DCS HMI:

1) Open-closed status. 2) Lead-lag control. 3) Remote-DCS control status based on the remote-MOCP-remote-

DCS switch in the MOCP LOI and based on the local-remote switch contact on the valve actuator.


E. LOX Vaporizer Outlet Temperature Transmitter: 1. References:


a. The LOX Vaporizer Outlet Temperature Transmitter monitors the outlet temperature of the gaseous oxygen downstream of the vaporizers.

b. This equipment will be provided by the Contractor. c. There is one temperature transmitter at each WTP.





7. MOCP LOI control: a. Low LOX vaporizer outlet temperature alarm setpoint. (Administrator only)

8. DCS HMI control: a. Low LOX vaporizer outlet temperature alarm setpoint. (Administrator only)


9. Indicators and alarms: a. The temperature transmitter shall have an input to the LOX Area RIO for

transmittal to the MOCP (-20 to +100 degrees F range). This signal shall be indicated in the MOCP LOI and the DCS HMI. The MOCP shall generate a low temperature alarm based on operator adjustable setpoints (-20 to 30 degrees F range, initial low setpoint = 0 degrees F. The alarm shall be annunciated at the MOCP LOI and the DCS HMI.


F. Oxygen Particulate Filter Differential Pressure Transmitter: 1. References:


a. The oxygen particulate filter differential pressure transmitter monitors the pressure differential across the particulate filter.

b. This equipment will be provided by the Contractor. c. There is one differential pressure transmitter at each WTP.





7. MOCP LOI control: a. High oxygen particulate filter differential pressure alarm setpoint.

(Administrator only). b. High-high oxygen particulate filter differential pressure alarm setpoint.

(Administrator only). 8. DCS HMI control:

a. High oxygen particulate filter differential pressure alarm setpoint. (Administrator only).

b. High-high oxygen particulate filter differential pressure alarm setpoint. (Administrator only).

9. Indicators and alarms: a. The differential pressure transmitter shall have an input to the LOX Area

RIO for transmittal to the MOCP (0.0 to 5.0 psid range). This signal shall be indicated in the MOCP LOI and the DCS HMI. The MOCP shall generate a high and high-high differential pressure alarm based on operator adjustable setpoints (1.0 to 5.0 psid range, initial high setpoint = 2.0 psid, and initial high-high setpoint = 4.0 psid). The alarm shall be annunciated at the MOCP LOI and the DCS HMI.


G. Pressure Reducing Valve Outlet Pressure Transmitter: 1. References:

a. In the General Contract Set of Drawings.


2. Abstract: a. The Pressure Reducing Valve Outlet Pressure Transmitter monitors the

pressure downstream of the pressure reducing valves. b. This equipment will be provided by the Contractor. c. There is one pressure reducing valve outlet pressure transmitter at each

WTP. 3. Hardwired control:

a. None. 4. Hardwired interlocks:

a. None. 5. MOCP PLC control:

a. None. 6. Software interlocks:

a. None. 7. MOCP LOI control:

a. High oxygen pressure reducing valve outlet pressure alarm setpoint. (Administrator only).

8. DCS HMI control: a. High oxygen pressure reducing valve outlet pressure alarm setpoint.

(Administrator only). 9. Indicators and alarms:

a. The pressure transmitter shall have an input 4-20 mA signal to the LOX Area RIO for transmittal to the MOCP (0.0 to 40.0 psig). This signal shall be indicated in the MOCP LOI and the DCS HMI. The MOCP shall generate a low pressure alarm based on operator adjustable setpoints (10.0 to 25.0 psig range, initial low setpoint = 15.0 psig). The alarm shall be annunciated at the MOCP LOI and the DCS HMI.


H. Oxygen Emergency Shut-off Valve: 1. References:


a. The oxygen feed gas piping shall be provided with an open-closed control valve.

b. The valve shall normally be open but will close upon a signal from MOCP or loss of power.

c. This equipment will be provided by the Contractor. d. There is one emergency shut-off valve at each WTP.

3. Hardwired control: a. Local-off-remote pushbutton at the actuator. b. Local open-stop-close pushbuttons at the actuator.


5. MOCP PLC control: a. The oxygen emergency shut-off valve shall be able to be opened and

closed manually if 'manual' is selected at the MOCP LOI and 'remote' is selected at the actuator.

6. Software interlocks: a. In automatic at the MOCP LOI, the valve shall be closed upon signal from

emergency stop control as described in the Ozone System Emergency


Shutdown Strategy or the Controlled Shutdown Strategy after a time delay.

7. MOCP LOI control: a. In the MOCP LOI, the operator shall be able to select manual or automatic

for the valve if 'remote' is selected at the actuator. b. In manual, the valve shall be controlled by the open and close commands

at the LOI. c. In automatic, the valve shall be controlled as described in the above

software interlock. 8. DCS HMI control:

a. None. 9. Indicators and alarms at the MOCP LOI and DCS HMI:

a. Control valve open status. b. Control valve closed status. c. Control valve remote status from the actuator. d. Control valve manual/automatic status from the MOCP.

10. Failure modes: a. None.

I. Oxygen Feed Dew Point Analyzer: 1. References:


a. The oxygen feed gas to the ozone generators shall be measured for dew point. This analyzer will be located downstream of the supplemental nitrogen system tie-in point with the oxygen feed gas.

b. This equipment will be provided by the Contractor. c. There is one oxygen feed dew point analyzer at each WTP.





7. MOCP LOI control: a. High oxygen feed dew point alarm setpoint. (Administrator only). b. High-high oxygen feed dew point alarm setpoint. (Administrator only).

8. DCS HMI control: a. High oxygen feed dew point alarm setpoint. (Administrator only). b. High-high oxygen feed dew point alarm setpoint. (Administrator only).

9. Indicators and alarms: a. The dew point analyzer shall have a 4-20 mA signal to the MOCP LOI and

DCS HMI (-150 to -40 degrees F range). b. The MOCP shall generate high and high-high dew point alarms based on

operator-adjustable setpoints (-100 to -40 degrees F range; initial high setpoint = -80 degrees F and initial high-high setpoint = -70 degrees F). The alarms shall be annunciated at the MOCP LOI and the DCS HMI.



J. Oxygen Feed Temperature Transmitter: 1. References:

a. In the General Contract Set of Drawings. b. This equipment will be provided by the Contractor. c. There is one oxygen feed temperature transmitter at each WTP.

2. Abstract: a. The oxygen feed gas to the ozone generators shall be measured for

temperature. 3. Hardwired control:





a. Low oxygen feed temperature alarm setpoint. (Administrator only). b. Low-low oxygen feed temperature alarm setpoint. (Administrator only).

8. DCS HMI control: a. Low oxygen feed temperature alarm setpoint. (Administrator only). b. Low-low oxygen feed temperature alarm setpoint. (Administrator only).

9. Indicators and alarms: a. The temperature transmitter shall have a 4-20 mA signal to the MOCP

(-30 to 100 degrees F range). This signal shall be indicated in the MOCP LOI and the DCS HMI.

b. The MOCP shall generate low and low-low temperature alarms based on operator-adjustable setpoints (-30 to 40 degrees F range; initial low setpoint = 10 degrees F and initial low-low setpoint = -10 degrees F). The alarms shall be annunciated at the MOCP LOI and the DCS HMI.


K. Supplemental Nitrogen System Overview: 1. The control descriptions in Paragraphs L-R apply to the supplemental nitrogen

system. The addition of small amounts of nitrogen into the GOX feed line can improve the performance of the ozone generators. The supplemental nitrogen system shall be equipped with a local control panel.

L. Supplemental Nitrogen System Control: 1. References:

a. P&IDs: 503-J-045, 505-J-045. b. Specification Section 46_31_54.

2. Abstract: a. Two oil-free, reciprocating compressors are provided to compress the air.

Only one compressor shall run at a time. An air receiver holds the compressed air and controls the operation of the compressors. Air flows from the receiver to two desiccant dryers. Only one desiccant dryer shall run at a time. Dried air is analyzed in a dew point analyzer prior to introduction into the gaseous oxygen stream. A flow controller regulates the nitrogen flow into the gaseous oxygen stream.


3. Hardwired control: a. The supplemental nitrogen system local control panel shall be provided

with an on-off switch in the local control panel: 1) When the switch is in the 'on' position, the compressors are enabled,

the desiccant dryers are enabled, all solenoid valves are enabled, and the dew point analyzer input is received and evaluated.

2) When the switch is in the 'off' position, the compressors are disabled, the desiccant dryers are disabled, all solenoid valves are closed, and the dew point analyzer is not evaluated.



6. Software interlocks: a. Operate the atmospheric and process solenoid valves in accordance with

the Emergency Shutdown and Controlled Shutdown Control Strategies. 7. MOCP LOI control:

a. None. 8. DCS HMI control:

a. None. 9. Indicators and alarms:

a. The supplemental nitrogen system shall have run status monitoring in the MOCP LOI and DCS HMI.

b. The supplemental nitrogen system shall have a failure alarm for annunciation in the MOCP LOI and DCS HMI and in a failure light on the supplemental nitrogen system local control panel.

10. Failure modes: a. The supplemental nitrogen system shall fail if both compressors have

failed or are off. b. The supplemental nitrogen system shall fail if both desiccant dryers are

off.

M. Supplemental Nitrogen System Compressors and Air Receiver: 1. References:


2. Abstract: a. The supplemental nitrogen system compressors shall operate in lead-lag

mode to provide the necessary air to the air receiver and desiccant dryers. 3. Hardwired control:

a. The supplemental nitrogen system local control panel shall be provided with a Lead-Lag selector switch for the compressors.

b. The supplemental nitrogen system local control panel shall be provided with a Hand-Off-Auto selector switch for each compressor: 1) In Hand, the compressor shall load and unload on low and high air

receiver tank pressure, respectively. 2) In Off, the compressor shall be off. 3) In Auto, the lead compressor shall load and unload on low and high

air receiver tank pressure, respectively. The lag compressor shall start on the low-low air receiver tank pressure under load and unload on high air receiver tank pressure if the lead compressor is not operating.


c. The solenoid valve on the air receiver shall open periodically to discharge moisture (opening interval 0 to 60 minutes range, initial setting 15 minutes; opening duration interval 0 to 10 seconds, initial setting 2 seconds).

4. Hardwired interlocks: a. The supplemental nitrogen system compressors shall be prevented from

operating at the same time. b. The supplemental nitrogen system compressors shall be prevented from

operating when the air receiver high-high pressure alarm is active. The compressors will be prevented to start for an adjustable time delay (0 to 20 minutes range, initial setting = 10 minutes) after the high-high pressure alarm is cleared.



7. MOCP LOI control: a. Air receiver solenoid valve adjustable opening interval input.

(Administrator only). b. Air receiver solenoid valve adjustable opening duration input.

(Administrator only). c. Air compressors restart time delay input. (Administrator only). d. High-high air receiver pressure alarm setpoint. (Administrator only). e. Low-low air receiver pressure alarm setpoint. (Administrator only).

8. DCS HMI control: a. Air receiver solenoid valve adjustable opening interval input.

(Administrator only). b. Air receiver solenoid valve adjustable opening duration input.

(Administrator only). c. Air compressors restart time delay input. (Administrator only). d. High-high air receiver pressure alarm setpoint. (Administrator only). e. Low-low air receiver pressure alarm setpoint. (Administrator only).

9. Indicators and alarms: a. The supplemental nitrogen system compressors shall each have run

status monitoring in the MOCP LOI and the DCS HMI. b. The supplemental nitrogen system compressors shall each have failure

alarms in the MOCP LOI, DCS HMI, and in a failure alarm indicator on the local control panel.

c. High-high air receiver pressure alarm in the MOCP LOI, DCS HMI, and in an alarm indicator on the supplemental nitrogen system local control panel (100 to 175 psig range, initial setpoint = 150 psig).

d. Low-low air receiver pressure alarm in the MOCP LOI, DCS HMI, and in an alarm indicator on the supplemental nitrogen system local control panel (50 to 100 psig range, initial setpoint = 75 psig). This alarm shall be by-passed when the supplemental nitrogen system is off.

10. Failure modes: a. As described above.

N. Supplemental Nitrogen System Coalescing Filters: 1. References:



2. Abstract: a. The coalescing filters removal small amounts of moisture prior to the

desiccant dryers. Each dryer has a solenoid valve to periodically discharge accumulated moisture to the drain.

3. Hardwired control: a. The solenoid valve on each dryer shall open periodically to discharge

moisture (opening interval 0 to 60 minutes range, initial setting 15 minutes; opening duration interval 0 to 10 seconds, initial setting 2 seconds).




7. MOCP LOI control: a. Coalescing filter solenoid valve opening interval setpoint. (Administrator

only). b. Coalescing filter solenoid valve opening duration setpoint. (Administrator

only). 8. DCS HMI control:

a. Coalescing filter solenoid valve opening interval setpoint. (Administrator only).

b. Coalescing filter solenoid valve opening duration setpoint. (Administrator only).

9. Indicators and alarms: a. The coalescing filter differential pressure switches shall generate high

differential pressure alarms in the MOCP LOI, DCS HMI, and in failure alarm indicators on the supplemental nitrogen system local control panel.


O. Supplemental Nitrogen System Desiccant Dryers: 1. References:


2. Abstract: a. The desiccant dryers remove moisture from the compressed air to level of

-80 degrees F dew point or better. 3. Hardwired control:

a. The supplemental nitrogen system local control panel shall be provided with a Lead-Lag selector switch for the desiccant dryers.

b. The supplemental nitrogen system local control panel shall be provided with a Hand-Off-Auto selector switch for each desiccant dryer: 1) In Hand, the desiccant dryer shall be on and the associated

upstream solenoid valve shall open. 2) In Off, the desiccant dryer shall be off and the associated upstream

solenoid valve closed. 3) In Auto, the supplemental nitrogen system control shall turn on the

lead desiccant dryer and open the associated upstream solenoid valve.





7. MOCP LOI control: a. None.

8. DCS HMI control: a. None.

9. Indicators and alarms: a. The supplemental nitrogen system local control panel shall indicate the

operational status of each desiccant dryer with lights. 10. Failure Modes:

a. None.

P. Supplemental Nitrogen System Particulate Filters: 1. References:


2. Abstract: a. The particulate filters removal small amounts of particulate after the

desiccant dryers. 3. Hardwired control:







a. The particulate filter differential pressure switches shall generate high differential pressure alarms in the MOCP LOI, DCS HMI, and in alarm indicators on the supplemental nitrogen system local control panel.


Q. Supplemental Nitrogen System Flow Meter/Control Valve: 1. References:


2. Abstract: a. The supplemental nitrogen system flow meter/control valve shall control

the discharge flow from the supplemental nitrogen system to meet a setpoint percentage of the oxygen flow fed to the ozone generators.




5. MOCP PLC control: a. The supplemental nitrogen system flow meter/control valve shall modulate

the discharge flow from the supplemental nitrogen system to meet a setpoint percentage of the oxygen flow as measured by the sum of the individual ozone generator oxygen inlet flowmeters (0.0 to 3.0 percent, by weight range; initial setpoint as specified by the OSS.)


7. MOCP LOI control: a. Supplemental nitrogen system flow percentage setpoint. (Administrator

only) 8. DCS HMI control:

a. Supplemental nitrogen system flow percentage setpoint. (Administrator only)

9. Indicators and alarms: a. The flow transmitter shall have a 4-20 mA signal to the MOCP (range as

specified by the OSS). This signal shall be indicated in the MOCP LOI and the DCS HMI.

b. The MOCP shall generate low and high flow percentage alarms based on operator-adjustable setpoints (0.0 to 3.0 percent range; initial settings as specified by the OSS). The alarms shall be annunciated at the MOCP LOI and the DCS HMI.


R. Supplemental Nitrogen System Dew Point Analyzer and Discharge Solenoid Valves: 1. References:


2. Abstract: a. The supplemental nitrogen system dew point analyzer monitors the dew

point of the dried, compressed air discharge from the desiccant dryers. The discharge solenoid valves direct the dried, compressed air to either the atmosphere or the process.

3. Hardwired control: a. The atmospheric solenoid valve shall open and the process solenoid

valve shall close on a high-high dew point signal from the dew point analyzer. The valves shall stay in these positions for an adjustable time delay (0 to 60 minutes, initial setting = 20 minutes).

b. The atmospheric solenoid valve shall close and the process solenoid valve shall open after the adjustable time period if the high-high dew point signal is no longer active.


5. MOCP PLC control: a. The atmospheric solenoid valve shall open and the process solenoid

valve shall close on an emergency shutdown signal to the supplemental nitrogen system from the MOCP.



7. MOCP LOI control: a. Atmospheric solenoid valve time delay input. (Administrator only). b. High supplemental nitrogen system dew point alarm setpoint.

(Administrator only). c. High-high supplemental nitrogen system dew point alarm setpoint.


a. Atmospheric solenoid valve time delay input. (Administrator only). b. High supplemental nitrogen system dew point alarm setpoint.

(Administrator only). c. High-high supplemental nitrogen system dew point alarm setpoint.


a. The dew point analyzer shall have a 4-20 mA signal to the MOCP (-150 to -40 degrees F dew point range). This signal shall be indicated in the MOCP LOI and the DCS HMI.

b. The dew point analyzer shall generate high and high-high dew point alarms based on operator-adjustable setpoints (initial high setpoint = -70 degrees F dew point and initial high-high setpoint = -60 degrees F dew point). The alarms shall be transmitted to and annunciated at the MOCP LOI, DCS HMI, and in an alarm indicator on the supplemental nitrogen system local control panel. These alarms shall be by-passed when the supplemental nitrogen system is off.


S. Ozone Generation System Overview: 1. General:

a. The ozone generation system at each WTP includes three ozone generators, each with a dedicated power supply unit (PSU); three closed loop cooling water pumps; three existing open loop cooling water pumps; and two existing heat exchangers. Each ozone generator shall be mounted on a skid with piping, valves, and instrumentation.

b. The ozone generation system generates ozone from gaseous oxygen produced by the LOX vaporization system. The generated ozone is conveyed to the contactors for diffusion into the plant flow.

c. Each ozone generator and PSU is cooled with a closed loop that includes a closed loop cooling water pump and heat exchanger. The three closed loop cooling water pumps and heat exchangers are mounted separately and are configured to allow operation of any closed loop cooling water pump and heat exchanger with any ozone generator. Any additional cooling equipment required by an OSS for their specific ozone generation design shall be programmed with similar control and monitoring characteristics.

d. Each ozone generator and PSU shall be provided with a PLC and LOI mounted on the dedicated PSU cabinet. These PLCs shall be provided and programmed by the Ozone System Supplier. These PLCs shall transmit signals to and from the MOCP for control and monitoring. All programming described in Paragraphs T, U, V, and W and this Ozone


Generation System Overview shall be programmed in the MOCP unless noted otherwise.

e. Each ozone generator and PSU shall be capable of running in manual mode from the local PSU LOI. The units will normally be run in automatic mode.

f. The open loop and closed loop cooling water pumps shall be controlled and monitored by the MOCP and the DCS as described herein.

g. Each closed and open loop cooling water pump shall be capable of running in manual mode from local control stations. The pumps will normally be run in automatic mode.

2. Ozone system production control: a. Ozone generator production shall be controlled by varying the feed gas

flow and applied power to the ozone generators. Typically, only one ozone generator will be in operation, but two and three generators will be needed periodically for higher production rates.

b. Ozone system applied power shall be capable of being controlled at the MOCP (Remote-MOCP) or the DCS (Remote-DCS): 1) In Remote-MOCP, ozone system production shall be controlled by

the MOCP either manually by adjusting the applied power input or automatically as described herein.

2) In Remote-DCS, ozone system production shall be controlled at the DCS manually by adjusting the applied power input.

3) The ozone dosage setpoint shall be input either from the MOCP HMI or the DCS HMI.

c. In Remote-MOCP, ozone system production shall be capable of being controlled manually or automatically as selected at the MOCP LOI: 1) In manual, individual ozone generators can be started and stopped

and individual applied power settings assigned. 2) In auto, the production rate control functions described herein shall

be performed. d. In auto, operators shall be able to input the ozone dosage setpoint (0.0 to

10.0 mg/L range, initial setting = 2.0 mg/L) and the control system shall automatically adjust the variables and monitor the process. The minimum ozone dose shall be a function of plant flow in accordance with the following table. If the operator at the DCS HMI or MOCP LOI enters in ozone dosage setpoint lower than the minimum value for a given flow, an ‘Ozone Dosage Setpoint Too Low’ message shall be generated and the value not accepted for entry. The following table shall be indicated in the MOCP LOI.

Raw Water Flow Range (mgd) Minimum Ozone Dose (mg/L) 15 to 25 1.20

>25 to 35 0.71 >35 to 45 0.51 >45 to 60 0.40

e. In auto, if the ozone dose setpoint is already below the minimum ozone dose in the table above as a result of the plant flow being decreased, the control system shall automatically increase the ozone dose setpoint to the minimum value in the above table and an ‘Ozone Dosage Increased to Minimum Value’ alarm shall be generated.

f. In auto, the MOCP shall calculate an ozone system production rate based on the plant raw water flow rate, the ozone dose setpoint, and appropriate conversion factors to determine the production rate in units of pounds of


ozone per day (lb/day). This calculated production rate will be used in subsequent control functions.

g. In auto, when the calculated ozone system production rate falls below an adjustable level (300 to 700 lb/day range, initial setting = 500 lb/day), the ozone concentration control described below shall be disabled until the ozone system production rate increases above an adjustable level (300 to 700 lb/day range, initial setting = 650 lb/day). The MOCP shall send a signal to the operational PSU or PSUs that ozone concentration control is disabled or enabled. When concentration control is disabled, the target ozone product gas flow rate as described below shall be a fixed value corresponding to the minimum gas flow through the diffusers of all operating contactors (0 to 20.0 scfm range, initial setting = 12.0 scfm for each operating contactor). This target gas flow will be the basis for the individual contactor gas flow setpoints for the Ozone Contactor Feed Flow Control Valves.

h. In auto, the MOCP shall send each operating ozone generator a target ozone production rate that corresponds to the calculated production rate divided by the number of operating ozone generators.

i. In auto, the MOCP shall use the target ozone production rate and programmed production versus power equations to calculate the appropriate power to achieve the target ozone production rate. The power equations shall incorporate cooling water temperature and ozone concentration in determining the appropriate power level. The power input shall be trimmed by the actual concentration measured by the individual ozone generator's high concentration analyzer. This trim factor shall range from 0.85 to 1.15 and shall have the option of being turned off when the high concentration analyzer is out of service.

j. In auto, the MOCP shall have the ability to adjust the target ozone production rate by an ozone residual trim factor. Actual ozone residual shall be calculated from average readings of the ozone residual analyzers for on-line ozone contactors. The average actual ozone residual values will be compared to an adjustable ozone residual set point (0.05 to 1.00 mg/L range, initial set point = 0.20 mg/L). This trim factor shall range from 0.85 to 1.15 and shall have the option of being turned off as desired.

k. In auto, the MOCP shall have the ability to adjust the target ozone production rate by an oxidation reduction potential (ORP) trim factor. Actual ORP shall be calculated from average readings of the ORP analyzers for on-line ozone contactors. The average actual ORP values will be compared to an adjustable ORP set point (500 to 1000 mV range, initial set point = 800 mV). This trim factor shall range from 0.85 to 1.15 and shall have the option of being turned off as desired.

3. Ozone system gas flow control: a. The MOCP shall calculate a target ozone product gas flow rate based on

the ozone system production rate manually input or calculated above and the product gas ozone concentration setpoint. The target ozone system gas flow rate shall be in units of standard cubic feet per minute (scfm). The product gas ozone flow rate setpoint calculation shall utilize the current product gas ozone concentration. The product gas ozone concentration shall be measured at an operating ozone generator’s discharge line or the average of concentrations of multiple operating ozone generators as selected by the operator.


b. The MOCP shall calculate the individual ozone contactor gas flow rate setpoint by dividing the calculated ozone system gas flow rate by the number of ozone contactors on-line. Each contactor shall have an input to the MOCP from the DCS HMI indicating whether it is operating or not.

c. If the calculated ozone contactor gas flow rate is greater than or increases above an adjustable flow rate (25.0 to 50.0 scfm, initial setting = 35.0 scfm), the calculated ozone contactor gas flow rate shall be divided by two and serve as the setpoint gas flow rate for each of the two diffuser grids in that contactor. If only the 'lead' grid is operational when this flow rate is reached, the 'lag' grid shall be brought on-line by opening the corresponding ozone contactor feed flow control valve.

d. If the calculated ozone contactor gas flow rate is less than or decrease below an adjustable flow rate (15.0 to 40.0 scfm, initial setting = 25.0 scfm), the calculated ozone contactor gas flow rate shall serve as the setpoint gas flow rate for the selected diffuser grid (1 or 2) in that contactor. If two grids are operational when this flow rate is reached, the 'lag' grid shall be taken off-line by closing the ozone contactor feed flow control valve.

4. Ozone generator lead-lag-standby control: a. The three ozone generators shall be provided to operate in a lead-lag-

standby manner. b. In the MOCP LOI, the operator shall be able to select (remote-MOCP or

remote-DCS) where to assign one of the following states to an ozone generator. In remote-MOCP, each ozone generator shall be assigned one of the following states from the MOCP LOI. In remote-DCS, each ozone generator shall be assigned one of the following states from the DCS HMI: 1) Lead. 2) Lag. 3) Standby. 4) Out of service - Only one ozone generator can be assigned to any

one state except up to three generators can be assigned as out-of-service. The out-of-service state can be assigned manually in remote-DCS at the DCS HMI, manually in remote-MOCP at the MOCP LOI, manually in local at the PSU LOI, or automatically upon ozone generator fault. Upon an ozone generator fault, the state shall remain as ‘out-of-service’ until the fault is cleared at the PSU LOI. After the ozone generator fault is cleared, the ozone generator shall be assigned as 'standby'.

c. The MOCP shall bring on-line the ozone generators in accordance to the assigned state and ozone system production rate requirements as established in a following Sub-paragraph.

d. The MOCP shall automatically bring on-line the lag ozone generator and power supply if the lead ozone generator and power supply faults or is changed to 'out of service'.

e. The MOCP shall automatically bring on-line the standby ozone generator and power supply if either the lead or lag ozone generator fault when both are operating or one is changed to 'out of service' when both are operating.

f. If there are insufficient ozone generators available to meet the ozone system production demands, the MOCP shall generate an ‘Insufficient Ozone Generators Available' alarm.


5. Closed loop cooling water pump lead-lag-standby control: a. The three closed loop cooling water pumps shall be provided to operate in

a lead-lag-standby manner. A closed loop cooling water pump shall be required to operate for each operational ozone generator.

b. In the MOCP LOI, the operator shall be able to select (remote-MOCP or remote-DCS) where to assign one of the following states to a closed loop cooling water pump. In remote-MOCP, each closed loop cooling water pump shall be assigned one of the following states from the MOCP LOI. In remote-DCS, each closed loop cooling water pump shall be assigned one of the following states from the DCS HMI: 1) Lead. 2) Lag. 3) Standby. 4) Out of service - Only one closed loop cooling water pump can be

assigned to any one state except three pumps can be assigned as out-of-service. The out-of-service state can be assigned manually in the DCS HMI, manually in remote-MOCP at the MOCP LOI, manually at the PSU LOI, or automatically upon closed loop cooling water pump fault. Upon a closed loop cooling water pump fault, the state shall remain as ‘out-of-service’ until the fault is cleared at the MOCP LOI.

c. The MOCP shall automatically bring on-line the closed loop cooling water pumps in accordance to the operating status of the ozone generators. The lead closed loop cooling water pump shall operate when the lead ozone generator is operating and the lag closed loop cooling water pump shall operate when the lag ozone generator is operating. The standby closed loop cooling water pump shall operate whenever all three ozone generators are running.

d. The MOCP shall automatically bring on-line the lag closed loop cooling water pump if the lead closed loop cooling water pump faults or is out of service.

e. The MOCP shall automatically bring on-line the standby closed loop cooling water pump if the either the lead or lag closed loop cooling water pumps fault when both are operating.

f. If there are insufficient closed loop cooling water pumps available to match the number of ozone generators, the MOCP shall generate an ‘Insufficient Closed Loop Cooling Water Pumps Available Alarm’.

6. Open loop cooling water pump lead-lag-standby control: a. There is existing programming in the existing control system for the open

loop cooling water pumps. New programming for the open loop cooling water pumps shall be provided in the MOCP.

b. The three open loop cooling water pumps shall be provided to operate in a lead-lag-standby manner. One open loop cooling water pump shall be required to operate at all times the ozone system is operational.

c. In the MOCP LOI, the operator shall be able to select (remote-MOCP or remote-DCS) where to assign one of the following states to an open loop cooling water pump. In remote-MOCP, each open loop cooling water pump shall be assigned one of the following states from the MOCP LOI. In remote-DCS, each open loop cooling water pump shall be assigned one of the following states from the DCS HMI: 1) Lead. 2) Lag.


3) Standby. 4) Out of service - Only one open loop cooling water pump can be

assigned to any one state except two pumps can be assigned as out-of-service. The out-of-service state can be assigned manually in the DCS HMI, manually in remote-MOCP at the MOCP LOI, manually at the PSU LOI, or automatically upon open loop cooling water pump fault. Upon an open loop cooling water pump fault, the state shall remain as ‘out-of-service’ until the fault is cleared at the MOCP LOI.

d. The MOCP shall automatically bring on-line the lead open loop cooling water pump when the lead or lead and lag ozone generators are operating.

e. The MOCP shall automatically bring on-line the lag open loop cooling water pump if the lead open loop cooling water pump faults or is out of service.

f. The MOCP shall automatically bring on-line the standby open loop cooling water pump if the lead open loop cooling water pump faults or is out of service and the lag open loop cooling water pump faults or is out of service.

g. If there are insufficient open loop cooling water pumps available to match the number of ozone generators, the MOCP shall generate an ‘Insufficient Open Loop Cooling Water Pumps Available' alarm.

7. Ozone generator rotation control: a. The MOCP shall rotate the state of each ozone generator at the same

time at an adjustable frequency (1 to 30 days, initial setting = 7 days) unless two of the ozone generators are out-of-service or all three ozone generators are operating. The lead ozone generator unit shall become the lag unit, the lag unit shall become the standby unit, and the standby unit shall become the lead unit. The transition between ozone generators shall be programmed to 'seamless' so that no alarms trip or undesirable process conditions trip occur during the rotation.

b. If the lag or standby ozone generators or other critical component is not available, then the rotation will be canceled and the time restarted. An ‘Ozone Generator Rotation Canceled Alarm’ shall be generated by the MOCP.

c. An administrator shall have an option to turn off this control function through the MOCP LOI or the DCS HMI.

8. Ozone generator production rate control: a. The ozone generators shall receive automatic start/stop commands and a

production rate setpoint from the MOCP. The ozone system production rate shall be calculated as described above.

b. The ozone production rate of each ozone generator shall normally range from 150 to 1,750 lb/day.

c. The calculated ozone system production rate shall dictate the number of ozone generators operational at any one time in accordance with the following table for increasing production rates, where the value 1,500 is adjustable from 1,100 to 1,700. The calculated ozone production rate shall stay above the setpoint value for an adjustable period of time (0 to 10 minutes, initial setting 2 minutes) prior to starting another ozone generator: Ozone System Production (lb/day) No. of Ozone Gentrs. Operating

150 to 1,500 1 >1,500 to Max Capacity 2


d. The calculated ozone system production rate shall dictate the number of ozone generators operational at any one time in accordance with the following table for decreasing production rate, where the value 1,300 is adjustable from 1,100 to 1,700. The production rate shall stay below the setpoint value for an adjustable period of time (0 to 10 minutes, initial setting 2 minutes) prior to stopping an ozone generator: Ozone System Production (lb/day) No. of Ozone Gentrs. Operating

150 to 1,300 1 >1,300 to Max Capacity 2

e. When two ozone generators are operating at the same time, the MOCP

shall send the PSU PLCs equal production rate setpoints that together total the calculated ozone system production rate.

9. Ozone concentration control: a. The MOCP shall send the required concentration signal to each PSU and

the PSU shall provide all control action to produce the required ozone production rate at the product gas ozone concentration setpoint.

b. The product gas ozone concentration setpoint (CSP) shall be adjustable (2.0 to 12.0 percent, by weight range, initial setting = 10.0 percent, by weight). The normal value for CSP will be approximately 10 percent.

c. When two generators are operating, the product gas ozone concentration setpoint shall decrease or be limited to the following values when the ozone system production rate is above the administrator-adjustable setpoints. These setpoints shall be adjustable from the MOCP LOI or the DCS HMI. 1) 8.0 percent, by weight, maximum ozone concentration for Setpoint 1

(3,000 to 3,600 lb/day, initial setpoint = 3,500 lb/day). 2) 6.0 percent, by weight, maximum ozone concentration for Setpoint 2

(3,500 to 4,000 lb/day, initial setpoint = 3,800 lb/day). 3) If the concentration setpoint has been reduced or limited to Setpoint

1 or Setpoint 2 as described above, concentration setpoint shall increase to the CSP value when the ozone system production rate decreases to Setpoint 3 (2,500 to 3,200 lb/day, initial setpoint = 3,000 lb/day).

d. The MOCP shall not allow the calculated ozone system production rate to exceed an adjustable maximum value (3,500 to 4,500 lb/day, initial setting 4,200 lb/day).

e. During periods of low plant water flow and associated low ozone production, the ozone concentration will need to be decreased in order to meet minimum gas flow requirements for the ozone generator valving and diffusers in the ozone contactors as described above in this overview.

f. When the ozone concentration control is disabled, the gas flow through the ozone system will be constant and the ozone concentration will vary as described above in this overview.

10. Ozone system automatic start control: a. The ozone system shall be capable of starting automatically upon

initiation of a command from the MOCP LOI or the DCS HMI. b. The MOCP LOI shall have a remote-MOCP/remote DCS control selector

switch for the automatic start control. c. The auto start sequence shall not begin until it is confirmed by the MOCP

PLC that the following devices are capable of being controlled at the MOCP, in automatic, not running (pumps and ozone generators) and have


no active shutdown alarms. The auto start sequence shall continue if the ozone destruct units are already operational. The MOCP LOI shall indicate the current state of all the devices adjacent to the automatic start control initiation command. 1) LOX vaporizer outlet valve - at least one. 2) Emergency oxygen shut-off valve - open. 3) Ozone generator and PSU – at least one. 4) Closed loop cooling water pump – at least one. 5) Open loop cooling water pump – at least one. 6) Ozone contactor feed flow control valve – at least one. The ozone

contactor associated with the ozone contactor feed flow control valve shall be operational.

7) Ozone destruct unit – at least one. d. The sequence shall perform the following steps to accomplish the auto

start. Each step shall be verified prior to moving onto the next step. Adjustable time delays shall be included between each step. If a step is not verified prior to the end of a time delay, an 'Auto Start Sequence Failed' alarm shall be generated. The cause of the failure shall be available on the DCS HMI and at the MOCP LOI. The OSS may incorporate additional steps as needed to meet the requirements of a specific ozone system: 1) Start the lead ozone destruct unit. 2) Open the lead LOX vaporizer outlet valve. 3) Open lead ozone generator inlet oxygen and outlet ozone gas

valves. 4) Confirm sufficient oxygen flow at ozone generator inlet flow meter

after an adjustable time delay (1 to 10 minutes, initial setting = 5 minutes).

5) Start the lead open loop cooling water pump. 6) Confirm the lead open loop cooling water flow after an adjustable

time delay (0 to 30 seconds, initial setting = 10 seconds). 7) Start the lead closed loop cooling water pump. 8) Confirm the lead closed loop cooling water flow after an adjustable

time delay (0 to 30 seconds, initial setting = 10 seconds). 9) Open ozone contactor feed flow control valves for all operating ozone

contactors to an adjustable preset position (10 to 50 percent open, initial setting 30 percent open).

10) Start the lead ozone generator and power supply. 11) The auto-start sequence shall have initial adjustable setpoints as

follows: 12) Ozone production rate (300 to 1,000 lb/day, initial setting = 500

lb/day). e. The initial product gas ozone concentration setpoint shall be as calculated

and input above for the ozone production rate initial setting. f. Once the auto-start sequence is complete and the system is stable, the

control system shall provide an ‘Ozone System Auto Start Sequence Complete’ indication and acknowledgment at the MOCP LOI and DCS HMI. Once acknowledged, the ozone system will begin all available automatic control as specified herein.

11. MOCP LOI control - minimum requirements: a. Remote-MOCP/remote-DCS control selectors for all parameters and

functions that can be controlled from either the MOCP or DCS.


b. Auto start initiation. c. Ozone dosage setpoint. d. Manual/auto ozone system production rate control selector. e. Manual ozone system production rate setpoint. f. Ozone production rate where concentration control is disabled setpoint.

(Administrator only). g. Ozone production rate where concentration control is enabled setpoint.

(Administrator only). h. Minimum ozone contactor gas flow setpoint (Administrator only). i. Ozone contactor gas flow setpoint to bring second diffuser grid on-line.

(Administrator only). j. Ozone contactor gas flow setpoint to take second diffuser grid off-line.

(Administrator only). k. Rotation frequency input. (Administrator only). l. Rotation control disabled input. (Administrator only). m. Ozone system maximum ozone production setpoint. (Administrator only). n. Ozone system production rate setpoint to bring second ozone generator

on-line. (Administrator only). o. Ozone system production rate setpoint to take second ozone generator

off-line. (Administrator only). p. Product gas ozone concentration setpoint. q. Ozone system production rate Setpoint 1 to decrease concentration

setpoint. (Administrator only). r. Ozone system production rate Setpoint 2 to decrease concentration

setpoint. (Administrator only). s. Ozone system production rate Setpoint 3 to resume operation at product

gas ozone concentration setpoint. (Administrator only). t. Ozone Generator No. 1 start/stop command. u. Ozone Generator No. 2 start/stop command. v. Ozone Generator No. 3 start/stop command. w. Closed Loop Cooling Water Pump No. 1 start/stop command. x. Closed Loop Cooling Water Pump No. 2 start/stop command. y. Closed Loop Cooling Water Pump No. 3 start/stop command. z. Open Loop Cooling Water Pump No. 1 start/stop command. aa. Open Loop Cooling Water Pump No. 2 start/stop command. bb. Open Loop Cooling Water Pump No. 3 start/stop command. cc. Ozone Generator No. 1 production rate setpoint. dd. Ozone Generator No. 2 production rate setpoint. ee. Ozone Generator No. 3 production rate setpoint. ff. Ozone Generator No. 1 lead/lag/standby/out-of-service selector. gg. Ozone Generator No. 2 lead/lag/standby/out-of-service selector. hh. Ozone Generator No. 3 lead/lag/standby/out-of-service selector. ii. Closed Loop Cooling Water Pump No. 1 lead/lag/standby/out-of-service

selector. jj. Closed Loop Cooling Water Pump No. 2 lead/lag/standby/out-of-service

selector. kk. Closed Loop Cooling Water Pump No. 3 lead/lag/standby/out-of-service

selector. ll. Open Loop Cooling Water Pump No. 1 lead/lag/standby/out-of-service

selector. mm. Open Loop Cooling Water Pump No. 2 lead/lag/standby/out-of-service

selector.


nn. Open Loop Cooling Water Pump No. 3 lead/lag/standby/out-of-service selector.

oo. Ozone Generator No. 1 concentration control enabled. pp. Ozone Generator No. 2 concentration control enabled. qq. Ozone Generator No. 3 concentration control enabled. rr. Auto-start ozone contactor feed flow control valves preset position

(Administrator only). ss. Auto-start oxygen flow at ozone generator inlet flow meter confirmation

time delay (Administrator only) tt. Auto-start open loop cooling water flow confirmation time delay

(Administrator only). uu. Auto-start closed loop cooling water flow confirmation time delay

(Administrator only). vv. Auto-start initial ozone zone production rate setpoint (Administrator only). ww. Auto-start initiation. xx. Ozone production rate ozone residual trim control set point. yy. Ozone production rate ORP trim control set point. zz. Other MOCP LOI controls as required by the OSS.

12. DCS HMI control - minimum requirements: a. Auto start initiation. b. Ozone dosage setpoint. c. Manual/auto production rate control selector. d. Ozone production rate where concentration control is disabled setpoint.

(Administrator only). e. Ozone production rate where concentration control is enabled setpoint.

(Administrator only). f. Minimum ozone contactor gas flow setpoint (Administrator only). g. Ozone contactor gas flow setpoint to bring second diffuser grid on-line.

(Administrator only). h. Ozone contactor gas flow setpoint to take second diffuser grid off-line.

(Administrator only). i. Rotation frequency input. (Administrator only). j. Rotation control disabled input. (Administrator only). k. Ozone system maximum ozone production setpoint. (Administrator only). l. Ozone system production rate setpoint to bring second ozone generator

on-line. (Administrator only). m. Ozone system production rate setpoint to take second ozone generator

off-line. (Administrator only). n. Product gas ozone concentration setpoint. o. Ozone system production rate Setpoint 1 to decrease concentration

setpoint. (Administrator only). p. Ozone system production rate Setpoint 2 to decrease concentration

setpoint. (Administrator only). q. Ozone system production rate Setpoint 3 to resume operation at product

gas ozone concentration setpoint. (Administrator only). r. Ozone Contactor No. 1 operating status input. s. Ozone Contactor No. 2 operating status input. t. Ozone Contactor No. 3 operating status input. u. Ozone Contactor No. 4 operating status input. v. Ozone Generator No. 1 start/stop command. w. Ozone Generator No. 2 start/stop command. x. Ozone Generator No. 3 start/stop command.


y. Closed Loop Cooling Water Pump No. 1 start/stop command. z. Closed Loop Cooling Water Pump No. 2 start/stop command. aa. Closed Loop Cooling Water Pump No. 3 start/stop command. bb. Open Loop Cooling Water Pump No. 1 start/stop command. cc. Open Loop Cooling Water Pump No. 2 start/stop command. dd. Open Loop Cooling Water Pump No. 3 start/stop command. ee. Ozone Generator No. 1 power input setpoint. ff. Ozone Generator No. 2 power input setpoint. gg. Ozone Generator No. 3 power input setpoint. hh. Ozone Generator No. 1 lead/lag/standby/out-of-service selector. ii. Ozone Generator No. 2 lead/lag/standby/out-of-service selector. jj. Ozone Generator No. 3 lead/lag/standby/out-of-service selector. kk. Closed Loop Cooling Water Pump No. 1 lead/lag/standby/out-of-service

selector. ll. Closed Loop Cooling Water Pump No. 2 lead/lag/standby/out-of-service

selector. mm. Closed Loop Cooling Water Pump No. 3 lead/lag/standby/out-of-service

selector. nn. Open Loop Cooling Water Pump No. 1 lead/lag/standby/out-of-service

selector. oo. Open Loop Cooling Water Pump No. 2 lead/lag/standby/out-of-service

selector. pp. Open Loop Cooling Water Pump No. 3 lead/lag/standby/out-of-service

selector. qq. Ozone Generator No. 1 concentration control enabled. rr. Ozone Generator No. 2 concentration control enabled. ss. Ozone Generator No. 3 concentration control enabled. tt. Product gas ozone concentration setpoint. uu. Ozone production rate ozone residual trim control set point. vv. Ozone production rate ORP trim control set point. ww. Other DCS HMI controls as required by the OSS.

13. Indicators and alarms at the MOCP LOI and DCS HMI - minimum requirements: a. Insufficient ozone generators available alarm. b. Insufficient closed loop cooling water pumps available alarm. c. Insufficient open loop cooling water pumps available alarm. d. Open loop cooling water low flow alarm. e. Ozone generator rotation canceled alarm. f. Ozone dosage too low alarm. g. Ozone dosage increased to minimum value alarm. h. Auto start sequence failed alarm. i. Ozone system auto start sequence complete indication. j. Other indicators and alarms as required by the OSS.

T. Ozone Generators Operation, Start-up, and Shutdown: 1. References:

a. P&IDs: 503-J-046.01,.02, and .03; 505-J-046.01, .02, and .03. b. Specification Section 46_31_55.

2. Abstract: a. See ‘General’ discussion in the Overview above for additional ozone

system and ozone generator control requirements for the MOCP and DCS, and for other control requirements.


b. The programming in these control loops shall be performed by the Ozone System Supplier and reside in the PSU PLCs.

c. The normal operation of the ozone generators is a constant ozone product gas concentration and variable feed and product gas flow. At low production rates, operation changes to variable ozone product gas concentration and constant feed and product gas flow.

d. Detailed control descriptions for the instruments on the ozone generator skids have not been included herein because of the differences in configurations and setpoints of different Ozone System Suppliers.

e. The functionality of each loop is identical for each ozone generator. 3. Hardwired control:

a. Emergency stop on PSU control panel. b. Any other controls required by the Ozone System Supplier.

4. Hardwired interlocks: a. As required by the Ozone System Supplier.

5. PSU PLC control: a. Local/Remote-MOCP selector for start-stop. b. Local Start/Stop control. c. In Remote-MOCP, each ozone generator shall respond to a signal from

the MOCP to start or stop. The Ozone System Supplier shall program the PSU PLCs to perform all the start or stop actions on the ozone generator skid including, but not limited to, the opening and closing of valves, purging of the generator, ramping up of power input, transition to ozone production, flow and concentration control as described below, and any other functions necessary for the starting or stopping of each ozone generator: 1) There shall be three different sequences for stopping each ozone

generator: a) Emergency stop as specified in the Ozone System Emergency

Shutdown strategy. b) Controlled shutdown as specified in the Ozone System

Controlled Shutdown strategy. c) Normal stop command as specified above.

2) The purge step of the ozone generators shall be accomplished through the ozone gas outlet valve. The program shall add the purge flow set point to the target ozone product gas flow rate during the purge step to account for the purge gas flow.

d. Each ozone generator shall send a signal to the MOCP to start or stop a closed loop cooling water pump at the appropriate time in the ozone generator start or stop sequence.

e. Each action required for starting an ozone generator shall be verified prior to moving onto the next task. As an example, if a valve is requested to open, the valve shall be confirmed to have opened prior to the next step. Cooling water flow shall be verified by the skid-mounted cooling water flow meter. Appropriate time delays prior to the confirmation step shall be incorporated into the sequence as required: 1) If the start step cannot be verified prior to end of the time delay, an

Automatic Start Failure alarm shall be generated for the specific generator and transmitted to the MOCP and the DCS HMI. In addition, the cause of the sequence failure shall be available at the PSU LOI and the generator shall be assigned an 'out-of-service' state.


f. Ozone production control over a range of 150 to 1,750 lb/day: 1) Manual/Automatic selector for ozone production. 2) Manual production control shall involve the manual input of

production setpoint in lb/day at the PSU LOI. The PSU PLC shall modulate power input only to achieve the manual production setpoint.

3) In automatic, each PSU PLC shall receive an ozone production rate setpoint from the MOCP: a) If concentration control is enabled by the MOCP, ozone

production control for each generator shall be dictated by the gas flow through each operational ozone generator as controlled by the MOCP. The PSU PLCs shall only control concentration in this scenario.

b) If concentration control is not enabled by the MOCP, ozone production control for each generator shall be dictated by the power input to each operational ozone generator under constant gas flow conditions.

g. Gas flow control: 1) With one generator operating, the flow control valve shall be 100

percent open. 2) With two generators operating, each generator’s flow control valve

shall be splitting flow equally between the two generators. Each generator’s flow control valve shall have a gas flow setpoint from the MOCP as described in the Ozone Generation System Overview above.

h. Ozone concentration control: 1) Manual/Automatic selector for ozone concentration. 2) Manual concentration control shall involve the manual input of

concentration setpoint at the PSU LOI. 3) In automatic, the PSU PLC shall receive its ozone concentration

setpoint from the MOCP. 4) The concentration setpoint shall be controlled by modulating the

power input from each PSU to its associated ozone generator unless the ozone generator’s concentration control is not enabled.

i. Ozone production control without the product gas ozone analyzer: 1) Operators shall be able to select between ozone production control

using the product gas ozone analyzer and not using the product gas ozone analyzer at the MOCP LOI. Operations with the product gas ozone analyzer shall be as described above. The operational mode selected shall apply to all ozone generators.

2) The ozone generator shall be able to operate without the product gas ozone analyzer. The PSU PLC shall be provided with ozone generation curves that are a function of power input and oxygen gas flow rate. In this mode, the ozone generators shall automatically use ozone generation curves to predict the power input necessary to generate a specific production rate. The control system shall keep the power input constant for a predetermined time delay before making further adjustments.

3) The ozone generator shall continuously compare the calculated ozone concentration to the actual concentration, and if the deviation exceeds an adjustable range (0.50 to 1.50 range, initial setting = 0.85 to 1.15), the ozone generator will generate an ‘Ozone Concentration


Out of Range’ alarm. The input from the product gas ozone analyzer shall be capable of being ignored by an input at the PSU LOI so that the ozone generator is controlled using the ozone generation curves as described immediately above.

j. Purge control: 1) Under normal startup and shutdown of the ozone generator, a purge

step shall be incorporated into the ozone generator startup and shutdown sequence. The purge step shall have adjustable time durations for both startup and shutdown at the MOCP LOI (start-up 0.0 to 10.0 minute range, initial setting = 5.0 minutes; shutdown 0.0 to 10.0 minute range, initial setting = 5.0 minutes). The purge step shall have an adjustable oxygen gas flow rate (0 to 100 scfm range, initial setting = 50 scfm).

2) Under normal operating conditions, the MOCP shall initiate the purge step for an ozone generator coming on line prior to taking an ozone generator off line during ozone generator rotation.

3) The auto-start sequence shall account for the adjustable duration of the purge step.

4) The Ozone System Controlled Shutdown strategy as defined in this section shall incorporate the purge step as part of the shutdown sequence.

6. Software interlocks: a. As required by the Ozone System Supplier.

7. MOCP LOI control: a. As described in the Ozone Generation System Overview. b. Ozone concentration deviation range setpoints (Administrator only).

8. PSU LOI control: a. As described herein and as required by the Ozone System Supplier.

9. DCS HMI control: a. Lead/Lag/Standby/Out-of-service selector as described in the Ozone

Generation System Summary section. b. Ozone generator Start/Stop control for each generator when the generator

is in 'remote-DCS' at the MOCP LOI. c. Ozone generator emergency stop control for each generator regardless of

the state of the ozone generator: 1) Provide the functionality described in the Ozone System Emergency

Shutdown strategy. d. Ozone generator controlled shutdown control for each generator

regardless of the state of the ozone generator: 1) Provide the functionality described in the Ozone System Controlled

Shutdown strategy. e. Ozone generator product gas ozone concentration setpoint for each

generator when concentration control is enabled and when the generator is in 'remote-DCS' at the MOCP LOI: 1) The setpoint shall be identical for each generator.

f. Ozone concentration deviation range setpoints (Administrator only). 10. Indicators and alarms:

a. The following indicators and alarms shall be available in DCS HMI and the MOCP LOI for each ozone generator: 1) Lead/Lag/Standby/out-of-service state indication. 2) Oxygen inlet valve open-closed status. 3) Oxygen inlet valve remote control status.


4) Oxygen flow control valve open-closed status. 5) Oxygen flow control valve position indication (0 to 100 percent open

range). 6) Oxygen flow control valve remote control status. 7) Cooling water inlet valve open-closed status. 8) Cooling water inlet valve remote control status. 9) Oxygen inlet pressure indication (0 to 50 psig range). 10) Oxygen inlet flow indication (0 to 300 scfm range). 11) Oxygen inlet temperature indication (0 to 100 degrees F range). 12) Cooling water flow indication (0 to 400 gpm range - greater if

required by OSS). 13) Ozone product gas outlet valve open-closed status. 14) Ozone product gas outlet valve remote control status. 15) Ozone product gas outlet temperature indication (0 to 150 degrees F

range). 16) Ozone product gas ozone concentration indication (0 to 15 percent

by weight range). 17) Automatic Start failure alarm. 18) Ozone concentration out of range alarm. 19) Uninterruptable power supply failure alarm. 20) All alarms generated at the PSU LOI as described below.

b. The following indicators and alarms shall be available at the PSU LOI for each ozone generator: 1) The following items are the minimum indicators and alarms that shall

be available at each PSU LOI. Additional signals may be provided by the Ozone System Supplier.

2) Oxygen inlet valve open-closed status. 3) Oxygen inlet valve remote control status. 4) Oxygen flow control valve open-closed status. 5) Oxygen flow control valve position indication. 6) Oxygen flow control valve remote control status. 7) Cooling water inlet valve open-closed status. 8) Cooling water inlet valve remote control status. 9) Oxygen inlet pressure indication. 10) Oxygen inlet flow indication. 11) Oxygen inlet temperature indication. 12) Cooling water flow indication. 13) Ozone product gas outlet valve open-closed status. 14) Ozone product gas outlet valve remote control status. 15) Ozone product gas outlet temperature indication. 16) Ozone product gas ozone concentration indication. 17) Voltage indication (each of three phases). 18) Amperage indication (each of three phases).

11. Failure modes: a. Power failure:

1) Each PSU PLC shall be provided with a UPS feed, as shown on the drawings. During a power failure that impacts all power to the PSU for longer than an adjustable time delay (0.0 to 10.0 minutes, initial setting = 1.0 minute), the PSU PLC shall adjust the power input to zero.


U. Closed Loop Pumps Operation, Start-up, and Shutdown: 1. References:

a. Drawings: 503-J-047, 505-J-047. b. Specification: 46_31_55.

2. Abstract: a. See ‘General’ discussion in the Overview above. b. The functionality of each loop is identical.

3. Hardwired control: a. Local/Off/Remote selector. b. Local Start/Stop pushbuttons.

4. Hardwired interlocks: a. High discharge pressure with local manual reset.

5. MOCP PLC Control: a. In Automatic, the MOCP shall have start/stop control over each pump in

accordance with the control system requirements to start and stop each pump.

b. In Manual, an operator shall be able to start and stop the pumps manually from MOCP LOI.

6. Software interlocks: a. Interlocked with ozone generator operation as described in the Ozone

Generation System Overview. 7. MOCP LOI control:

a. Lead/Lag/Standby/Out-of-service selector. b. Manual/Automatic selector for each pump. c. Manual Start/Stop control for each pump. d. High closed loop cooling water pump discharge pressure alarm setpoint.


a. Lead/Lag/Standby/Out-of-service selector as described in the Ozone Generation System Summary section.

b. Ozone generator Start/Stop control for each closed loop cooling water pump when the pump is in 'remote-DCS' at the MOCP LOI.

c. High closed loop cooling water pump discharge pressure alarm setpoint. (Administrator only).

9. Indicators and alarms at MOCP LOI and the DCS HMI: a. Lead/Lag/Standby/Out-of-service state indication for each pump. b. Insufficient closed loop cooling water pumps available alarm. c. Motor overload alarm for each pump. d. High closed loop cooling water pump high discharge pressure for each

pump (0 to 25 psig, initial setting = 15 psig). 10. Failure modes:

a. None.

V. Open Loop Pumps Operation, Start-up, and Shutdown: 1. References:


a. See ‘General’ discussion in the Overview above. b. These three pumps are existing. c. The functionality of each loop is identical.

3. Hardwired control: a. Local/Off/Remote selector.


b. Local Start/Stop pushbuttons. 4. Hardwired interlocks:

a. High discharge pressure with local manual reset. 5. MOCP PLC Control:

a. In Automatic, the MOCP shall have start/stop control over each pump in accordance with the control system requirements to start and stop each pump. 1) Upon a low-low cooling water flow, the MOCP shall attempt to start

the lag open loop cooling water pump. b. In Manual, an operator shall be able to start and stop the pumps manually

from MOCP LOI. 6. Software interlocks:

a. Interlocked with ozone generator operation as described in the Ozone Generation System Overview.

7. MOCP LOI control: a. Lead/Lag/Standby/Out-of-service selector. b. Manual/Automatic selector for each pump. c. Manual Start/Stop control for each pump. d. High open loop cooling water pump discharge pressure alarm setpoint.


a. Lead/Lag/Standby/Out-of-service selector as described in the Ozone Generation System Summary section.

b. Ozone generator Start/Stop control for each open loop cooling water pump when the pump is in 'remote-DCS' at the MOCP LOI.

c. High open loop cooling water pump discharge pressure alarm setpoint. (Administrator only).

9. Indicators and alarms at the MOCP LOI and DCS HMI: a. Lead/Lag/Standby/Out-of-service state indication for each pump. b. Insufficient open loop cooling water pumps available alarm. c. Motor overload alarm for each pump. d. High open loop cooling water pump high discharge pressure for each

pump (0 to 25 psig, initial setting = 15 psig). 10. Failure modes:

a. None.

W. Open Loop Cooling Water Inlet Temperature Transmitter: 1. References:

a. In the General Contract Set of Drawings. b. This equipment will be provided by the Contractor. c. There is one open loop cooling water inlet temperature transmitter at each

WTP. 2. Abstract:

a. The raw water flow to the heat exchangers shall be measured for temperature.








9. Indicators and alarms: a. The temperature transmitter shall have a 4-20 mA signal to the MOCP

LOI and DCS HMI (40 to 90 degrees F range). 10. Failure modes:

a. None.

X. Open Loop Cooling Water Flow Transmitter: 1. References:

a. In the General Contract Set of Drawings. b. This equipment will be provided by the Contractor. c. There is one open loop cooling water flow transmitter at each WTP.

2. Abstract: a. The open loop cooling water shall be measured for flow.





7. MOCP LOI control: a. Low open loop cooling water flow alarm setpoint. (Administrator only). b. Low-low open loop cooling water flow alarm setpoint. (Administrator only).

8. DCS HMI control: a. Low open loop cooling water flow alarm setpoint. (Administrator only). b. Low-low open loop cooling water flow alarm setpoint. (Administrator only).

9. Indicators and alarms: a. The flow transmitter shall have a 4-20 mA signal to the MOCP LOI and

DCS HMI (0 to 1500 gpm range). b. The MOCP shall generate low and low-low open loop cooling water flow

alarms based on operator-adjustable setpoints (300 to 750 gpm range; initial low setpoint = 600 gpm and initial low-low setpoint = 500 gpm). The alarms shall be annunciated at the MOCP LOI and the DCS HMI.


Y. Closed Loop Cooling Water Heat Exchanger Inlet and Outlet Temperature Transmitters: 1. References:

a. In the General Contract Set of Drawings. b. This equipment will be provided by the Contractor. c. There is one closed loop cooling water heat exchanger inlet temperature

transmitter and one on the outlet at each WTP.


2. Abstract: a. The closed loop cooling water flow to and from the heat exchangers shall

be measured for temperature. 3. Hardwired control:



a. The MOCP PLC shall calculate the difference in temperature between inlet and outlet temperature readings.


7. MOCP LOI control: a. High closed loop cooling water differential temperature alarm setpoint.


a. High closed loop cooling water differential temperature alarm setpoint. (Administrator only).

9. Indicators and alarms: a. Each temperature transmitter shall have a 4-20 mA signal to the MOCP

LOI and DCS HMI (40 to 90 degrees F range). b. The MOCP shall generate a high closed loop cooling water differential

temperature alarm based on an operator-adjustable setpoint (0.0 to 15.0 degrees F, initial setpoint = 10.0 degrees F). The alarm shall be annunciated at the MOCP LOI and the DCS HMI.


Z. Closed Loop Cooling Water Flow Transmitter: 1. References:

a. In the General Contract Set of Drawings. b. This equipment will be provided by the Contractor. c. There is one closed loop cooling water flow transmitter at each WTP.

2. Abstract: a. The closed loop cooling water shall be measured for flow.





7. MOCP LOI control: a. Low closed loop cooling water flow alarm setpoint. (Administrator only). b. Low-low closed loop cooling water flow alarm setpoint. (Administrator


a. Low closed loop cooling water flow alarm setpoint. (Administrator only). b. Low-low closed loop cooling water flow alarm setpoint. (Administrator

only).


9. Indicators and alarms: a. The flow transmitter shall have a 4-20 mA signal to the MOCP LOI and

DCS HMI (0 to 1500 gpm range). b. The MOCP shall generate low and low-low closed loop cooling water flow

alarms based on the number of ozone generators/PSUs that are operational. The alarms shall be annunciated at the MOCP LOI and the DCS HMI. The specific low and low-low closed loop cooling water flow alarm setpoints shall be set by the Ozone System Supplier for the following conditions. Adequate time delays shall be incorporated to prevent nuisance alarms with generators are coming on or off line. 1) One ozone generator/PSU operating. 2) Two ozone generators/PSUs operating. 3) Three ozone generators/PSUs operating


AA. Ozone Contactors Overview: 1. General:

a. There are four existing ozone contactors at each plant. b. All four ozone contactors can operate over the entire plant flow range.

Ozone contactors may be periodically taken out-of-service to improve turndown or for maintenance.

2. CT Calculations: a. Ozone is not currently used at the plant to meet primary disinfection

requirements but may be used in the future. The CT calculations herein are used by the plant staff for advisory purposes only.

b. CT calculations shall be provided for each ozone contactor. c. There are currently insufficient ozone residual analyzers to provide all the

values specified in this strategy. Provide the ability to manually enter a value at each cell location described in this strategy.

d. Calculation of CT (Concentration x Time) is performed to determine ozone contactor disinfection credit. The Surface Water Treatment Rule (SWTR) requires 0.5-log Giardia and 2-logs virus inactivation required from disinfection. The operating target shall be 2-logs virus inactivation. Downstream of Cell 1, CT will be calculated using the effluent method for virus and Giardia inactivation. Calculated CT shall be converted to log inactivation credit based on water temperature. Disinfection performance ratio shall be determined from the CT credit (calculated) and the target credit.

e. CT credit is not allowed in the first cell where ozone is added. Ozone residual shall normally be measured at the outlet of Cells 2, 3, 4, and 5 of the contactors. CT values are converted to virus and Giardia log inactivation credit.

f. HDT (Hydraulic Residence Time): 1) Plant Flow = Total raw water flow rate to the ozone contactors as

measured by the raw water flow meter. The flow rate used in these calculations shall be averaged over an operator-adjustable time interval of 0-10 minutes, initially set at 1 minute.

2) Number of Contactors = Number of contactors in service. To be determined by manual input by operators in DCS HMI.

3) Cell Volume = Volume of one contactor cell (MG). The volume of Cell 2 in each contactor at the Sobrante WTP is 0.0321 MG. The volume


of Cell 2 in each contactor at the USL WTP is 0.0482 MG. The volume of Cell 3 in each contactor at the Sobrante WTP is 0.0321 MG. The volume of Cell 3 in each contactor at the USL WTP is 0.0482 MG. The volume of Cell 4 in each contactor at the Sobrante WTP is 0.0210 MG. The volume of Cell 4 in each contactor at the USL WTP is 0.0320 MG. The volume of Cell 5 in each contactor at the Sobrante WTP is 0.0207 MG. The volume of Cell 5 in each contactor at the USL WTP is 0.0307 MG.

4) HDTY = Theoretical hydraulic detention time of Cell Y (minutes):

( )440,1*/

=

ContactorsofNumberFlowPlantVolumeYCellHDTY

5) Example: Assume Plant Flow = 30 mgd at Sobrante WTP, 4 contactors in service, cell volume = 0.0321 MG. Find HDT of Cell 2:

( ) utesHDT min2.6440,1*4/30

0321.02 =

=

g. CT (Concentration x Time): 1) This calculation is typical of each contactor. The example is for

Contactor 1. 2) CT value is calculated using the effluent method for each section of

the contactor preceding a residual analyzer. 3) No CT is allowed for Cell 1. 4) T10/T = hydraulic efficiency ratio (unitless) (0.01 to 1.00 range, initial

setting = 0.65). 5) CX,Y = Residual measured at the outlet of Contactor X at Cell Y

(mg/L). 6) HDTY = Theoretical hydraulic detention time of Cell Y as calculated

above (minutes). 7) CTX,Y = Contactor X CT value between the end of Cell Y

(mg/L*minutes):

( ) ( )YYXYX HDTCT

TCT ** ,

10,

=

8) The above equation shall only be calculated if CX,Y is greater than or equal to an operator-adjustable minimum residual setpoint, (0.00 to 0.10 mg/L range, initial setting = 0.05 mg/L). If CX,Y is less than the minimum residual setpoint, then CTX,Y equals 0.0 mg/L*minutes.

9) Example: Cell 2 outlet residual is 0.25 mg/L as measured in Contactor 2. T10/T is 0.65. Theoretical hydraulic detention time of Cell 2 is 6.2 minutes as calculated in the previous example. Find CT value of Cell 2 for Contactor 2: ( ) ( ) ( ) ( )utesLmgCT min*/00.12.6*25.0*65.02,1 ==

h. Total Effluent CT: 1) This calculation is typical of each contactor. 2) Total effluent CT for the contactors is the sum of the CT for each cell

calculated above. Only one CT value will be calculated for all ozone contactors.


3) Example: Assume CT1,2 = 1.00 mg/L*min as calculated above; assume CT1,3 = 0.17 mg/L*min; assume CT1,4 = 0.12 mg/L*min and assume CT1,5 = 0.03. Find total effluent CT value for the contactors:

( ) ( ) ( ) ( )utesLmgCT Total min*/29.112.017.000.1,1 =++=

i. Giardia and virus inactivation rate. Inactivation rate is a function of water temperature: 1) Virus inactivation rate:

a) WT = Water temperature as measured by the raw water temperature transmitter (Degrees C). If the water temperature is above 25 degrees C, use a value of 25 degrees C.

b) e = 2.718. c) KV = Virus inactivation rate ((Log I)/(mg/L*min)):

( ) ( )( )WTxV eK 0701.0*1744.2=

2) Giardia inactivation rate: a) WT = Water temperature as measured by the existing ozone

contactor raw water temperature transmitter (degrees C). If the water temperature is above 25 degrees C, use a value of 25 degrees C.

b) e = 2.718. c) KG = Giardia inactivation rate ((Log I)/(mg/L*min)):

( ) ( )( )WTxG eK 0714.0*038.1=

3) Example: Find virus inactivation rate if the water temperature = 20 degrees C:

( ) ( ) ( )( )

==

utesLmgILogeK x

V min*/84.8*1744.2 200701.0

j. Giardia and virus inactivation credit from CT: 1) This calculation is typical of each contactor. 2) Virus Log Inactivation from CT (Logs I):

( ) TotalXV CTKCTfromonInactivatiLogVirus ,*=

3) Giardia Log Inactivation from CT (Logs I):

( ) TotalXG CTKCTfromonInactivatiLogGiardia ,*=

4) Example: Assume CT1,Total = 1.29 mg/L*min and KV = 8.84 (Log I)/ (mg/L*min) as calculated above. Find virus log inactivation (from CT):

( ) ILogsxCTfromonInactivatiLogVirus 4.1129.184.81, ==

k. Virus and Giardia performance ratio: 1) This calculation is typical of each contactor. 2) PRV = Virus performance ratio:

onInactivatiLogVirusquiredonInactivatiLogVirusPRV Re

1,1, =

1) This calculation is typical of each contactor. 2) PRG = Giardia performance ratio:


( )( )onInactivatiLogGiardiaquired

onInactivatiLogGiardiaPRG Re1,

1, =

3) Example: Assume 5.7 logs virus inactivation credit as calculated above. Required virus inactivation is 2.0 logs:

7.50.24.11

1, =

=VPR

l. Analyzer Maintenance Mode: 1) Ozone residual analyzers undergoing maintenance or calibration

should not be included in the CT calculation. Operator shall have the ability to manually input a residual value into DCS HMI for use in the CT calculations.

2) The PLC program shall include a maintenance mode setting for each ozone residual analyzer. The operator shall have the ability to place an analyzer in maintenance mode from DCS HMI. The PLC shall not use residual values from any analyzer in maintenance mode.

m. DCS HMI Control: 1) The following control functions are typical of each of the four

contactors: a) Cell 2 manual-automatic selector. b) Cell 3 manual-automatic selector. c) Cell 4 manual-automatic selector. d) Cell 5 manual-automatic selector. e) Cell 2 manual residual input (0.00 to 1.00 mg/L range, initial

setting = 0.25 mg/L). f) Cell 3 manual residual input (0.00 to 1.00 mg/L range, initial

setting = 0.15 mg/L). g) Cell 4 manual residual input (0.00 to 1.00 mg/L range, initial

setting = 0.10 mg/L). h) Cell 5 manual residual input (0.00 to 1.00 mg/L range, initial

setting = 0.10 mg/L). 2) Number of contactors in service: 1, 2, 3, or 4.

n. Indicators and alarms to the MOCP LOI and DCS HMI: 1) The following control functions are typical of each of the four

contactors: a) Total effluent CT (0 to 5.0 mg/L*minutes range). b) Virus performance ratio (1.00 to 9.99 range). c) Giardia performance ratio (1.00 to 9.99 range). d) Low virus performance ratio (1.00 to 5.00 range, initial setpoint

= 1.25). e) Low Giardia performance ratio (1.00 to 5.00 range, initial

setpoint = 1.25). f) High virus performance ratio (3.00 to 9.99 range, initial setpoint

= 5.00). g) High Giardia performance ratio (3.00 to 9.99 range, initial

setpoint = 5.00). 3. Ozone contactor operational status:

a. In the MOCP, each ozone contactor shall be assigned one of the following states based on a manual entry in DCS HMI: 1) Operational. 2) Out-of-Service.


b. The ozone contactor operational status shall be used to calculate the individual ozone contactor gas flow rate setpoints as described in the Ozone Generation System Overview.

BB. Ozone Contactor Gates: 1. References:

a. P&IDs: In the General Contract Set of Drawings. b. The gates and actuators will be provided by the Contractor. c. There are eight inlet gates at the Sobrante WTP and twelve inlet gates at

the USL WTP. d. There is one bypass gate at the Sobrante WTP and one bypass gate at

the USL WTP. e. There is one bifurcation gate at the Sobrante WTP and one bifurcation

gate at the USL WTP. 2. Abstract:

a. The control signals of each gate will each be wired into the Ozone Destruct Room Remote I/O Unit.






8. DCS HMI control: a. Manual open control of each gate. b. Manual closed control of each gate.

9. Indicators and alarms: a. Open status of each gate. b. Closed status of each gate. c. Gate remote status from the actuator.


CC. Ozone Contactor Feed Flow Control Valves: 1. References:

a. P&IDs: In the General Contract Set of Drawings. b. This equipment will be provided by the Contractor. c. There are two feed flow control valves, one for each diffuser grid, for each

of four contactors at each WTP. 2. Abstract:

a. The inlet gas flow control valves shall control the gas flow rate to each ozone contactor's diffuser grid.

b. The functionality of each valve control strategy is identical. 3. Hardwired control:




a. Calculation of each ozone contactor's gas flow rate setpoint as described in the Ozone Generation System Overview.

b. Calculation of each ozone contactor diffuser grid flow rate setpoint as described in the Ozone Generation System Overview.

c. Modulation of each flow control valve based on the feedback signal from the ozone contactor feed flow meters, as described in the paragraph below, and the flow rate setpoint.

d. Automatic lead-lag alternation of the diffuser grids when one grid is operational (1 to 30 days, initial setting = 7 days). The alternation shall not be performed if one of the diffuser grids is out-of-service.


7. MOCP LOI control: a. Remote-MOCP/Remote-DCS control selector switch. b. In remote-MOCP control for each valve:

1) Lead/lag/out-of-service selector switch. Only one diffuser grid can be assigned to any one state except out-of-service.

2) Manual/Automatic selector. 3) Manual position control. 4) Automatic position control based on the individual ozone contactor

diffuser grid gas flow rate setpoint. 8. DCS HMI control for each valve:

a. In 'remote-DCS' at the MOCP LOI: 1) Lead/lag/out-of-service selector switch. Only one diffuser grid can be

assigned to any one state. 2) Manual/Automatic selector. 3) Manual position control. 4) Automatic position control based on the individual ozone contactor

diffuser grid gas flow rate setpoint. 9. Indicators and alarms at the MOCP LOI and DCS HMI for each valve:

a. Control valve position indication (0 to 100 percent open range). b. Control valve open status. c. Control valve closed status. d. Control valve remote status from the actuator (MOCP) and from the

MOCP (DCS). 10. Failure modes:

a. None.

DD. Ozone Contactor Feed Flow Meters: 1. References:

a. P&IDs: In the General Contract Set of Drawings. 2. Abstract:

a. The inlet gas flow to each ozone contactor diffuser grid shall be provided with a flow meter. There are two diffuser grids in each of four ozone contactors.

b. The functionality of each flow meter control strategy is identical. c. This equipment will be provided by the Contractor. d. There are two feed flow meters for each of four contactors at each WTP.






7. MOCP LOI control: a. Low diffuser grid inlet gas flow alarm setpoint. (Administrator only). b. High diffuser grid inlet gas flow alarm setpoint. (Administrator only).

8. DCS HMI control: a. Low diffuser grid inlet gas flow alarm setpoint. (Administrator only). b. High diffuser grid inlet gas flow alarm setpoint. (Administrator only).

9. Indicators and alarms: a. The inlet gas flow meters shall each have a 4-20 mA signal to the MOCP

LOI and DCS HMI (0 to 40 scfm range). b. Low inlet gas flow alarm for each diffuser grid in MOCP LOI and DCS HMI

(0 to 80 scfm range, initial setpoint = 12 scfm). This alarm shall be by-passed when the diffuser grid is not operational.

c. High inlet gas flow alarm for each diffuser grid in MOCP LOI and DCS HMI (0 to 80 scfm range, initial setpoint = 60 scfm).

d. Standard conditions: 1) Temperature = 60 degrees F. 2) Pressure = 14.7 psia.

e. Design process conditions: 1) Temperature = 80 degrees F. 2) Pressure = 10.0 psig.

f. Adjust inlet gas flow for the deviation from design process conditions as measured by the ozone feed temperature transmitter and the contactor feed pressure transmitter, respectively. Use the orifice plate flow calculation adjustment equations provided by the orifice plate manufacturer.


EE. Contactor Feed Temperature Transmitter: 1. References:


a. The inlet gas to the contactors shall be provided with a temperature transmitter.

b. This equipment will be provided by the Contractor. c. There is one contactor feed temperature transmitter at each WTP.








9. Indicators and alarms: a. Temperature indication in MOCP LOI and DCS HMI (30 to 120 degrees F

range). b. High temperature alarm in MOCP LOI and DCS HMI (90 to 120 degrees F

range, initial setpoint = 110 degrees F). 10. Failure modes:

a. None.

FF. Contactor Feed Pressure Transmitter: 1. References:


a. The inlet gas to the contactors shall be provided with a pressure transmitter.

b. This equipment will be provided by the Contractor. c. There is one contactor feed pressure transmitter at each WTP.





7. MOCP LOI control: a. High contactor feed gas pressure alarm setpoint (Administrator only). b. Low contactor feed gas pressure alarm setpoint (Administrator only).

8. DCS HMI control: a. High contactor feed gas pressure alarm setpoint (Administrator only). b. Low contactor feed gas pressure alarm setpoint (Administrator only).

9. Indicators and alarms: a. Pressure indication in MOCP LOI and DCS HMI (0 to 20 psig range). b. High pressure alarm in MOCP LOI and DCS HMI (7 to 15 psig range,

initial setpoint = 9.0 psig at Sobrante WTP, initial setpoint = 10.0 at USL WTP).

c. Low pressure alarm in MOCP LOI and DCS HMI (5 to 10 psig range, initial setpoint = 6.0 psig at Sobrante WTP, initial setpoint = 7.0 psig at USL WTP).


GG. Ozone Contactor Off-gas Pressure Transmitters: 1. References:


a. The off-gas from each contactor shall be provided with a pressure transmitter. This transmitter shall be capable of measuring vacuum and pressure.

b. The ozone contactor off-gas pressure transmitters will be provided by others.

c. The functionality of each loop is identical.




5. MOCP PLC control: a. The off-gas pressure transmitter values will be averaged for on-line ozone

contactors. The averaged value will be used by the Headspace Pressure Control strategy.


7. MOCP LOI control: a. High ozone contactor off-gas pressure alarm setpoint. (Administrator

only). b. High-high ozone contactor off-gas pressure alarm setpoint. (Administrator


a. High ozone contactor off-gas pressure alarm setpoint. (Administrator only).

b. High-high ozone contactor off-gas pressure alarm setpoint. (Administrator only).

9. Indicators and alarms for each contactor: a. The pressure indication at the MOCP LOI and DCS HMI (12 inches H2O –

vacuum to 12 inches H2O – pressure range). b. High pressure alarms in the MOCP LOI and DCS HMI (2 inches H2O -

vacuum to 6 inches H2O - pressure range, initial setpoint = 0 inches H2O - pressure). Alarm for a contactor shall be by-passed when that contactor is off-line.

c. High-high pressure alarms in the MOCP LOI and DCS HMI (2 inches H2O - vacuum to 6 inches H2O - pressure range, initial setpoint = 4 inches H2O - pressure).


HH. Off-gas Ozone Analyzers: 1. References:

a. P&IDs: in the General Contract Set of Drawings. 2. Abstract:

a. There are four ozone off-gas analyzers in the Ozone Destruct Room. b. These analyzers are existing. The analyzers will be wired to the Ozone

Destruct Room RIO by the Contractor. 3. Hardwired control:





a. High off-gas ozone concentration alarm setpoint. (Administrator only). 8. DCS HMI control:

a. High off-gas ozone concentration alarm setpoint. (Administrator only).


9. Indicators and alarms for each contactor: a. Off-gas ozone concentration to the MOCP LOI and DCS HMI (0.0 to 5.0

%, by weight range). b. High off-gas ozone concentration alarm in the MOCP LOI and DCS HMI

for each 4-20 mA signal (0.0 to 5.0 %, by weight range, initial setpoint = 3.0 %, by weight).


II. Ozone Contactor Ozone Residual Analyzers: 1. References:


a. The ozone residual analyzers will be provided by others. Each ozone residual analyzer has four ball valves to control the flow from individual ozone contactor cells. Only one ball valve will be opened at a time. Normally, one analyzer will be manually assigned to one cell in its ozone contactor as described in the Ozone Contactors Overview.

b. The ozone residual analyzers will be supplied by others. This equipment will be wired to the Ozone Destruct Room RIO by the Contractor.





7. MOCP LOI control: a. Low ozone residual alarm setpoint. (Administrator only). b. Low ozone residual alarm adjustable time delay input. (Administrator

only). c. High ozone residual alarm setpoint. (Administrator only). d. High ozone residual alarm adjustable time delay input. (Administrator


a. Low ozone residual alarm setpoint. (Administrator only). b. Low ozone residual alarm adjustable time delay input. (Administrator

only). c. High ozone residual alarm setpoint. (Administrator only). d. High ozone residual alarm adjustable time delay input. (Administrator

only). 9. Indicators and alarms for each analyzer:

a. Ozone residual concentration to the MOCP LOI and DCS HMI (0 to 2.00 mg/L range).

b. The active cell for each analyzer will be indicated at the MOCP LOI and DCS HMI.

c. Low ozone residual concentration alarm in the MOCP LOI and DCS HMI (0.01 to 0.20 mg/L range, initial setpoint = 0.05 mg/L). Activate alarm only if low residual is sustained for an adjustable time delay (0 to 10 minutes range, initial setpoint = 2 minutes). This alarm shall be by-passed when the ozone contactor is not operational.


d. High ozone residual concentration alarm in the MOCP LOI and DCS HMI (0.20 to 1.00 mg/L range, initial setpoint = 1.50 mg/L). Activate alarm only if high residual is sustained an adjustable time delay (0 to 10 minutes range, initial setpoint = 2 minutes).


JJ. Ozone Destruct Unit Overview: 1. General:

a. The ozone destruct system includes three ozone destruct units that each include preheaters, catalytic destruct vessels, and off-gas blowers.

b. The ozone destruct units provide elimination of any unutilized ozone in the off-gas prior to discharge to the atmosphere.

c. A vendor control panel shall be provided for each ozone destruct unit. This panel shall have local control pushbuttons and status and alarm indicators as described herein.

d. Each ozone destruct unit can be run in manual mode from the local control panel. The units will normally be run in automatic mode.

e. The ozone destruct units and blowers shall be controlled and monitored by the MOCP.

2. Ozone destruct unit Lead/Lag control: a. The three ozone destruct units shall be provided to operate in a

Lead/Lag/Standby manner. Only one ozone destruct unit will typically be required to treat the off-gas.

b. In the MOCP, each ozone destruct unit shall be assigned one of the following states: 1) Lead. 2) Lag. 3) Standby. 4) Out-of-service - Only one ozone destruct unit can be assigned to any

one state except the out-of-service state. The out-of-service state can be assigned manually in DCS HMI, manually at the PSU LOI, or automatically upon ozone destruct unit fault. Upon an ozone destruct unit fault, the state shall remain as ‘out-of-service’ until the fault is cleared at the MOCP LOI.

c. The MOCP shall bring on-line the ozone destruct units in accordance to the assigned state and gas flow requirements as established in the below Paragraph.

d. If only the lead ozone destruct unit is operating, the MOCP shall automatically perform the following if all local controls are in 'remote': 1) Upon a preheater high element skin temperature alarm or VFD

failure, the lead ozone destruct unit shall shutdown and the control system shall attempt to start the lag ozone destruct unit. The shutdown of an ozone destruct unit shall close the inlet valve and shutdown the preheater, if not already off. The state of the shutdown ozone destruct unit shall change to out-of-service and the operational ozone destruct unit shall change to lead.

e. If both the lead and lag ozone destruct units are operating, the MOCP shall automatically perform the following if all local controls are in 'remote': 1) Upon a preheater high element skin temperature alarm or VFD

failure in either the lead or lag ozone destruct unit, the ozone destruct unit with the alarm or failure shall shutdown and the control system


shall attempt to start the standby ozone destruct unit. The shutdown of an ozone destruct unit shall close the inlet valve and shutdown the preheater, if not already off. The state of the shutdown ozone destruct unit shall change to out-of-service and the operational ozone destruct unit shall change to the previous state of the shutdown ozone destruct unit.

f. If there are insufficient ozone destruct units available to meet the flow demands, the MOCP shall generate an ‘Insufficient Ozone Destruct Units Available' alarm and initiate the Emergency Ozone System Shutdown.

3. Indicators and alarms at the MOCP LOI and DCS HMI: a. Insufficient ozone destruct units available alarm.

KK. Ozone Destruct Units and Blowers Operation, Start-up and Shutdown: 1. References:

a. P&IDs: 503-J-050.01, .02, and .03; 505-J-050.01, .02, and .03. b. Specification Section 46_31_57.

2. Abstract: a. See ‘General’ discussion in the Overview above. b. The functionality of each Blower strategy is identical.

3. Hardwired control: a. Each ozone destruct unit shall have the following control at the skid

vendor control panel: 1) Inlet valve local-remote control (at the valve actuator). 2) Inlet valve local open-closed control (at the valve actuator). 3) Preheater local-remote control. 4) Preheater local on-off control. 5) Preheater temperature control setpoint. 6) Blower local-remote control. 7) Blower local start-stop control. 8) Blower local manual speed control.

b. Preheater differential temperature control: 1) Compare the ozone destruct system inlet temperature to an ozone

destruct unit’s preheater outlet temperature and modulate the output of the preheater to maintain an adjustable temperature differential setpoint (range: 0 to 60 degrees F, initial setting = 30 degrees F). Control is performed by a single loop controller mounted in the local vendor control panel of each ozone destruct unit.

4. Hardwired interlocks: a. The preheater shall be shut down on high element skin temperature. This

shutdown shall also shut down the ozone destruct unit. 5. MOCP PLC control:

a. Start/stop control in automatic mode: 1) The MOCP PLC shall control all elements of each ozone destruct

unit including inlet valve, preheater, and blower to automatically bring ozone destruct units on and off-line as described herein.

2) The ozone system shall calculate a gas flow rate as specified herein. The ozone destruct system will approximately match the gas flow requirements of the ozone system.

3) The target ozone product gas flow rate as calculated in the Ozone Generation System Overview of this Section shall dictate the number of ozone destruct units operational at any one time in accordance with the following table for increasing gas flow rates, where the value


150 is adjustable from 100 to 250. The target ozone product gas flow rate shall stay above the setpoint value for an adjustable period of time (0 to 5 minutes, initial setting 2 minutes):

Target Gas Flow (scfm) No. of Destruct Units and Blowers Operating

Minimum Flow to 150 1 Greater than 150 2

4) The target ozone product gas flow rate shall dictate the number of ozone destruct units operational at any one time in accordance with the following table for decreasing ozone system gas flow rates, where the value 125 is adjustable from 100 to 250. The target ozone product gas flow rate shall stay below the setpoint value for an adjustable period of time (0 to 5 minutes, initial setting 2 minutes):

Target Gas Flow (scfm) No. of Destruct Units and Blowers Operating

Minimum Flow to 125 1 Greater than 125 2

5) The ozone destruct system control strategy shall also bring on the lag ozone destruct unit if the ozone contactor headspace pressure increases to an adjustable setpoint in any on-line ozone contactor (range: -2 inches H2O to +2 inches H2O, initial setting = 0 inches H2O).

6. Software interlocks: a. The insufficient ozone destruct units available alarms shall activate an

Emergency Ozone System Shutdown as described in the Emergency Ozone System Shutdown control strategy.

7. MOCP LOI control: a. For each ozone destruct unit:

1) Lead/Lag/Standby/Out-of-service selector. 2) Remote-MOCP manual inlet valve open-closed control. 3) Remote-MOCP manual preheater start-stop control. 4) Remote-MOCP manual blower Start/Stop control.

b. Ozone system gas flow rate setpoint to bring second ozone destruct unit on-line. (Administrator only).

c. Time delay to bring second ozone destruct unit on-line. (Administrator only).

d. Ozone system gas flow rate setpoint to take second ozone destruct unit off-line. (Administrator only).

e. Time delay to bring second ozone destruct unit on-line. (Administrator only).

f. Ozone contactor headspace off-gas pressure setpoint to bring second ozone destruct unit on-line. (Administrator only).

8. DCS HMI Control: a. Ozone system gas flow rate setpoint to bring second ozone destruct unit

on-line. (Administrator only). b. Time delay to bring second ozone destruct unit on-line. (Administrator

only). c. Ozone system gas flow rate setpoint to take second ozone destruct unit

off-line. (Administrator only). d. Time delay to bring second ozone destruct unit on-line. (Administrator

only).


e. Ozone contactor headspace off-gas pressure setpoint to bring second ozone destruct unit on-line. (Administrator only).

9. Indicators and alarms: a. The following indicators and alarms shall be available in the MOCP LOI

and DCS HMI for each ozone destruct unit: 1) Lead/Lag/Standby/Out-of-service state indication. 2) Inlet valve open-closed status. 3) Inlet valve remote control status. 4) Preheater run status. 5) Preheater remote control status. 6) Preheater high skin temperature alarm (setting per manufacturer). 7) Preheater low differential temperature alarm (5 to 75 degrees F

range, initial setting = 15 degrees F). 8) Preheater high differential temperature alarm (5 to 75 degrees F

range, initial setting = 60 degrees F). 9) Catalytic destruct high differential pressure alarm (0 to 20 inches of

water range, initial setting = 12 inches of water). 10) Catalytic destruct high outlet temperature alarm (50 to 150 degrees F

range, initial setting = 120 degrees F). 11) Blower motor VFD run status. 12) Blower remote control status. 13) Blower speed indication (0 to 100 percent range). 14) Blower VFD failure alarm. 15) Blower high motor bearing temperature alarm. 16) Blower low inlet pressure alarm.

b. The following indicators and alarms shall be available at the local vendor control panel for each ozone destruct unit: 1) Preheater run status. 2) Preheater high skin temperature alarm (setting per manufacturer). 3) Blower high motor bearing temperature alarm.

10. Failure modes: a. For ozone destruct unit:

1) Preheater high element skin temperature alarm and shutdown. b. For each blower:

1) Blower VFD failure.

LL. Headspace Pressure Control: 1. References:


2. Abstract: a. The headspace of the ozone contactors shall be controlled to maintain

adequate vacuum with the blowers of the ozone destruct system. b. Each ozone contactor has a pressure transmitter for the headspace

monitoring. c. The blower speed is modulated to control the headspace pressure.




5. MOCP PLC control: a. The headspace of the ozone contactors shall be controlled to maintain an

adjustable vacuum level (1 inch of water vacuum to 8 inches of water vacuum, initial setting = 2 inches of water vacuum).

b. If both the lead and lag blowers are on, the blower speed setpoint to each shall be identical.

c. The vacuum readings of the individual contactors shall be surveyed on a continuous basis and the lowest vacuum (highest pressure) shall serve as the controlled variable.


7. MOCP LOI control: a. Headspace vacuum setpoint. (Administrator only). b. Headspace vacuum alarm setpoint. (Administrator only).

8. DCS HMI control: a. Headspace vacuum setpoint. (Administrator only). b. Headspace vacuum alarm setpoint. (Administrator only).

9. Indicators and alarms for each contactor: a. Low vacuum alarms to the MOCP LOI and DCS HMI (2 inches H2O –

vacuum to 2 inches H2O – pressure range, initial setting = 0 inches H2O vacuum). Alarm for a contactor shall be by-passed when that ozone contactor is not operational.


MM. Ozone Destruct System Inlet and Outlet Temperature Transmitters: 1. References:


2. Abstract: a. There is one inlet and one outlet temperature transmitter on each ozone

destruct unit. 3. Hardwired control:

a. The transmitter output shall be used by the single loop controller of each ozone destruct unit to calculate the differential temperature across the preheater and control the output of the preheater as described previously.






9. Indicators and alarms: a. Each temperature transmitter shall have a 4-20 mA signal to the MOCP

LOI and DCS HMI (0 to 150 degrees F range). 10. Failure modes:

a. None.


NN. Blower Inlet Pressure Switch: 1. References:


2. Abstract: a. There is one blower inlet pressure switch on each ozone destruct unit. b. This switch is on a line that is normally under vacuum.


4. Hardwired interlocks: a. As required by Ozone System Supplier.





9. Indicators and alarms for each destruct unit: a. Blower low inlet pressure alarm in MOCP LOI and DCS HMI.


OO. Ozone Destruct Unit Outlet Ozone Analyzer: 1. References:


2. Abstract: a. There is one ozone destruct system outlet ozone concentration analyzer

for each ozone destruct unit. These analyzers sample the discharge of each ozone destruct unit.



5. MOCP PLC control: a. On high-high ozone destruct unit outlet ozone concentration alarm from

the analyzer, the Ozone System Controlled Shutdown, as described below, shall be activated. The high-high off-gas ozone concentration shall be maintained continuously for a minimum of 10 minutes prior to initiation of the Ozone System Controlled Shutdown.

b. The analyzer can be placed in ‘Service’ mode for maintenance or calibration. Alarms will be disregarded from the analyzer in Service mode.


7. MOCP LOI control: a. High ozone destruct unit outlet ozone concentration alarm setpoint.

(Administrator only). b. High-high ozone destruct unit outlet ozone concentration alarm setpoint.

(Administrator only).


8. DCS HMI control: a. High ozone destruct unit outlet ozone concentration alarm setpoint.

(Administrator only). b. High-high ozone destruct unit outlet ozone concentration alarm setpoint.


a. Each analyzer shall have a 4-20 mA signal to the MOCP LOI and DCS HMI (0.00 to 1.00 ppm range).

b. High ozone destruct unit outlet ozone concentration alarm for each analyzer in MOCP LOI and DCS HMI (0.01 to 0.30 ppm range, initial setpoint = 0.08 ppm). This alarm shall be by-passed when the ozone destruct unit is off.

c. High-high ozone destruct unit outlet ozone concentration alarm for each analyzer in MOCP LOI and DCS HMI (0.01 to 0.50 ppm range, initial setpoint = 0.20 ppm).

d. Each analyzer shall have a discrete failure alarm for annunciation at the MOCP LOI and DCS HMI.

10. Failure modes: a. As described above.

PP. Ozone System Emergency Shutdown: 1. References:


a. The ozone system emergency shutdown logic is provided to immediately stop production of oxygen and ozone if an event occurs that could impact the safety of personnel in the ozone and oxygen generation areas. These events include ambient gas conditions that are dangerous, detection of smoke, and manual initiation by personnel in the ozone and oxygen generation areas or at the MOCP LOI or DCS HMI. A less severe controlled shutdown is provided in the Ozone System Controlled Shutdown strategy below.

b. The fire alarm system and HVAC equipment will be supplied by others. Signals from this equipment will be wired to the MOCP by the Contractor.



5. MOCP PLC control: a. The following signals shall shut down the ozone system on an emergency

basis: 1) Insufficient ozone destruct units available alarm. 2) High-high ambient ozone alarm from any ambient ozone analyzer. 3) High-high ambient oxygen alarm from any ambient oxygen analyzer. 4) Manual emergency shutdown initiation from MOCP LOI or DCS HMI. 5) Activation of any emergency pushbutton at exits of Ozone Generator

Room. 6) Fire alarm from ozone area fire alarm control panel thru DCS. 7) Smoke alarm from ozone area HVAC system. 8) HVAC emergency system shutdown from break glass initation.

b. The following actions shall be taken for an emergency shutdown: 1) Reduce power input to zero for all operating ozone generators.


2) Close ozone generator inlet and outlet gas valves. 3) Close emergency oxygen shutoff valve. 4) Close supplemental nitrogen system generator process solenoid

valve and open the atmospheric solenoid valve. 5) Activate horns and strobes in Ozone Generator Room. 6) Increase ventilation to the emergency ventilation rate in Ozone

Generation Room for high-high ambient ozone or oxygen alarms in that room.

7) Stop ventilation for smoke and fire alarms. 8) Indicate ozone system emergency shutdown in MOCP LOI and DCS

HMI. 9) Send signal to the 24-hour emergency monitoring system of a

haz/mat emergency. c. The MOCP LOI shall indicate the current state of all the devices impacted

by the emergency shutdown actions adjacent to the manual emergency shutdown initiation and reset commands.

d. The ozone system must be manually reset from the MOCP LOI in order for the operator to reinitiate ozone system operation. The reset function shall perform the following actions if the cause for the emergency shutdown is also cleared: 1) Deactivate horns and strobes in Ozone Generator Room. 2) Return ventilation rate to normal if modified.


7. MOCP LOI control: a. Manual emergency shutdown initiation. b. Manual emergency shutdown reset.

8. DCS HMI control: a. Manual emergency shutdown initiation.

9. Indicators and alarms: a. Local horns and strobes. b. Emergency shutdown alarm in MOCP LOI and DCS HMI.


QQ. Ozone System Controlled Shutdown: 1. References:


a. The ozone system controlled shutdown logic is provided to gradually stop production of oxygen and ozone if an event occurs in the ozone and oxygen generation areas that could eventually impact the safety of personnel in the ozone and oxygen generation areas or be detrimental to ozone system operation. These events include safety system malfunctions, high-high ozone destruct units discharge concentration, and manual initiation by personnel in the ozone and oxygen generation areas or at the MOCP LOI or DCS HMI.

b. The HVAC equipment will be supplied by others. This equipment will be wired to the MOCP by the Contractor.




5. MOCP PLC control: a. The following signals shall shut down the ozone system on a controlled

basis: 1) High-high ozone destruct unit outlet ozone concentration from any

ozone destruct unit. 2) Manual controlled shutdown initiation from the MOCP LOI or DCS

HMI. 3) HVAC system failure. This is defined as no exhaust fans operational

in the Ozone Generator Room. 4) Ambient ozone monitoring system failure in the Ozone Generator

Room, as defined in the ambient ozone analyzer control strategy below.

5) Ambient ozone monitoring system failure in the Ozone Destruct Room, as defined in the ambient ozone analyzer control strategy below.

b. The following initial actions shall be taken for a controlled shutdown after an adjustable time delay (0 to 60 minutes range, initial setting = 10 minutes): 1) Reduce power input to zero for all operating ozone generators. 2) Close ozone generator inlet and outlet gas valves. 3) Close emergency oxygen shutoff valve. 4) Close supplemental nitrogen system process solenoid valve and

open the atmospheric solenoid valve. 5) Activate strobes in Ozone Generator Room.

c. If a reset button is activated in the MOCP LOI or DCS HMI prior to expiration of the time delay, the controlled shutdown shall be cancelled and no actions shall take place.

d. The MOCP LOI shall indicate the current state of all the devices impacted by the controlled shutdown actions adjacent to the manual controlled shutdown initiation and reset commands. After the controlled shutdown has occurred, the ozone system must be manually reset from the MOCP LOI in order for the operator to reinitiate ozone system operation. The reset function shall perform the following actions if the cause for the emergency shutdown is also cleared: 1) Deactivate horns in Ozone Generator Room.


7. MOCP LOI control: a. Manual controlled shutdown initiation. b. Manual controlled shutdown reset. c. Controlled shutdown time delay input. (Administrator only).

8. DCS HMI control: a. Manual controlled shutdown initiation. b. Manual controlled shutdown reset. c. Controlled shutdown time delay input. (Administrator only).

9. Indicators and alarms: a. Local horns and strobes. b. Ozone system controlled shutdown alarm in MOCP LOI and DCS HMI.



RR. Ambient Ozone Analyzers: 1. References:


a. There are three ambient ozone analyzers in the Ozone Generator Room, three additional analyzers in rooms adjacent to the Ozone Generator Room, and two analyzers in the Ozone Destruct Room.

b. These analyzers will be supplied by others. The analyzers will be wired to the MOCP or the Ozone Destruct Room RIO by the Contractor.



5. MOCP PLC control: a. On high ambient ozone concentration alarm from any ambient ozone

analyzers in Ozone Generator Room, Ozone Destruct Room or rooms adjacent to the Ozone Generator Room, activate alarms as indicated below.

b. On high-high ambient ozone concentration alarm from any ambient ozone analyzers in either the Ozone Generator Room or Ozone Destruct Room, start emergency ventilation rate for that area and activate alarms as indicated below.

c. On high-high-high ambient ozone concentration alarm from any ambient ozone analyzer in the Ozone Generator Room, activate the Ozone System Emergency Shutdown as previously described in the control strategy above.

d. If all three ambient ozone analyzers in the Ozone Generator Room have active failure alarms or are in Service mode, activate the Ozone System Controlled Shutdown as previously described in the control strategy above. This is defined as an ambient ozone monitoring system failure for this room.

e. If both of the ambient ozone analyzers in the Ozone Destruct Room have active failure alarms or are in Service mode, activate the Ozone System Controlled Shutdown as previously described in the control strategy above. This is defined as an ambient ozone monitoring system failure for this room.

f. Any ambient ozone analyzer can be placed in ‘Service’ mode for maintenance or calibration. Alarms will be disregarded from analyzers in Service mode. Alarm for excessive service mode duration (4 to 48 hour range, initial setting = 8 hours).


7. MOCP LOI control: a. On/Service Mode selector switch for each ambient ozone analyzer. b. Service Mode maximum duration set point (Administrator only). c. High ambient ozone concentration alarm setpoint. (Administrator only). d. High-high ambient ozone concentration alarm setpoint. (Administrator

only). e. High-high-high ambient ozone concentration alarm setpoint.


a. Service Mode maximum duration set point (Administrator only).


b. High ambient ozone concentration alarm setpoint. (Administrator only). c. High-high ambient ozone concentration alarm setpoint. (Administrator

only). d. High-high-high ambient ozone concentration alarm setpoint.


a. Each ambient ozone analyzer shall have a 4-20 mA signal to the MOCP LOI and DCS HMI (0 to 1.00 ppm range).

b. High ambient ozone concentration alarm in the MOCP LOI and DCS HMI for each 4-20 mA signal (0.05 to 0. 30 ppm range, initial setpoint = 0.07 ppm).

c. High-high ambient ozone concentration alarm in the MOCP LOI and DCS HMI for each 4-20 mA signal (0.05 to 1.00 ppm range, initial setpoint = 0.10 ppm).

d. High-high-high ambient ozone concentration alarm in the MOCP LOI and DCS HMI for each 4-20 mA signal (0.05 to 1.00 ppm range, initial setpoint = 0.30 ppm).

e. Each ambient ozone analyzer shall have a discrete failure alarm to the MOCP for annunciation in the MOCP LOI and DCS HMI.

10. Failure modes: a. See MOCP PLC Control for failure mode in this Paragraph.

SS. Ambient Oxygen Analyzers: 1. References:


a. There are two ambient oxygen analyzers in the Ozone Generator Room. b. These analyzers will be supplied by others. The analyzers will be wired to

the MOCP by the Contractor. c. The functionality of each analyzer control strategy is identical.



5. MOCP PLC control: a. On high ambient oxygen concentration alarm from either ambient oxygen

analyzer, start emergency ventilation rate in the Ozone Generator Room and activate alarms as indicated below.

b. On high-high ambient oxygen concentration alarm from any ambient oxygen analyzer, activate the Ozone System Emergency Shutdown as described previously.

c. Any ambient oxygen analyzer can be placed in ‘Service’ mode for maintenance or calibration. Alarms will be disregarded from analyzers in Service mode. Alarm for excessive service mode duration (4 to 48 hour range, initial setting = 8 hours).


7. MOCP LOI control: a. On/Service Mode selector switch for each ambient ozone analyzer. b. Service Mode maximum duration set point (Administrator only). c. High ambient oxygen concentration alarm setpoint. (Administrator only).


d. High-high ambient oxygen concentration alarm setpoint. (Administrator only).

8. DCS HMI control: a. Service Mode maximum duration set point (Administrator only). b. High ambient oxygen concentration alarm setpoint. (Administrator only). c. High-high ambient oxygen concentration alarm setpoint. (Administrator

only). 9. Indicators and alarms:

a. Each ambient oxygen analyzer shall have a 4-20 mA signal to the MOCP LOI and DCS HMI (16.0 to 25.0 percent by weight range).

b. High ambient oxygen concentration alarm in the MOCP LOI and DCS HMI for each 4-20 mA signal (21.0 to 25.0 percent, by weight range, initial setpoint = 22.5 percent).

c. High-high ambient oxygen concentration alarm in the MOCP LOI and DCS HMI for each 4-20 mA signal (21.0 to 25.0 percent, by weight range, initial setpoint = 24.0 percent).


TT. Emergency Ozone System Shutdown Pushbutton Stations: 1. References:


a. There are three emergency ozone system shutdown pushbutton stations in the Ozone Generator Room. These shutdown pushbuttons shall be located at each exit door.

b. These pushbutton stations will be supplied by the Contractor. The pushbutton stations will be wired to the MOCP by the Contractor.

c. The functionality of each shutdown pushbutton station control strategy is identical.



5. MOCP PLC control: a. On depression of any emergency ozone system shutdown pushbutton,

activate the Ozone System Emergency Shutdown control strategy as described previously.




9. Indicators and alarms: a. Each shutdown pushbutton shall have an individual pushbutton activation

alarm in the MOCP LOI and DCS HMI. 10. Failure modes:

a. None.


UU. Emergency HVAC System Shutdown Pushbutton Stations: 1. References:


a. There are three emergency HVAC system shutdown pushbutton stations in the Ozone Generator Room. These shutdown pushbuttons shall be located outside of each exit door.

b. These pushbutton stations will be supplied by the Contractor. The pushbutton stations will be wired to the MOCP by the Contractor.

c. The functionality of each shutdown pushbutton station control strategy is identical.



5. MOCP PLC control: a. On depression of any emergency HVAC system shutdown pushbutton,

shutdown the Ozone Generator Room Air Handler and Ventilation Fans. 6. Software interlocks:




a. Each shutdown pushbutton shall have an individual pushbutton activation alarm in the MOCP LOI and DCS HMI.


VV. Ozone Generator Room Air Handler: 1. References:


a. There is one air handler that is dedicated to the Ozone Generator Room. b. The air handler will be supplied by the Contractor. The air handler will

have status signals wired to the MOCP by the Contractor. c. The air handler will operate continuously to provide the necessary

ventilation for the Ozone Generator Room. The air handler will operate in conjunction with an exhaust fan.

d. There are three emergency ventilation system pushbutton stations in the Ozone Generator Room. These shutdown pushbuttons shall be located at each exit door.

e. The air handler will normally be controlled by local switches and thermostats.

3. Hardwired control: a. None by OSS.

4. Hardwired interlocks: a. None by OSS.

5. MOCP PLC control: a. If the air handler run status switches to 'off', the MOCP will send a signal

to open Ozone Generator Room louvers.


b. On depression of any emergency HVAC system shutdown pushbutton, deactivate the air handler.




9. Indicators and alarms at the MOCP LOI and DCS HMI: a. Air handler run status.


WW. Ozone Generator Room Ventilation Fans and Louvers: 1. References:


a. There are two ventilation fans that are dedicated to the Ozone Generator Room. There is one set of louvers that is dedicated to the Ozone Generator Room.

b. The ventilation fans and louvers will be supplied by the Contractor. The ventilation fans and louvers will have status and control signals wired to the MOCP by the Contractor.

c. The lead ventilation fan will operate continuously and in conjunction with the air handler to provide the necessary ventilation for the Ozone Generator Room.

d. There are three emergency ventilation system pushbutton stations in the Ozone Generator Room. These shutdown pushbuttons shall be located at each exit door.

e. The ventilation fans and louvers will normally be controlled by local switches. There will be a local/remote switch at each device. This switch will normally be left in 'remote' so that the MOCP control functions described herein are active.



5. MOCP PLC control: a. If the lead ventilation fan status switches to 'off', the MOCP will send a

signal to start the lag ventilation fan. b. On high ambient ozone or oxygen concentration alarm from any ambient

ozone or oxygen analyzer in the Ozone Generator Room, start the lag fan and open the louvers.

c. On depression of any emergency HVAC system shutdown pushbutton, deactivate the ventilation fans and close the louvers.


7. MOCP LOI control: a. Lead/lag ventilation fan selector switch.



9. Indicators and alarms at the MOCP LOI and DCS HMI for each fan: a. Ventilation fan run status. b. Lead/lag selector switch position status. c. Louver position status.


XX. Ozone Destruct Room Ventilation Fans: 1. References:


a. There are two ventilation fans that are dedicated to the Ozone Destruct Room.

b. The ventilation fans will be supplied by the Contractor. The ventilation fans will have status and control signals wired to the MOCP via the Ozone Destruct Room RIO by the Contractor.

c. The lead ventilation fan will operate continuously to provide the necessary ventilation for the Ozone Destruct Room.

d. The ventilation fans will normally be controlled by local switches. There will be a local/remote switch at each fan. This switch will normally be left in 'remote' so that the MOCP control functions described herein are active.



5. MOCP PLC control: a. If the lead ventilation fan status switches to 'off', the MOCP will send a

signal to start the lag ventilation fan. 6. Software interlocks:


a. Lead/lag ventilation fan selector switch. 8. DCS HMI control:

a. None. 9. Indicators and alarms at the MOCP LOI and DCS HMI for each fan:

a. Ventilation fan run status. b. Lead/lag selector switch position status. c. Louver position status.


YY. Response to a Power Failure: 1. References:


a. There are two types of power failures that will be addressed in this control strategy: 1) Short-term power failures lasting shorter than an adjustable time

delay (0 to 60 seconds, initial setting = 5.0 seconds). 2) Long-term power failures lasting longer than the same adjustable

time delay.


b. The power failure will be monitored from the motor control center feeding the ozone generator power supplies.

c. The MOCP will be provided with an external, uninterruptable power supply.

d. All functionality of this control strategy can be turned on and off at the MOCP LOI.



5. MOCP PLC control: a. For short-term power failures, the following steps shall occur after power

is restored: 1) Confirm the operational status of the following ozone system

components: a) Supplemental nitrogen system. b) Closed loop cooling water pumps - at least one for each

operating ozone generator. c) Open loop cooling water pumps - at least one. d) Ozone destruct units - appropriate number per the control

strategy. 2) If the operational status of all these components is not adequate, this

strategy performs no additional steps. 3) If the operational status of all these components is adequate, the

following steps shall be performed: a) Any off-line ozone generator(s) that were on-line prior to the

short-term power failure shall be re-started without the purge step. Indicate at MOCP LOI and DCS HMI which ozone generator(s) were restarted automatically after a short-term power failure.

b) If the off-line ozone generator(s) that were on-line prior to the short-term power failure does not re-start, then a lag or stand-by generator is started with the purge step. Indicate at MOCP LOI and DCS HMI which ozone generator(s) were restarted automatically after a short-term power failure.

b. For long-term power failures that last longer than an adjustable time delay (0.0 to 30.0 minutes, initial setting = 10.0 minutes), the following steps shall be performed assuming all local control devices are in 'remote': 1) Close oxygen emergency shut-off valve. 2) Close supplemental nitrogen system process solenoid valve and

open the atmospheric solenoid valve. If the supplemental nitrogen system does not have power, then this action will not be realized.


7. MOCP LOI control: a. On-off control for this control strategy. (Administrator only). b. Short-term power failure time delay. (Administrator only). c. Long-term power failure time delay. (Administrator only).

8. DCS HMI control: a. On-off control for this control strategy. (Administrator only). b. Short-term power failure time delay. (Administrator only). c. Long-term power failure time delay. (Administrator only).


9. Indicators and alarms at the MOCP LOI and DCS HMI: a. On-off status for this control strategy. b. Ozone generator(s) restarted automatically after a short-term power

failure indication. 10. Failure modes:

a. None.










END OF SECTION



SECTION 40_71_13

FLOW MEASUREMENT: MAGNETIC FLOWMETERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Full-body magnetic flowmeters.






C. Provide all instruments identified in the Contract Drawings.

1.02 REFERENCES


B. NSF International (NSF).

1.03 DEFINITIONS


1.04 SUBMITTALS

A. Furnish submittals as specified in Sections 01_33_00 and 40_61_00.



B. Examine the complete set of Contract Documents and verify that the instruments are compatible with the installed conditions including: 1. Process conditions: Fluids, pressures, temperatures, flows, materials, etc. 2. Physical conditions:

a. Installation and mounting requirements. b. Location within the process.


c. Accessories: Verify that all required accessories are provided and are compatible with the process conditions and physical installation.

C. Notify the Engineer if any installation condition does not meet the instrument manufacturer’s recommendations or specifications.





1.08 WARRANTY

A. As specified in the Supplier Agreement.

1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal as approved by the Engineer: 1. Endress+Hauser: Promag 53. 2. Rosemount: 8700E. 3. Krohne: IFC. 4. Yokogawa: AXF. 5. ABB: Watermaster.


A. Magnetic flowmeter: 1. General:

a. Magnetic flowmeters obtain the flow velocity by measuring the changes of induced voltage of the conductive fluid passing across a controlled magnetic field.

b. Complete zero stability shall be an inherent characteristic of the flowmeter system.

c. Include for each magnetic flow metering system: 1) A metering tube with electrodes (sensor). 2) Signal cable. 3) Transmitter integral or remote as indicated on the Drawings. 4) Flowmeter grounding rings.

2. Performance requirements: a. Accuracy:

1) 0.25 percent of flow rate from 10 to 100 percent of full scale for velocities ranging between 1.9 to 10 feet per second.


b. Repeatability: 1) 0.25 percent of rate.

3. Element: a. Metering tube:

1) Constructed of carbon steel or Type 304 stainless steel (unless specifically noted otherwise in the instrument data sheets) with flanged connections to match with piping material.

2) Liner material in conformance with: a) Manufacturer’s recommendations for the intended service.

3) Electrodes type and material in conformance with: a) Manufacturer’s recommendations for the intended service. b) Utilize a minimum of 2 electrodes.

4) Meter terminal housing NEMA Type 4X unless specifically noted otherwise in the instrument data sheets.

5) Meter coating consisting of epoxy painted finish. 6) Components:

a) 2 grounding rings: (1) Which are in conformance with the manufacturer’s bore and

material recommendation for the meter’s intended service. (2) Designed to protect and shield from abrasion of the liner’s

edge interface at the meter’s end. 4. Transmitter:

a. Power supply: 1) 120 VAC. 2) Power consumption: 60 VA maximum.

b. Outputs: 1) As noted in the instrument data sheets. 2) For all instruments with 4 to 20 mA HART or digital bus protocol,

provide a Device Type Manager (DTM) certification by FDT group. c. Microprocessor-based signal converter/transmitter. d. Utilize DC pulse technique to drive flux-producing coils. e. Contain a 6-digit display for flow rate, percent of span, and totalizer. f. Operator keypad interface. g. Integral zero return to provide consistent zero output signals in response

to an external dry contact closure. h. Integral low flow cut-off zero return. i. Programmable parameters including:

1) Meter size. 2) Full-scale flow rate. 3) Magnetic field frequency. 4) Time constant.

j. Data retention for a minimum of 5 years without auxiliary main or battery power.

k. Self-diagnostics and automatic data checking. l. Protected terminals and fuses in a separate compartment which isolates

field connection from electronics. m. Ambient operating temperature limits of -5 to 140 degrees Fahrenheit (-20

to 60 degrees Celsius).

2.03 ACCESSORIES

A. Stainless steel tag labeled as specified in the Contract Documents.


B. Provide sunshades for all transmitters located outdoors.

C. Provide galvanic isolation gaskets, nylon/Teflon flange bolt insulation bushings and nylon washers on all meters installed on pipes with cathodic protection.



B. Factory calibrate each flow metering system at a facility that is traceable to the NIST.

C. A real-time computer generated printout of the actual calibration date indication actual velocities and as read values of the flow tube: 1. Flow calibration report of the manufacturers flow lab calibration procedure

shall be shipped with the meter system. 2. Minimum calibration shall be a 3 point calibration including 1, 3, and 10 feet

per second velocities for every meter and transmitter system. 3. Manufacturer shall archive all calibration reports for future reference.

PART 3 EXECUTION



3.03 INSTALLATION




B. Provide manufacturer’s services to perform installation inspection.

3.05 ADJUSTING

A. Verify factory calibration of all instruments in accordance with the manufacturer’s instructions: 1. Return factory calibrated devices to the factory if they do not meet the field

verification requirements for calibration.

3.06 CLEANING




B. Demonstrate performance of all instruments to the Engineer before commissioning.


3.08 PROTECTION


3.09 SCHEDULES

A. Instrument Data Sheets included in this Section.

B. The provided information does not necessarily include all required instruments.

C. Provide all instruments identified in the Contract Documents: 1. Instruments may be indicated on the Drawings, specified in the Specifications,

or both.

END OF SECTION


A/E: Carollo Engineers

MAGNETIC FLOWMETERS

INSTRUMENT DATA SHEETS

Spec. No. Rev. Contractor: No By Date Revision 40_71_13 Project: Contract Date Customer: Plant: Req. P.O. Location: BOM No.: By Chk App File: 1 Instrument Tag No. 2 Service 3 P&ID 4 C Line Size / Schedule 5 O Line Material

6 N Connection Type/ Pressure Rating

7 N Connection Materials 8 Tube Size

E 9 Tube Material L 10 Liner Material E 11 M Electrode Type Mfg Standard M 12 E Electrode Material E 13 T Meter Casing N 14 E Power Spply Phase 120 VAC 1P T 15 R Grounding Type & Matl. 16 Enclosure Class NEMA 4X 17 Other 18 Fluid 19 F Max Flow 20 L Min Velocity 21 U Min Flow Norm Flow 22 I Min Temp Max Temp 23 D Min Press Max Press 24 Vacuum Possibility 25 Conductivity

T 26 Function R 27 Mounting Integral A 28 Enclosure Class NEMA 4X N 29 Length Signal Cable S 30 Type Span Adjustment M 31 Power Supply I 32 Transmitter Output 4-20 mA HART Relay Outputs Form C

T 33 Accuracy 0.25% T 34 Calibrated Range E 35 Empty Pipe Detection R 36 Bi-Directional Flow 37 Display Scale Size Range 38 Alarm Contact No. Form 39 Manufacturer 40 Element (Meter) Model No. 41 Transmitter (Inst.) Model No.

Notes:


SECTION 40_71_23.21

FLOW MEASUREMENT: ORIFICE PLATE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Orifice plate flow measuring instruments.





Instrumentation Systems. c. Section 40_73_29 - Pressure/Vacuum Measurement: Differential. d. Section 40_80_01 - Testing, Calibration, and Commissioning.

C. Provide all instruments identified in the Contract Documents.

1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS


B. Provide complete documentation covering the traceability of all calibration instruments.

C. Orifice sizing calculation: 1. Submit calculations for each orifice plate using manufacturer’s standard sizing

program. 2. Include the following at a minimum:

a. Discharge coefficient of the orifice plate. b. Beta ratio. c. Orifice bore diameter.


d. Pipe inside diameter. e. Normal operating process temperature and pressure. f. Orifice plate thickness. g. Expected differential pressure at normal and maximum flow rates. h. Permanent pressure loss at normal and maximum flow rates.



B. Examine the complete set of Contract Documents and verify that the instruments are compatible with the installed conditions including: 1. Process conditions: Fluids, pressures, temperatures, flows, materials etc. 2. Physical conditions:

a. Installation and mounting requirements. b. Location within the process. c. Accessories: Verify that all required accessories are provided and are

compatible with the process conditions and physical installation.





A. Project environmental conditions as specified in Section 40_61_00. 1. Provide instruments suitable for the installed site conditions including, but not

limited to, material compatibility, site altitude, site seismic conditions, humidity, and process and ambient temperatures.

1.08 WARRANTY


1.09 MAINTENANCE

A. Furnish all parts, materials, fluids, etc. necessary for operation, maintenance, and calibration purposes throughout the warranty period. Deliver all of these supplies before project substantial completion.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal as approved by the Engineer: 1. Wyatt Engineering. 2. Meriam Instrument. 3. ABB. 4. Rosemount.



A. Orifice plates: 1. General. 2. Performance requirements:

a. Refer to the data sheet for required accuracy. 3. Elements:

a. Orifice plates consist of a flat metal disc with a concentric circular hole. b. Orifice diameters shall be selected so that the ratio of orifice diameter to

actual internal pipe diameter (d/D) does not exceed: 1) 0.75 for liquids. 2) 0.70 for gas and steam. 3) Not less than .0.25 (recommended). 4) A d/D ratio between 0.4 and 0.6 is preferred.

c. Orifice plate: 1) Provide square-edged concentric orifice plate with the appropriate

thickness that can withstand the plate deflection due to the differential pressure across the orifice plate.

2) Quadrant type thickness shall be dependent upon its radius. d. Flange types: Use orifice flange - 300 pound minimum or higher to match

with piping rating. e. All hardware for complete assembly shall be provided, including studs,

bolts, nuts, jackscrews, and gaskets. f. Special integral orifice plate assembly (For 1-1/2 inch, 1 inch, and 1/2 inch

and smaller pipe sizes: 1) Hone internal upstream and downstream section of integral orifice

assembly. 2) Provide and mount the appropriate differential pressure flow

transmitter with the integral orifice assembly. Calibrate and span the transmitter to meet the process and orifice plate differential pressure. The transmitter shall be the one specified.

4. The orifice handle shall be permanently marked on the inlet side with the: a. Orifice tag number. b. Orifice diameter, “d” - inches (to nearest 0.001 inch). c. Beta ratio. d. Plate material. e. Line size and flange rating.

2.03 ACCESSORIES

A. Differential pressure transmitters: 1. As specified in Section 40_73_29.

B. Provide sunshades for outdoor installations.



B. The orifice plate needs to be bench calibrated.

C. Supply as built dimensions of the orifice plate along with the installation and operation manual.


D. Factory calibrate each flow metering system hydraulically at a facility that is traceable to the NIST.

PART 3 EXECUTION

3.01 EXAMINATION

A. Examine the installation location for the instrument and verify that the instrument will work properly when installed: 1. Notify the Engineer promptly if any installation condition does not meet the

instrument manufacturer’s recommendations or specifications.


3.03 INSTALLATION


B. Coordinate the installation with all trades to ensure that the mechanical system has all necessary appurtenances including weld-o-lets, valves, etc. for proper installation of instruments.



3.05 ADJUSTING


3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES

A. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents: 1. Instruments may be indicated on the Drawings, specified in the Specifications,

or both.

END OF SECTION


A/E: Carollo Engineers

ORIFICE PLATE FLOWMETERS

Spec. No. Rev. Contractor: No By Date Revision Project: Contract Date Customer: Plant: Req. P.O. Location: BOM No.: By Chk App File: 1 Instrument Tag No. FE- 2 Service 3 P&ID 4 Type Concentric: X Other: Concentric: X Other: 5 Material 316 Stainless Steel: Other: 316 Stainless Steel: Other: 6 Beta (d/D) 7 P Orifice Bore Diameter 8 L Pipe Size 9 A Pipe Inside Diameter

10 T Plate Thickness 11 E Taps Flange: Vena Contracta: Pipe: Other: Flange: Vena Contracta: Pipe: Other: 12 Tap Size 1/2-Inch: Other: 1/2-Inch: Other: 13 Pressure Drop at Norm Flow 14 Perm. Press. Drop at Norm Flow 15 Other 16 Other 17 F Type Weld Neck: Slip-On: Threaded: Weld Neck: Slip-On: Threaded: 18 L Flange Material 316 Stainless Steel: Other: 316 Stainless Steel: Other: 19 A Flange Rating ANSI 150 lb.: ANSI 300 lb.: Other: ANSI 150 lb.: ANSI 300 lb.: Other: 20 N Other 21 G Other 22 E Other 23 Fluid 24 Fluid State Liquid: Gas: Liquid: Gas: 25 Pressure 26 F Temperature 27 L Specific Gravity 28 U Reynolds Number 29 I Max Flow Units 30 D Max Velocity Units 31 Norm Flow Min Flow 32 Max Temp Min Temp 33 Max Press Min Press 34 Other

35 Transmitter See Transmitter Data Sheet in Spec. 40_73_29

See Transmitter Data Sheet in Spec. 40_73_29

36 Calibrated Range 37 Combined Accuracy 38 Orifice Plate Manufacturer 39 Orifice Plate Model No. Notes: 1. Refer to Specification 40_73_29 for additional differential pressure transmitter requirements. 2. Provide oxygen cleaning services for these devices.




SECTION 40_71_79

FLOW MEASUREMENT: SWITCHES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Thermal dispersion flow switches. 2. Piston type flow switches. 3. Vane type flow switches. 4. Shuttle flow switches. 5. Magnetic flow switches.

B. Related sections: 1. Section 01_33_00 - Submittal Procedures. 2. Section 40_61_00 - Common Work Results for Process Control and


C. Provide all instruments identified in the Contract Drawings.

1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS













A. As specified in Section 40_61_00. 1. Provide instruments suitable for the installed site conditions including, but not


1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal as approved by the Engineer: 1. Thermal dispersion type:

a. Fluid Components International LLC FLT93. b. Kayden.

2. Piston type: a. Universal Flow Monitors Inc. Model LL. b. Gems Sensors and Controls Model FS. c. Dwyer Instruments Model AFS.

3. Vane type: a. Universal Flow Monitors Inc.

4. Shuttle: a. Magnetrol Model F50. b. Flotect Series V6.

5. Magnetic: a. Krohne Model DWM 1000.


A. Thermal dispersion type: 1. General:

a. Instrument uses a heated probe and a reference probe: 1) Deviation in the amount of heat measured by the reference probe

deviates beyond the setpoint an adjustable relay closes.


2) Switch: a) Micro-processor based with continuous self-diagnostics, “Smart

Heater” to prevent sensor failure, no mechanical jumpers or trim pots, and a 3-year warranty.

b) Capability to offer a 4 to 20 milliamperes output. 2. Performance requirements:

a. Accuracy: Within 2 degrees Fahrenheit. b. Repeatability: Within 1 percent of setpoint range. c. Response time: 0.5 to 2.5 seconds. d. Adjustable Bypass Delay Timer. e. Adjustable range.

3. Switch characteristics: a. Exposed parts: Powder coated aluminum housing. b. Wetted parts:

1) Materials as recommended by the manufacturer and approved by the Engineer.

c. Power supply: 1) 115 VAC. 2) Power consumption: 13 VA maximum.

d. Operating temperature range: -40 degrees Fahrenheit to 140 degrees Fahrenheit.

e. Enclosure: 1) NEMA Type 4X.

B. Piston type: 1. General:

a. Fluid flow causes a piston (with a central circular opening) to move along the axis of a precision-tapered shaft, creating a variable orifice between the hole and the shaft.

2. Performance requirements: a. Accuracy: Within 10 percent full scale. b. Adjustable range.

3. Switch characteristics: a. Material:

1) Body: Brass or stainless steel. 2) Other internals: Stainless steel.

b. Contacts: Single pole, double throw (SPDT). c. Maximum operating temperature: 200 degrees Fahrenheit. d. Enclosure: NEMA Type 4X.

C. Rotary vane type: 1. General:

a. Fluid is passed around a semicircular swinging vane or variable orifice that resists the flow due to constant-torque spring.



1) Body: Brass and nylon. 2) Other internals: Stainless steel.

b. Contacts: Single pole, double throw (SPDT).


c. Maximum operating temperature: 200 degrees Fahrenheit. d. Enclosure: NEMA Type 4X. e. Shall contain a display for flow rate.

4. Shuttle type. 5. General:

a. Fluid pushes against a disk or shuttle and moves the element to close contact by means of a magnetic pick up point.



1) Body: Stainless steel. 2) Magnetic sleeve: Stainless steel.

b. Inline installation for pipes ranging between 1/2-inch to 2-inch diameter. c. Contacts: Single pole, double throw (SPDT), rated 5 amperes at 120 volts. d. Maximum operating temperature range: 140 degrees Fahrenheit. e. Enclosure: NEMA Type 4X.

D. Magnetic type: 1. General:

a. The induced voltage of a conductive fluid across a magnetic field is converted into a switching signal.

2. Performance requirements: a. Accuracy: Within 5 percent. b. Adjustable range.

3. Switch characteristics: a. Housing material: Aluminum with epoxy finish or Type 316L stainless

steel. b. Contact: Single pole single throw (SPST). c. Power supply: 120 VAC. d. Enclosure: NEMA Type 4X.

2.03 ACCESSORIES

A. Provide sunshades for outdoor installations.



B. Factory calibrate each instrument with a minimum 3-point calibration or according to Manufacturer’s standard at a facility that is traceable to the NIST: 1. Submit calibration data sheets to the Engineer at least 30 days before

shipment of the instruments to the project site.


PART 3 EXECUTION

3.01 EXAMINATION




3.03 INSTALLATION




3.05 ADJUSTING


3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES

A. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents: 1. Instruments may be indicated on the Drawings, specified in the Specifications

or both.

END OF SECTION


A/E: Carollo Engineers FLOW SWITCHES

Spec. No. Rev. Contractor: N

o By

Date Revision 40_71_79

Project: Contract Date Customer: Plant: Req. P.O. Location: BOM No.: By Chk App File: D 1 Type Thermal: X Rotary Vane: Shuttle: Other E 2 Setting Set in Field: Factory Set: X Internal: External: Dial: V 3 Dead Band Fixed: Adj.: X Min.: Other: I 4 Material Bronze: SS: Alloy St.: Other C 5 Connection 1/2-Inch NPT: X 3/4-Inch NPT: X Other: 6 Mounting Local: X Surface: Flush: 7 Accuracy 8 Other 9 Type Mercury: Snap: Other X

S 10 Quantity Single: X Dual: Other W 11 Form SPST: SPDT: X DPDT: Other

I 12 Rating: Amps Volts Hertz 10 120 60

T 13 Other C 14 Load Inductive: Non-Inductive: H 15 Enclosure General Purpose: Weatherproof: X None: Explosion proof: 16 Enclosure Class 17 Conduit Connection MFR STD: Other 18 Other 19 Manufacturer FCI [or equal as approved by the Engineer]. 20 Model No.

Rev Tag Number

Adj. Range

SP Process

Signal SP

Op. Temp. P&ID Service Notes

Notes: 1. Provide oxygen cleaning services for devices.


SECTION 40_73_13

PRESSURE/VACUUM MEASUREMENT: GAUGES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Pressure/vacuum gauges.





Instrumentation Systems. c. Section 40_73_63 - Pressure/Vacuum Measurement: Diaphragm and

Annular Seals. d. Section 40_73_64 - Pressure/Vacuum Measurement: Instrument Valves.

C. Provide all instruments specified in the Contract Documents.

1.02 REFERENCES


B. American Society of Mechanical Engineers (ASME): 1. B40.100 - Pressure Gauges and Gauge Attachments.

1.03 DEFINITIONS


1.04 SUBMITTALS


B. Additional requirements: 1. Product data:

a. Accessories such as diaphragm seals, valve manifold, snubbers, and pulsation dampeners.












1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Manufacturers: One of the following or equal as approved by the Engineer: 1. Ashcroft:

a. Maximum pressure less than 10 pounds per square inch: Model 1189. b. Maximum pressure greater than or equal to 10 pounds per square inch:

Model 1279. 2. Wika. 3. Ametek U.S. Gauge.


A. General: 1. Pressure gauge assembly shall include pressure sensing element, gauge

case, and dial mechanism.


B. Performance requirements: 1. Pressure range:

a. As specified in the Contract Documents. 2. Accuracy:

a. Grade 2A, as defined by ASME B40.100. b. Within 1.0 percent of span after friction errors are eliminated by tapping or

vibration. c. Maximum allowable friction inaccuracy: Within 1.0 percent of span.

3. Element: a. Where the maximum pressure is less than 10 pounds per square inch,

provide socket and bellows; for all other pressure ranges, employ a Bourdon tube.

b. Socket tips for bellows and Bourdon tube: 1) Materials: Type 316 stainless steel.

c. Overpressure: Minimum 130 percent of maximum range pressure without damage to gauge or sensing element.

d. Wetted materials: Type 316 stainless steel. 4. Dial gauge:

a. Dial size: 4-1/2 inches. b. Dial case material. c. Maximum pressure less than 10 pounds per square inch:

1) Phenolic. d. Maximum pressure greater than or equal to 10 pounds per square inch:

1) Stainless steel. e. Provide safety gauge with safety blow out through the back or top of the

unit. f. Dial face: Gasketed shatterproof glass or polycarbonate. g. Provide gauge locks on all pressure gauges directly connected to

diaphragm seals. h. Provide gauge locks where possible. i. Hermetically sealed. j. Connection and mounting:

1) Direct mounted and suitable for outdoor installation. 2) 1/2 inch NPT. 3) Connection material: Stainless steel.

k. Pointer: Externally adjustable.

2.03 ACCESSORIES

A. Pulsation dampeners and snubbers: 1. Provide pulsation dampener or snubber with each pressure gauge installed on

discharge of positive displacement type pump. 2. Provide piston-type snubber if pressure spikes will exceed 130 percent of

gauge maximum range. 3. Materials: Type 316 stainless steel. 4. Mount pulsation dampener or snubber integrally to the pressure gauge. 5. Connection: 1/2-inch NPT.

B. Provide diaphragm seals as specified in the Contract Documents and in Section 40_73_63: 1. Diaphragm seal and pressure gauge shall be assembled by manufacturer and

shipped as an assembly.


C. Provide means for gauge isolation as specified in Section 40_73_64: 1. Mount valve manifold integrally to the gauge. 2. Valve manifold and pressure gauge shall be assembled by manufacturer and




B. Factory calibrate each pressure gauge at a facility that is traceable to the NIST.

C. Provide complete documentation covering the traceability of all calibration instruments.

PART 3 EXECUTION



3.03 INSTALLATION





3.05 ADJUSTING



3.06 CLEANING





3.08 PROTECTION


3.09 SCHEDULES


or both.

END OF SECTION


A/E: Carollo Engineers PRESSURE GAUGES

Spec. No. Rev. Contractor: No By Date Revision 40_73_13 Project: Contract Date Customer: Plant: Req. P.O. Location: BOM No.: By Chk App File: 1 Type Direct Rdg.: √ Receiver: Other: 2 Mounting Surface: Local: Flush: 3 Dial Diameter: 4.5” Color: 4 Case Cast Iron: Aluminum: Phenolic: √ Polished SS Other: 5 Ring Screwed: Hinged: Slip: Std: Other: 6 Blowout Protection None: Disc: Front: Other: Mfr. Std. 7 Lens Glass: √ Plastic: 8 Options Siphon: N/A Material: 9 Other Snubber:

10 Other Pressure Limit Valve: N/A 11 Other Movement Damping: N/A 12 Nominal Accuracy Required 13 Pressure Element Bourdon: √ Bellows: Other: 14 Element Material Bronze: Steel: Type SS: 316 √ Other: 15 Socket Material Bronze: Steel: SS: 316 Other: 16 Connection ¼ in.: ½ in.: √ Bottom: Other: 17 Movement Dampened: Standard: √ Other: 18 Diaphragm Seal Mfr.: Wetted Part Mat’l: Type: 19 Other Other Mat’l: Fill Fluid: Model: 20 Manufacturer 21 Model No. Rev Tag Number Range P&ID Service Notes

Notes: Refer to Section 40_73_64 for additional instrument valve requirements.


SECTION 40_73_23

PRESSURE/VACUUM MEASUREMENT: DIRECT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Pressure transmitters and indicators.

B. Related sections: 1. Section 01_33_00 - Submittal Procedures. 2. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. 3. Section 40_73_63 - Pressure/Vacuum Measurement: Diaphragm and Annular

Seals. 4. Section 40_73_64 - Pressure/Vacuum Measurement: Instrument Valves. 5. Section 40_80_01 - Testing, Calibration, and Commissioning.


1.02 REFERENCES


1.03 DEFINITIONS


B. Specific definitions: 1. Lower range value (LRV): Lowest pressure that the pressure transmitter is

capable of measuring. 2. Upper range value (URV): Highest pressure that the pressure transmitter is

capable of measuring. 3. Calibrated range: The range that the pressure transmitter is configured to

measure. The low end of the calibrated range must be greater than the LRV of the transmitter. The high end of the calibrated range must be less than or equal to the URV. The calibrated range corresponds to the flow signal sent from the transmitter.

1.04 SUBMITTALS










D. Provide instruments manufactured at facilities certified to the quality standards of ISO 9001.





B. Project environmental conditions as specified in Section 40_61_00: 1. Provide instruments suitable for the installed site conditions including, but not


1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal as approved by the Engineer: 1. Rosemount: 3051 Series. 2. Yokogawa: EJA Series. 3. ABB: 266 Series. 4. Endress & Hauser: Cerabar S Series.



A. Pressure transmitters – direct: 1. General:

a. Pressure transmitter assembly shall include a diaphragm type pressure transducer and microprocessor based transmitter for measurement of gauge, vacuum, or absolute pressure.

2. Performance requirements: a. Maximum ratio of total instrument range to calibrated span: 10 to 1. b. Accuracy:

1) Reference accuracy: Plus or minus 0.075 percent of calibrated span, including effects of hysteresis, nonlinearity, and repeatability.

2) Total performance accuracy: Plus or minus 0.30 percent of calibrated span, including reference accuracy effects, static pressure and ambient temperature effects.

3) Stability: Plus or minus 0.15 percent of upper range limit over 5 years.

3. Element: a. Diaphragm type transducer integral to pressure transmitter. b. Diaphragm material: Stainless steel or ceramic. c. Process material compatibility:

1) Verify all material compatibilities with the instrument manufacturer. d. Process connection: As specified in the Instrument Data Sheets.

4. Transmitter: a. Power supply:

1) 24 VDC - 2 wire loop powered. 2) Power consumption: 3 VA maximum.

b. Outputs: 1) Isolated 4-20mA DC with HART communication protocol.

c. Provided with electronic microprocessor. d. Adjustments: Adjustable electronic zero and span, with elevated or

suppressed zero as required by application. Adjustment shall be possible without mechanical fulcrum points or handheld configurator.

e. Local display: 1) 5-digit LCD. 2) Scaled in engineering units.

f. Enclosure: 1) NEMA Type 4X.

g. Over range protection: To maximum process line pressure. h. Conduit: 1/2 inch male NPT.

5. Components: a. Transmitter mounting:

1) As specified in the Instrument Data Sheets. 2) Provide all necessary hardware for transmitter mounting.

2.03 ACCESSORIES

A. Provide valve manifolds as specified in Section 40_73_64: 1. Mount valve manifold integrally to the transmitter. 2. Valve manifold and transmitter shall be assembled by Manufacturer and



3. Provide remote or integral diaphragm seals as specified in the Instrument Data Sheets and in Section 40_73_63.






PART 3 EXECUTION

3.01 EXAMINATION




3.03 INSTALLATION





3.05 ADJUSTING


3.06 CLEANING





3.08 PROTECTION


3.09 SCHEDULES


or both.

END OF SECTION


A/E: Carollo Engineers PRESSURE TRANSMITTERS

Spec. No. Rev. Contractor: No By Date Revision 40_73_23 Project: Contract Date Customer: Plant: Req. P.O. Location: BOM No.: By Chk App File:

1 Instrument Tag No. PIT-xxx GENERAL 2 Service Ozone

3 P&ID 4 Pressure

SERVICE 5 Process Temperature 35-70 deg F 6 Ambient Temperature 7 Manufacture 8 Model No. 9 Pressure Transmitter Type Direct

TRANSMITTER 10 Calibrated Span 11 Accuracy 12 Adjustable Range 13 Output Signal 4-20 mA HART 14 Body Rating 15 Process Flange Type Threaded

16 Drain/Vent None 17 Process Flange MNPT 18 Adapters

BODY 19 Wetted O-Ring 20 Housing 21 Bolts 22 Mounting Brackets 23 Conduit Entry Size

ELEMENT 24 Isolating Diaphragm Not Required 25 Fill Fluid Not Required 26 Certification / Approval Type 27 Meter

OPTIONS 28 Zero Span & Adjustment 29 Surge Protection 30 Custom Configuration 31 Manufacturer

MANIFOLD 32 Model Number 33 Manifold Style Reference Details 34 Manifold Type Block and Bleed

Notes: Refer to Section 40_73_64 for additional instrument valve requirements.


SECTION 40_73_29

PRESSURE/VACUUM MEASUREMENT: DIFFERENTIAL

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Differential pressure transmitters and indicators.








1.02 REFERENCES


1.03 DEFINITIONS


B. Specific definitions: 1. Lower range value (LRV): Lowest pressure that the pressure transmitter is

capable of measuring. 2. Upper range value (URV): Highest pressure that the pressure transmitter is

capable of measuring. 3. Calibrated range: The range that the pressure transmitter is configured to

measure. The low end of the calibrated range must be greater than the LRV of the transmitter. The high end of the calibrated range must be less than the URV. The calibrated range corresponds to the pressure signal sent from the transmitter.


1.04 SUBMITTALS


B. Product data: 1. Accessories such as diaphragm seals, valve manifold, snubbers, and pulsation

dampeners.











A. Project environmental conditions as specified in Section 40_61_00: 1. Provide instruments suitable for the installed site conditions including, but not


1.08 WARRANTY


1.09 MAINTENANCE



PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following no equal: 1. Rosemount Series. 2. Yokogawa EJA Series. 3. ABB 264 Series. 4. Endress + Hauser Deltabar S Series. 5. SMAR LD300 Series.


A. Pressure transmitters - differential: 1. General:

a. Differential pressure transmitter assembly shall include a diaphragm-type pressure transducer and microprocessor-based transmitter for measurement of differential pressure.

b. Differential pressure transmitters shall be used for differential pressure, flow, or liquid level measurement as indicated on the Drawings.

2. Performance requirements: a. As specified in data sheets or instrument index. b. Maximum ratio of total instrument range to calibrated span: 10 to 1. c. Accuracy:

1) Reference accuracy: Plus or minus 0.075 percent of calibrated span, including effects of hysteresis, nonlinearity, and repeatability.

2) Total performance accuracy: Plus or minus 0.30 percent of calibrated span, including reference accuracy effects, static pressure and ambient temperature effects.

3) Stability: Plus or minus 0.15 percent of upper range limit over 5 years.

3. Element: a. Diaphragm-type transducer integral to differential pressure transmitter. b. Diaphragm material: Stainless steel or ceramic. c. Wetted materials: Stainless steel:

1) Process material compatibility: a) Verify all material compatibilities with the instrument

manufacturer. d. Diaphragm fill fluid: Inert Halocarbon. e. Process connection: 1/2-inch NPT.

4. Transmitter: a. Power supply:

1) 24 VDC - loop powered. b. Outputs:

1) Isolated 4-20 mA DC with HART communication protocol. c. Provided with electronic microprocessor. d. Adjustments: Adjustable electronic zero and span, with elevated or

suppressed zero as required by application. Adjustment shall be possible without mechanical fulcrum points or handheld configurator.

e. Square root extraction for flow calculation. f. Local display:

1) 5-digit LCD.


2) Scaled in engineering units. g. Enclosure: NEMA Type 4X. h. Overrange protection: To maximum process line pressure. i. Conduit connection: 1/2 inch male NPT.

5. Components: a. Transmitter mounting:

1) As specified in the data sheets or instrument index. 2) Provide all necessary hardware for transmitter mounting.

2.03 ACCESSORIES

A. Provide Blowdown type 5-valve manifold as specified in Section 40_73_64: 1. Mount valve manifold integrally to the transmitter. 2. Valve manifold and transmitter shall be assembled by manufacturer and


B. Provide integral diaphragm seals as specified in data sheets or instrument index and as specified in Section 40_73_63. 1. Diaphragm seal and transmitter shall be assembled by manufacturer and


C. Provide sunshades for outdoor installations.



B. Each differential pressure transmitter shall be factory calibrated with 5-point calibration at a facility that is traceable to the NIST.


PART 3 EXECUTION





3.03 INSTALLATION






3.05 ADJUSTING



3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES


or both.

END OF SECTION


A/E: Carollo Engineers DIFFERENTIAL PRESSURE TRANSMITTERS


1 Instrument Tag No. DPIT- GENERAL 2 Service

3 P&ID 4 Pressure

SERVICE 5 Process Temperature 6 Ambient Temperature 7 Manufacturer 8 Model No. 9 Pressure Transmitter Type

TRANSMITTER 10 Calibrated Span 11 Accuracy 12 Adjustable Range 13 Output Signal 4-20 mA 14 Body Rating 15 Process Flange Type 16 Drain/Vent 17 Process Flange 18 Adapters

BODY 19 Wetted O-Ring 20 Housing 21 Bolts 22 Mounting Brackets 23 Conduit Entry Size

ELEMENT 24 Isolating Diaphragm 25 Fill Fluid 26 Certification / Approval Type 27 Meter

OPTIONS 28 Zero Span & Adjustment 29 Surge Protection 30 Custom Configuration 31 Manufacturer

MANIFOLD 32 Model Number 33 Manifold Style 34 Manifold Type

Notes: Refer to Section 40_73_63 for additional diaphragm seal requirements. Refer to Section 40_73_64 for additional instrument valve requirements.


SECTION 40_73_36

PRESSURE/VACUUM MEASUREMENT: SWITCHES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Pressure/vacuum switches.




3. The following sections are related to the Work described in this Section. This list of related sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents. a. Section 01_33_00 - Submittal Procedures. b. Section 40_61_00 - Common Work Results for Process Control and




1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS



a. Accessories such as diaphragm seals, valve manifold, snubbers, and pulsation dampeners.













1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Mechanical type pressure switch: One of the following or equal as approved by the Engineer: 1. Ashcroft B Series Type 400. 2. United Electric Controls 400 Series. 3. ASCO S-Series.


A. Mechanical type pressure switches: 1. General:

a. Pressure switch shall be diaphragm or diaphragm-sealed piston type. 2. Performance requirements:

a. Pressure range: 1) As specified in data sheets following this Section.


b. Accuracy: 1) Within 1.0 percent of range.

c. Repeatability: 1) Within 1.0 percent of range.

3. Element: a. Type: Diaphragm, diaphragm-sealed piston, or bourdon tube. b. Overpressure:

1) Minimum 130 percent of maximum range pressure without damage to switch or sensing element.

2) Minimum 400 percent of nominal range without leakage or rupture. c. Sensing element shall not require ambient temperature compensation. d. Wetted materials: Stainless steel. e. Setpoint:

1) Dual. 2) Switch shall activate at setpoint on increasing pressure for high-

pressure alarm applications and on decreasing pressure for low-pressure alarm applications.

f. Fixed deadband. g. Switch elements:

1) Snap acting. 2) Single pole-double throw (SPDT). 3) Rated at 5 A, 125/250 VAC. 4) Automatic reset type.

h. Enclosure: Epoxy coated: 1) NEMA Type 4X.

i. Switch mounting: 1) Process connection: 1/2-inch NPT.

4. Components: a. Provide all necessary hardware for pressure switch mounting.

2.03 ACCESSORIES

A. Pulsation dampeners and snubbers: 1. Provide pulsation dampener or snubber with each pressure switch installed on

discharge of positive displacement type pump. 2. Materials: Stainless steel. 3. Mount pulsation dampener or snubber integrally to the pressure switch. 4. Connection: 1/2-inch NPT.

B. Provide diaphragm seals as specified in data sheets or as indicated on the Drawings and as specified in Section 40_73_63: 1. Diaphragm seal and pressure switch shall be assembled by manufacturer and


C. Furnish block and bleed valves as specified in Section 40_73_64.



B. Factory calibrate each instrument with a minimum 3-point calibration or according to Manufacturer’s standard at a facility that is traceable to the NIST.


1. Submit calibration data sheets to the Engineer at least 30 days before shipment of the instruments to the project site.

PART 3 EXECUTION



3.03 INSTALLATION





3.05 ADJUSTING



3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES

A. The provided information does not necessarily include all required instruments. Provide all instruments specified in the Contract Documents: 1. Instruments may be indicated on the Drawings, specified in the Specifications

or both.

END OF SECTION


A/E: Carollo Engineers PRESSURE/VACUUM SWITCHES


1 Type Press: Vacuum: Comp.: Diff.Press: Other D 2 Setting Set in Field: Factory Set: Internal: External: Dial: E 3 Dead Band Fixed: Adj.: Min.: Other: V 4 Mtl : Body Seat Tube I 5 Element Type Diaphragm: Bourdon: Bellows: Other C 6 Material Bronze: SS: Alloy St.: Other E 7 Connection ½ in NPT √ Bottom: Back: 8 Mounting Local: Surface: Flush: 9 Accuracy 10 Other 11 Type Mercury: Snap: Other 12 Quantity Single: Dual: Other

S 13 Form SPST: SPDT: DPDT: Other W 14 Rating: Amps Volts Hertz 10 120 60 I 15 Other T 16 Load Inductive: Non-Inductive: √ C 17 Enclosure General Purpose: Weatherproof: None: Explosion proof: H 18 Enclosure Class 19 Conduit Connection MFR STD: Other 20 Other 21 Manufacturer 22 Model No.

Rev Tag Number Adj. Range SP Process Signal SP Op. Temp. P&ID Service Notes PSL- or PSH- Notes: Refer to Section 40_73_63 for additional diaphragm seal requirements. Refer to Section 40_73_64 for additional instrument valve requirements.



SECTION 40_73_63

PRESSURE/VACUUM MEASUREMENT: DIAPHRAGM AND ANNULAR SEALS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Diaphragm seals. 2. Annular seals.






C. Provide all seals identified in the Contract Documents.

1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS



a. Manufacturer’s installation instructions. b. Seal type. c. Body materials. d. Diaphragm material. e. Fill fluid type. f. Seal size. g. Options. h. Process connection.












1.08 WARRANTY


1.09 MAINTENANCE


B. Provide spare annular seal for every size indicated in the project for each water treatment plant.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Diaphragm seals: 1. For chemical applications and liquids with pulsating flow having pressures less

than or equal to 15 pounds per square inch gauge: One of the following or equal as approved by the Engineer: a. Ashcroft:

1) Flushing connection: Type 741. 2) Without flushing connection: Type 740.

b. Mansfield and Green: 1) Flushing connection: Type SGT. 2) Without flushing connection: Type SBT.

c. Wika, Type L990.40. d. Rosemount.


2. For chemical applications and liquids with pulsating flow having pressures greater than or equal to 15 pounds per square inch gauge: One of the following or equal as approved by the Engineer: a. Ashcroft:

1) Flushing connection: Type 201. 2) Without flushing connection: Type 200. 3) Saddle mount: Type 205.

b. Mansfield and Green: 1) Flushing connection: Type SG. 2) Without flushing connection: Type SB. 3) Saddle mount: Type SJ.

c. Wika: 1) Type L990.10. 2) Saddle mount: L910.ZA.

d. Rosemount.


A. Diaphragm seals: 1. General:

a. Diaphragm seal and pressure instrument shall be assembled by pressure instrument manufacturer and shipped as an assembly.

2. Requirements: a. Seal type:

1) Metallic diaphragm: Welded to upper housing. 2) Elastomer diaphragm: Bonded to upper housing.

b. Process connection: 1 inch NPT or Saddle flange. c. Instrument connection: 1/2 inch NPT. d. Material Construction: Type 316 Stainless Steel. e. Provide 1/4-inch flushing connection in diaphragm lower housing or

provide flushing ring. f. Flush port plug: Same material of construction as diaphragm lower

housing. g. Provide fill/bleed connection. h. Mounting: As indicated in the Contract Documents. i. Provide Type 316 stainless steel armored capillary for all remote

installations. j. Nuts and bolts: Type 316 stainless steel. k. Materials of construction:

1) Ozone: a) Diaphragm: Type 316 stainless steel. b) Lower housing: Type 316 stainless steel. c) Upper housing: Manufacturer’s standard. d) Fill fluid: Halocarbon.

2) Engineer’s approval.

2.03 ACCESSORIES

A. Provide field fill kits.




PART 3 EXECUTION



3.03 INSTALLATION



C. Do not use Teflon thread seal tape on pressure instruments with silicon oil fill fluid.




3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES

A. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents: 1. Instruments may be indicated on the Drawings, in the Specifications or both.

END OF SECTION


SECTION 40_73_64

PRESSURE/VACUUM MEASUREMENT: INSTRUMENT VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Valve manifolds and instrument valves.







1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS



C. Additional requirements: 1. Product data:

a. Valve type. b. Body material. c. Size. d. Options.

2. Shop drawings: a. Mounting details for all manifold valves.











B. Protect valve manifolds and protective coatings from damage during handling and installation. Repair coating where damaged.




1.08 WARRANTY


1.09 MAINTENANCE


B. Furnish all parts, materials, fluids, etc. necessary for operation, maintenance, and calibration purposes throughout the warranty period. Deliver all of these supplies before project substantial completion.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Valve manifold manufacturers: One of the following or equal as approved by the Engineer: 1. Anderson Greenwood.


2. Hex Valve. 3. Noshok. 4. Rosemount.

B. Block and bleed valve manufacturers: One of the following or equal as approved by the Engineer: 1. Anderson Greenwood. 2. Hex Valve.

C. Gauge valve manufacturers: One of the following or equal as approved by the Engineer: 1. Anderson Greenwood. 2. Hex Valve.

D. Level sensor isolation valve manufacturers: One of the following or equal as approved by the Engineer: 1. Indu-Tech Level Sensor Isolation Valve. 2. DeZURIK Level Sensor Isolation Valve. 3. Tyco Rovalve Isolation Knife Gate Valve.


A. Valve manifolds: 1. General:

a. Provide 2-valve, 3-valve, blowdown type 5-valve, or metering type 5-valve manifolds as indicated on the Drawings.

b. Valve manifolds shall have one piece bonnet with a metal to metal seal to the valve body below the bonnet threads.

2. Requirements: a. Bonnet lock pin to prevent accidental loosening. b. Gas leak tested metal-to-metal hard seat design for hard seat valves. c. Gas leak tested soft seat design with replaceable seat for soft seat valves. d. Manifold valves shall have straight through portion for bi-directional flow

and easy roddable cleaning. e. Manifold valves shall allow for direct or remote instrument mounting. f. Shall be able to withstand pressures up to 6,000 psi for soft seat valves

and 10,000 psi for hard seat valves at maximum 200 degrees Fahrenheit. g. Materials of construction:

1) Body material: Type 316 stainless steel. 2) O-Ring: Teflon.

h. 2-Valve manifolds: 1) 1 isolation valve and 1 drain/vent and calibration valve.

i. 3-Valve manifolds: 1) 2 isolation valves and 1 equalizing valve for differential pressure

applications. 2) Plugged vent connections used for vent/drain or calibration.

j. Blowdown 5-valve manifold: 1) 2 isolation valves, 1 equalizing valve, 2 blowdown valves for

differential pressure applications. k. Metering 5-valve manifold:

1) 2 isolation valves, 2 equalizing valves, 1 vent/drain and calibration valve for differential pressure applications.


B. Block and bleed valves: 1. General:

a. Valve shall provide process isolation and venting/draining capabilities. b. Gas leak tested metal-to-metal hard seat design for hard seat valves. c. Gas leak tested soft seat design with replaceable seat for soft seat valves. d. Valve shall not be used with fluids with high solids content, such as raw

wastewater or sludge. 2. Requirements:

a. Materials of construction: 1) Body material: Type 316 stainless steel. 2) O-Ring: Teflon.

C. Gauge valves: 1. General:

a. Valve shall provide process isolation from pressure instrument. b. Gas leak tested, metal-to-metal hard seat design for hard seat valves. c. Gas leak tested soft seat design with replaceable seat for soft seat valves.

2. Requirements: a. Materials of construction:

1) Body material: Type 316 stainless steel. 2) O-Ring: Teflon.

D. Level sensor isolation valves: 1. General:

a. Valve shall provide process isolation from level diaphragm. b. Gas leak tested, metal-to-metal hard seat design for hard seat valves. c. Gas leak tested soft seat design with replaceable seat for soft seat valves.

2. Requirements: a. Materials of construction:

1) Body material: Type 316 stainless steel. 2) Flange diameter size: 3 inches.

2.03 ACCESSORIES

A. Provide tube fitting, female NPT, or pipe butt weld connections if necessary.

B. Provide stainless steel concentric or eccentric pipe nipples when necessary.






PART 3 EXECUTION

3.01 EXAMINATION




3.03 INSTALLATION





3.05 ADJUSTING


B. Verify factory calibration of all instruments in accordance with the manufacturer’s instructions: 1. Return factory calibrated devices to the factory if they do not meet the field


3.06 CLEANING





3.08 PROTECTION



3.09 SCHEDULES


or both.

END OF SECTION


SECTION 40_74_13

TEMPERATURE MEASUREMENT: RTD

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. RTD temperature instruments.





Instrumentation Systems. c. Section 40_80_01 - Testing, Calibration, and Commissioning.


1.02 REFERENCES


1.03 DEFINITIONS


B. Specific definitions: 1. RTD - Resistance temperature detector.

1.04 SUBMITTALS















1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal as approved by the Engineer:

1. Rosemount Model 3144P transmitter with Series 68 sensor. 2. Acromag 1500 Series. 3. Siemens SITRANS T. 4. Foxboro Model RTT20.


A. RTDs: 1. General:

a. Temperature measuring instrument shall include an RTD temperature element, transmitter, and thermowell.


2. Performance requirements: a. Accuracy:

1) Within 0.25 percent of calibrated span. b. Repeatability:

1) 0.25 percent of full scale. c. Sensor lead wire compensation: Maximum zero shift of 0.2 percent of the

temperature range. 3. Element:

a. 100-Ohm platinum thin film resistance temperature detector (RTD). b. 3-wire. c. Hermetically sealed, and enclosed in Type 316 stainless steel outer

sheath. d. Single element temperature sensor shall be spring-loaded.

4. Transmitter: a. Microprocessor based. b. Compatible with 3-wire and 4-wire RTD inputs. c. Local display:

1) 5-digit LCD. 2) Scaled in engineering units.

d. Power supply: 1) 24 VDC - loop powered.

e. Outputs: 1) Isolated 4 to 20 milliamperes DC with HART communication protocol.

f. Transmitter enclosure: NEMA Type 4X. g. Transmitter mounting:

1) As specified on the Instrument Data Sheets or Instrument Index. 2) Connection to thermowell: 1/2-inch NPT. 3) Provide all necessary hardware for transmitter mounting.

2.03 ACCESSORIES

A. Thermowell: 1. Unless otherwise noted, provide a thermowell with each RTD. 2. Process connection: As identified on instrument data sheet. 3. Thermowell material: manufacturer recommendation for fluid. 4. Stem style: As identified on instrument data sheet. 5. Immersion depth:

a. Minimum 3 inches or 10 times the diameter of the thermowell, whichever is larger.

b. Where pipe diameter is inadequate for appropriate immersion depth, install thermowell in an elbow on the axis of the pipe.

c. As identified on instrument data sheet.






PART 3 EXECUTION

3.01 EXAMINATION




3.03 INSTALLATION



C. Apply thermally conductive silicone grease to the sensor tip before insertion in thermowell.



3.05 ADJUSTING


3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES


or both.

END OF SECTION


A/E: Carollo Engineers TEMPERATURE TRANSMITTERS - RTD


1 Instrument Tag No. TE/TIT- GENERAL 2 Service

3 P&ID SERVICE 4 Process Temperature

5 Ambient Temperature 6 Manufacturer 7 Model No. 8 Display

TRANSMITTER 9 Calibrated Span 10 Adjustable Range 11 Accuracy 12 Output Signal 13 Body Rating 14 Manufacturer 15 Model No. 16 Type

TEMPERATURE 17 Temperature Range ELEMENT 18 Mounting

19 Connection 2-Wire: 3-Wire: 4-Wire: 20 Leads Standard: Potted: Hermetically Sealed: 21 Sheath Material Stainless Steel 22 Element Length 23 Type Straight: Tapered: Stepped:

THERMOWELL 24 Material 25 Insertion Length 26 Process Connection 1/2-inch Thread: 3/4-inch Thread: Flange: Weld Mount: 27 28

OPTIONS 29 30 31

Notes:



SECTION 40_74_43

TEMPERATURE MEASUREMENT: TEMPERATURE GAUGE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Temperature gauges.







1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS






a. Installation and mounting requirements.


b. Location within the process. c. Accessories: Verify that all required accessories are provided and are









1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Bimetallic type temperature gauge: One of the following or equal as approved by the Engineer: 1. Ashcroft Type EI. 2. Weiss Instruments Series BM. 3. Noshok 300 Series.

B. Liquid filled temperature thermometer: One of the following or equal as approved by the Engineer: 1. Weksler Type AS5. 2. Dwyer Type IT.

C. Gas actuated temperature gauge: One of the following or equal as approved by the Engineer: 1. Ashcroft Series 600. 2. Weiss Instruments Series G. 3. Noshok.



A. Bimetallic type temperature gauges: 1. General:

a. Temperature gauges shall consist of a bimetallic temperature sensor with a dial-type temperature gauge.

2. Performance requirements: a. Temperature range:

1) As indicated in the Contract Documents. b. Accuracy:

1) Within 1.0 percent of range. 3. Element:

a. Type: Bimetallic. b. Stem material: Stainless steel. c. Temperature gauge sensor shall be tamperproof, hermetically sealed, and

silicon dampened. d. Process connection: 1/2 inch NPT.

4. Dial gauge: a. Dial size: 3 inches. b. Dial case material: Stainless steel. c. Dial face: Gasketed shatterproof glass. d. Orientation: Straight or angled as required to provide most convenient

direct viewing. e. Mounting: Direct mounted and suitable for outdoor installation. f. External adjustable recalibration screw.

B. Liquid filled thermometer: 1. General:

a. Liquid-filled thermometer shall consist of a liquid filled tube. 2. Performance requirements:

a. Temperature range: 1) As indicated in the Contract Documents.

b. Accuracy: 1) Within 1.0 percent of range.

3. Element: a. Type: Liquid filled in a tube. b. Stem material: Stainless steel. c. Easy adjustment permits case and stem to be rotated 360 degrees.

4. Thermometer: a. Scale size: 9 inches. b. Scale material: White aluminum scale with bold black graduations and

figures. c. Mounting: Direct mounted and suitable for outdoor installation.

5. Thermowell: As specified in this Section.

C. Gas actuated temperature gauges: 1. General:

a. Temperature gauges shall consist of a gas actuated temperature sensor with a dial-type temperature gauge.


2. Performance requirements: a. Temperature range:

1) As indicated in the Contract Documents. b. Accuracy:

1) Within 1.0 percent of range. 3. Element:

a. Type: Gas actuated. b. Bulb and capillary material shall be stainless steel. c. Temperature gauge sensor shall be tamperproof and hermetically sealed. d. Process connection: 1/2 inch NPT.

4. Dial gauge: a. Dial size: 4-1/2 inches. b. Dial case material: Stainless steel. c. Dial face: Gasketed shatterproof glass. d. Orientation: Straight or angled as required to provide most convenient

direct viewing. e. Mounting: As indicated in the contract documents.

2.03 ACCESSORIES

A. Thermowell: 1. Unless otherwise noted, provide Thermowell with each temperature gauge. 2. Process connection: As indicated in the contract documents. 3. Thermowell material: Material compatible with the service fluid identified and

recommended by the manufacturer for the process condition. 4. Stem style: Straight or tapered. 5. Immersion depth:

a. Minimum 3 inches or 10 times the diameter of the sensor protection tube or Thermowell, whichever is larger.




B. Factory calibrate each instrument with a minimum 3-point calibration or according to manufacturer’s standard at a facility that is traceable to the NIST. 1. Submit calibration data sheets to the Engineer at least 30 days before


PART 3 EXECUTION

3.01 EXAMINATION





3.03 INSTALLATION




3.05 ADJUSTING


3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES


or both.

END OF SECTION


A/E: Carollo Engineers TEMPERATURE GAUGES

Spec. No. Rev. Contractor: No By Date Revision 40_74_43 Project: Contract Date Customer: Plant: Req. P.O. Location: BOM No.: By Chk App File: 1 Type Bimetallic: Gas Actuated: 2 Mounting Surface: Local: Flush: Thermowell: 3 Stem Material Stainless Steel: Other: 4 Thermowell Type Straight: Tapered: Stepped: 5 Thermowell Material Stainless Steel: Other: 6 Thermowell Insertion Length 7 Process Connection 1/2-inch Thread: 3/4-inch Thread: Flange: Weld Mount: 8 Dial Diameter: Color: 9 Case Polypropylene: Aluminum: Phenolic.: Polished SS Other:

10 Lens Polycarbonate: Glass: Shatterproof Glass: 11 Accuracy 12 Manufacturer 13 Model No. 14 Other 15 Other Rev Tag Number Range P&ID Service Notes

TI-

Notes:


SECTION 40_74_66

TEMPERATURE MEASUREMENT: TEMPERATURE SWITCH

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Temperature switch instruments.







1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS





B. Examine the complete set of Contract Documents and verify that the instruments are compatible with the installed conditions including: 1. Process conditions: Fluids, pressures, temperatures, flows, materials, etc.


2. Physical conditions: a. Installation and mounting requirements. b. Location within the process. c. Accessories: Verify that all required accessories are provided and are









1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal as approved by the Engineer: 1. Ashcroft B Series. 2. United Electric 400 Series.


A. Temperature switches: 1. General:

a. Temperature switch shall be bulb type with snap-action switch element. 2. Performance requirements:

a. Temperature range: As indicated in the data sheets or the P&IDs. b. Accuracy:

1) Within 2.0 percent of range. c. Repeatability:

1) Within 2.0 percent of range.


3. Element: a. Sensing element material: Stainless steel. b. Sensing element shall not require ambient temperature compensation. c. Switch elements:

1) Snap acting. 2) Hermetically sealed.

4. Transmitter: a. Setpoint:

1) Dual. 2) Activate switch at setpoint on increasing temperature for high

temperature alarm applications and on decreasing temperature for low temperature alarm applications.

b. Fixed deadband. c. Automatic reset type. d. Enclosure: Epoxy coated NEMA Type 4X. e. Switch mounting:

1) Local mount directly to thermowell. 2) Process connection: 1/2-inch NPT. 3) Provide all necessary hardware for temperature switch mounting.

f. Outputs: 1) Relay outputs:

a) Form C contact: 1. b) Rated at 10A, 125/250VAC.

2.03 ACCESSORIES

A. Thermowell: 1. Unless otherwise noted, provide thermowell with each temperature switch. 2. Process connection: As indicated in the Data sheets. 3. Thermowell material: As Indicated in the Datasheets. 4. Stem style: As indicated in the Data sheets. 5. Immersion depth:

a. Minimum 3 inches or 10 times the diameter of thermowell, whichever is larger.

b. Where pipe diameter is inadequate for appropriate immersion depth, install thermowell in an elbow on the axis of the pipe.







PART 3 EXECUTION

3.01 EXAMINATION

A. Examine the installation location for the instrument and verify that the instrument will work properly when installed. 1. Notify the Engineer promptly if any installation condition does not meet the



3.03 INSTALLATION




3.05 ADJUSTING


3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES


or both.

END OF SECTION


A/E: Carollo Engineers TEMPERATURE SWITCHES


1 Type D 2 Setting Set in Field: Factory Set: Internal: External: Dial: E 3 Dead Band Fixed: Adj.: Min.: Other: V 4 Wetted Material I 5 Connection MFR STD: Bottom: Back: C 6 Mounting Local: Surface: Flush: Thermowell: Remote: E 7 Thermowell Type Straight: Tapered: Stepped: 8 Thermowell Material Stainless Steel: Other: 9 Thermowell Insertion Length 10 Process Connection 1/2-inch Thread: 3/4-inch Thread: Flange: Weld Mount: 11 Other 12 Type Mercury: Snap: Other : 13 Quantity Single: Dual: Other :

S 14 Form SPST: SPDT: DPDT: Other W 15 Rating: Amps Volts Hertz 10 120 60 I 16 Other T 17 Load Inductive: Non-Inductive: √ C 18 Enclosure General Purpose: Weatherproof: None: Explosion proof: H 19 Enclosure Class 20 Conduit Connection MFR STD: Other 21 Accuracy 22 Other 23 Manufacturer 24 Model No.

Rev Tag Number Adj. Range SP Process Signal SP Op. Temp. P&ID Service Notes

TSL- or TSH-

Notes:




SECTION 40_75_85

ANALYZERS: DEW POINT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes requirements for: 1. Dew Point Analyzers for permanent installations.



subcontractors, suppliers, and other individuals or entities performing or furnishing any of Contractor’s Work: a. Items involving electrical, control, and instrumentation construction may

be indicated on the Drawings or specified in the Specifications that do not apply specifically to electrical, control and instrumentation systems.

3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 40_61_00 - Common Work Results for Process Control and


C. Furnish all instruments identified in the Contract Documents.

1.02 REFERENCES


1.03 DEFINITIONS


1.04 SUBMITTALS

A. Furnish complete submittals as specified in Sections 01_33_00 and 40_61_00.

B. Test reports: 1. Certified factory and field calibration data sheets for instruments and devices

that require set-up and calibration: a. Include factory calibration for each instrument with stated accuracy.

C. Operating Manuals: 1. Certified factory and field calibration data sheets for instruments and devices

that require set-up and calibration: a. Include factory calibration for each instrument with stated accuracy.


2. Complete installation, calibration, and testing manuals.



B. Examine the complete set of Contract Documents and verify that the instruments are compatible with the installed conditions including:

1. Process conditions: Fluids, pressures, temperatures, flows, materials, etc. 2. Physical conditions:







A. As specified in Section 40_61_00 for project environmental conditions.

1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Panel mount GE moisture. 2. IQ analyzer with IQ series probe. 3. Kahn Cermet ii Hygrometer.


A. General: 1. Each measuring system shall consist of a moisture probe and a

microprocessor-based Dew Point Analyzer. 2. Performance requirements:

a. Function: 1) Dew point. 2) PPMv (PPM by volume) in gases at constant pressure.


b. Dew point measurement range (minimum): -148 to +68 degrees F. c. Accuracy: plus/minus 5.4 degrees F from -112 to -87 degrees F dew point

and plus/minus 3.6 degrees F from -85 to 50 degrees F dew point. d. Repeatability: plus/minus 1.8 degrees F from -112 to -87 degrees F dew

point and plus/minus 0.9 degrees F from -85 to 50 degrees F dew point.

B. Moisture probe: 1. Suitable for use with the furnished Dew Point Analyzer. 2. Material: Thin-film aluminum oxide. 3. Operating pressure range: 5 microns mercury (Hg) to 75 pounds per square

inch gauge. 4. Operating temperature range: -166 to 140 degrees Fahrenheit. 5. Process connection: As indicated on the P&IDs. 6. Inlet flow range:

a. Gases: Static to 10,000 cm/s linear velocity at 1 atm. 7. Provide all probe mounting hardware.

C. Dew point analyzer: 1. Microprocessor-based, single channel analyzer. 2. Touch screen display. 3. Output: As indicated on the data sheets at the end of this Section. 4. Power supply: 120-volt, single phase, 60 hertz. 5. Enclosure: As indicated on the data sheets at the end of this Section. 6. Provide all analyzer mounting hardware. 7. Operating temperature: 32 to 140 degrees Fahrenheit.

D. Cable between probe and analyzer: Manufacturer’s standard cable with length as required for the skid dimensions.


A. As specified in Section 40_61_00 and noted in this Section.

B. Factory calibrate each probe and analyzer at a facility that is traceable to the NIST: 1. Provide complete documentation covering the traceability of all calibration

instruments.

PART 3 EXECUTION




3.03 INSTALLATION

A. As specified in Section 40_61_00. B. Coordinate the installation with all trades to ensure that the mechanical system has

all necessary appurtenances including weld-o-lets, valves, etc. for proper installation of instruments.



B. Provide manufacturer’s services to perform installation inspection, start-up and calibration/verification.

3.05 ADJUSTING



3.06 CLEANING





3.08 PROTECTION


3.09 SCHEDULES

A. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents: 1. Instruments may be indicated on the Drawings, in the Specifications or both.

END OF SECTION


A/E: ANALYZER – DEW POINT Spec. No. Rev. Contractor: No By Date Revision 40_75_85 Project: Contract Date Customer: Plant: Req. P.O. Location: BOM No.: By Chk App File: G 1 Tag No. Element Transmitter AE/AIT- E 2 Service N 3 P&ID 4 Type 5 Measurement Range 6 Accuracy

E 7 Repeatability L 8 Operating Temperature range E 9 Operating Pressure range M 10 Operating Flow range E 11 Process Fluid N 12 Calibration NIST traceable T 13 Other 14 Other 15 Manufacturer 16 Model No.

C 17 Style Manufacturer’s Standard A 18 Length B 19 Other L 20 Other E 21 Other 22 Type Measurement unit and display

T 23 Function Dew Point: PPMv: R 24 Mounting A 25 Enclosure NEMA 4X Weatherproof N 26 Power Requirements S 27 Display M 28 Calibrated Range I 29 Operating Tempeature Range T 30 Outputs Isolated 4 - 20 mA DC T 31 Contacts 1 Form C – fault alarm E 32 Manufacturer R 33 Model No. 34 Other 35 Other 36 Other 37 Other 38 Other

O 38 Manufacturer’s Sample Cell P 39 Integral Temperature Sensor T 38 Manufacturer’s software S 38 Hermetically sealed contact 39 Two additional Form C contacts

Notes:



February 2016 40_76_13_1-1 9905A10 pw://Carollo/Documents/Client/CA/EBMUD/9905A10/02 Pre-Purchase/Specifications/40_76_13_1 (FINAL)

SECTION 40_76_13

ANALYZERS: GAS MONITORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. High concentration ozone analyzers. 2. Ambient and low concentration ozone analyzers.

B. All analyzers in this section shall be provided by the Ozone System Supplier and installed and commissioned by the Contractor.




3. The following sections are related to the Work described in this Section. This list of related sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents. a. Section 01_33_00 - Submittal Procedures. b. Section 40_61_00 - Common Work Results for Process Control and


D. Provide all instruments identified in the Contract Documents.

1.02 REFERENCES


1.03 DEFINITIONS


B. Specific definitions: 1. Single-channel gas monitor: A single-channel gas monitor is used to monitor a

single type of gas.

1.04 SUBMITTALS
















1.08 WARRANTY


1.09 MAINTENANCE


B. As specified in Section 40_61_00.

C. Furnish: 1. One complete spare analyzer. 2. Manufacturer recommended spare parts for one analyzer.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. High concentration ozone analyzers: 1. BMT 964C, no equal.


B. Ambient and low concentration ozone analyzers: 1. Teledyne-API 465L, or equal as approved by the Engineer.


A. High concentration ozone analyzers: 1. General:

a. Measures ozone gas concentration based on UV absorption (Beer Lambert Law).

b. Provide one analyzer for each ozone generator. Mount on ozone generator skid.

c. Destroy all ozone prior to discharge from the analyzer. d. Single channel configuration. e. Long-life mercury lamp with 5-year warranty.

2. Performance Requirements: a. Minimum range: 0 to 14 percent ozone, by weight. b. Accuracy: Plus or minus 0.5 percent full scale. c. Repeatability error: 0.2 percent of measurement. d. Response Time: 30 seconds to 95 percent.

3. Technical Characteristics: a. Gas flow rate: 0.1 - 1.0 LPM. b. Automatic pressure and temperature compensation. c. Pressure readout in psig. d. Operating Temperature Range: 5 - 45 Degrees C. e. Humidity: 10 - 90 percent relative humidity, non-condensing. f. Output: Isolated 4-20 mA. g. Relay outputs: System OK, Invalid reading, UV Lamp low output,

overrange, summary error. h. Housing: NEMA 4X aluminum cabinet. i. Power Supply: 120 volts AC, single phase.

B. Low concentration analyzers: 1. General:

a. Measures ozone gas concentration based on UV absorption (Beer Lambert Law).

b. Provide one analyzer for each ozone destruct unit. Mount of ozone destruct unit skid.

c. Provide outlet connection for tubing to outside discharge. d. Single channel configuration. e. Provide with sample pump to draw in off-gas.

2. Performance Requirements: a. Range: 0 to 1.0 ppm ozone. b. Accuracy: Plus or minus 1 percent full scale. c. Response Time: 30 seconds to 95 percent.

3. Technical Characteristics: a. Gas flow rate: 0.8 LPM. b. Automatic pressure and temperature compensation. c. Operating Temperature Range: 5 - 45 Degrees C. d. Humidity: 10 - 90 percent relative humidity, non-condensing. e. Output: Isolated 4-20 mA. f. Relay outputs: System OK, Invalid reading, UV Lamp Fault. g. Housing: NEMA 4X.


2.03 ACCESSORIES

A. Provide manufacturer’s flow cell and sampling system for applications indicated on the instrument data sheets.



B. Factory-calibrate each instrument with a minimum 3-point calibration or according to Manufacturer’s standard at a facility that is traceable to the NIST. 1. Submit calibration data sheets to the Engineer at least 30 days before


PART 3 EXECUTION

3.01 EXAMINATION

A. Examine the installation location for the instrument and verify that the instrument will work properly when installed. 1. Notify the Engineer promptly if any installation condition does not meet the


3.02 INSTALLATION




B. Provide manufacturer’s services to perform installation inspection, start-up and calibration/verification.

3.04 ADJUSTING


3.05 CLEANING




3.07 PROTECTION


END OF SECTION


A/E: Carollo Engineers ANALYZERS - GAS MONITORS Spec. No. Rev. Contractor: No By Date Revision 40_76_13_1 Project: Contract Date Customer: Plant: Req. P.O. Location: BOM No.: By Chk App File: G 1 Tag No. Sample Unit Transmitter E 2 Service N 3 P&ID S 4 Gas Type Oxygen

E 5 Sensor Type Electrochemical: Infra Red: Catalytic Bead:

N 6 Operating Temperature Range Near Ambient S 7 Operating Humidity Range Minus 80 degrees F dew point O 8 Operating Pressure Range 25 to 60 psig R 9 Enclosure Rating NEMA 4 10 Sensor Mounting to Transmitter Integral: Remote: X 10 Repeatability 11 Accuracy 12 Calibrated Range 80 to 100% Oxygen by weight 13 Other 14 Other 15 Manufacturer 16 Model No.

C 17 Style A 18 Length B 19 Model No. L 20 Other E T 21 Type Control Unit and Display R 22 Enclosure Rating A 23 Mounting Wall: X Panel: Other: N 24 Power Requirements 120-volt AC S 25 Display LED or LCD M 26 Output 4 to 20 mA I 27 Calibration Type Factory: X Custom: T 28 Operating Temperature Range 32 to 100 degrees F T 29 SPDT Relay outputs E 30 Other R 31 Other 32 Manufacturer 33 Model No.

C 34 Input type (from transmitter) N 35 Number of channels (transmitter inputs) 1 T 36 Output 4-20 mA R 37 Power Requirements 120 Vac L 38 Enclosure Rating NEMA 4 E 39 Operating Temperature Range 32 to 100 degrees F R 40 Mounting WALL O 41 Mfr’s flow cell and sampling system P 42 T 43 Notes:



SECTION 40_80_01

TESTING, CALIBRATION, AND COMMISSIONING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Testing requirements that apply to process control and instrumentation

systems for the entire Project.




3. The following sections are related to the Work described in this Section. This list of related sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 01_75_17 - Commissioning and Process Start-Up. c. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. d. Section 40_61_05 - Packaged Control System. e. Section 40_61_16 - Specific Control Strategies. f. Section 40_95_13 - Process Control Panels and Hardware.

1.02 REFERENCES


B. Electronics Industries Alliance (EIA).

C. Telecommunications Industry Association (TIA).

1.03 DEFINITIONS

A. As specified in Sections 01_75_17 and 40_61_00.

B. Specific definitions: 1. PTO: Profibus Trade Organization.

1.04 SYSTEM DESCRIPTION (NOT USED)

1.05 SUBMITTALS

A. Furnish submittals as specified in Section 01_33_00.


B. General: 1. Reference additional detailed test submittal scheduling and prerequisite

requirements as specified in the Sequencing article of Section 40_61_00.

C. Test procedures: 1. Develop and submit detailed test procedures to show that the integrated

SCADA system hardware and software is fully operational and in compliance with the requirements specified in the Contract Documents.

2. Provide a statement of test objectives for each test. 3. Prepare specific procedures for each process system. 4. Describe sequentially the steps to be followed in verifying the correct operation

of each process system, including all features described in the loop descriptions, control strategies, and shown in the P&IDs. Implied or generic test procedures are not acceptable.

5. Specify who will perform the tests, specifically what testing equipment will be used (including serial numbers and NIST-traceable calibration), and how the testing equipment will be used.

6. Describe the expected role of the Engineer, as well as any requirements for assistance from Owner’s staff.

7. Provide the forms and checklists to be used.

D. Test forms: 1. Provide test and calibration forms and checklists for each of the following:

a. Calibration. b. Factory acceptance tests (FAT). c. Loop validation tests. d. Installation tests. e. Functional tests. f. Instrumentation and Controls Performance test. g. Communication Testing including all digital bus and all forms of Ethernet.

2. Test forms shall include the detailed test procedures, or shall include clear references to separate pages containing the complete test procedure applicable to each form. If references to procedures are used, the complete procedure shall be included with each test binder.

3. Every page of each test form shall include project name, date, time, name of person conducting the test, signature of person conducting the test, and for witnessed tests, place for signature of person (Engineer and Owner) witnessing the test.

4. Some sample test forms are included at the end of this Section. These test forms show the minimum required test form content. They are not complete, and have not been customized for this Project. The Contractor is to develop and submit test forms customized for the Project and meeting all of the specified test and submittal requirements.

E. Testing binders: 1. Sub-system to be tested, provide and submit a test binder containing all test

procedures and individual test forms for the test. References to other documents for test procedures and requirements are not acceptable.

2. Fill out in advance headings and all other information known before the test. 3. Include applicable test plan information, as well as a list of all test

prerequisites, test personnel, and equipment. 4. Include or list reference material and provide separately at the time of the test.


5. Record test results and verify that all test requirements and conditions have been met.

F. FAT procedure additional minimal requirements: 1. Prepare and submit a FAT procedure which includes:

a. Control system testing block diagram. b. Estimated test duration. c. Details on the simulator construction, components, and operation.

G. Test reports: 1. At the conclusion of each test, submit a complete test report, including all test

results and certifications. 2. Include all completed test binders, forms, and checklists. 3. Submission, review, and acceptance of each test report is required before the

start of the sub-system.


A. Test personnel: 1. Furnish qualified technical personnel to perform all calibration, testing, and

verification. The test personnel are required to be familiar with this Project and the equipment, software, and systems before being assigned to the test program.

1.07 DELIVERY, STORAGE, AND HANDLING (NOT USED)

1.08 PROJECT OR SITE CONDITIONS (NOT USED)


1.10 SCHEDULING



1.12 SYSTEM START-UP (NOT USED)

1.13 OWNER’S INSTRUCTIONS (NOT USED)


PART 2 PRODUCTS

2.01 MANUFACTURERS (NOT USED)


2.03 MATERIALS (NOT USED)










PART 3 EXECUTION



3.03 INSTALLATION


B. Installation supervision: 1. Provide as specified in Section 40_61_00.





A. Source Testing: 1. Provide manufacturer services as specified in the table below:

Section Number Section Title

Source Testing (Witnessed or Non-Witnessed)

40_61_05 Packaged Control System Witnessed

40_61_16 Specific Control Strategies Witnessed

40_95_13 Process Control Panels and Hardware Witnessed

40_80_01 Testing, Calibration, and Commissioning Witnessed

2. FAT - general: a. Performed during the Commissioning Phase, source testing activity. b. Before shipment to the Project Site, the complete OSS-provided control

system including allPLCs, Remote I/Os, LCPs, CCS, peripherals, communications equipment, and other equipment, shall be assembled,


connected, and all software loaded for a fully functional FAT of the integrated system.

c. Perform tests to show that the integrated system hardware and software is fully operational and in compliance with the requirements specified in the Contract Documents.

d. Additional factory tests are specified in other sections of the Instrumentation and Control Specifications.

e. The FAT will be witnessed. f. Right of observation: The Owner retains the right to observe all factory

test activities including any and all subsystem preparation, pretests, troubleshooting, retests, warm-up, and software modification and/or update.

g. The Owner reserves the right to test any specified function, whether or not explicitly stated in the test submittal.

h. Correction of deficiencies: Any deficiencies observed during the test shall be corrected and retested before completion of the test.

i. Any changes and/or corrections shall be noted on the test forms. Engineer shall witness the revisions and/or corrections prior to leaving the test site.

j. If the corrections and/or revisions are too extensive to be made while the Engineer is scheduled to be at the FAT test site, the FAT shall be, at the Engineer’s sole discretion, considered failed, and the test shall be restarted at a later date. All costs for the re-test shall be borne by theOzone System Supplier.

3. Testing simulation: a. The FAT shall make use of hardware simulators that contain switches,

pilot lights, variable analog signal generators, and analog signal level displays, which shall be connected to the I/O points within the SCADA system. All inputs and outputs shall be simulated and proper control and system operation shall be validated.

b. The hardware simulator may consist of a PLC, operating under a SCADA software package, or other approved software that has its I/O points wired to PLC’s I/O points. Software operating on a PC may then act as the switches, pilot lights, variable analog signal generators, and analog signal level displays.

4. Preliminary FAT: a. A complete preliminary FAT (pre-FAT) shall be conducted utilizing test

procedures approved by the Engineer. The pre-FAT test procedure shall be a subset of the full FAT.

b. The purpose of the pre-FAT is to provide assurance to the Engineer that the SCADA system is ready for the full, witnessed FAT, in terms of both stability and functionality. Debugging of software and troubleshooting of hardware shall occur during and before the pre-FAT, not during the FAT. The Contractor shall fully test the SCADA system and fix all deficiencies found before the full FAT.

c. The Owner shall have the right to witness any or all of the pre-FAT testing and shall be notified in writing 20 days before the start of the pre-FAT.

d. The pre-FAT test results submittal shall include a letter, signed by the Contractor’s project manager or company officer, certifying that the system is complete, has been tested successfully, and is fully ready for the full, witnessed FAT. The submittal shall include completed pre-FAT test forms, signed by the Contractor’s staff, and shall be submitted for review before the start of the FAT.


5. Panel inspections: a. The Engineer will inspect each control panel for completeness,

workmanship, fit and finish, and compliance with the Contract Documents and the accepted shop drawings.

b. Provide panel inspection forms as part of the FAT procedures submittal. c. Inspection to include, as a minimum: Layout, mounting, wire and data

cable routing, wire tags, power supply, components and wiring, I/O components layout (including terminals, wiring and relays), device layout on doors and front panels, and proper ventilation operation.

d. A sample FAT control panel form has been provided at the end of this Section.

6. I/O test: a. Verify that I/O is properly wired to field terminals and is properly mapped

into the PLC and the rest of the SCADA system, including all operator interface devices.

b. Test methodology: 1) Use the submitted and approved system simulator for this test. 2) Discrete inputs: Apply appropriate input from simulator at panel

terminal, observe input card indicator, observe data value at each indicated data address, observe data received on all operator interface displays (SCADA workstations and local operator interface (LOI) displays).

3) Discrete outputs: Issue commands from operator interface screen, verify output card indicator light and measure response on simulator. Repeat for each operator interface screen.

4) Analog inputs: Apply appropriate analog input signal at panel terminals on simulator, observe data value at each indicated data address, and observe data properly received at each operator screen. Check each point at 0 percent, 50 percent, and 100 percent of scale.

5) Analog outputs: Enter scaled values in the output buffer file, observe the output data file value, and measure appropriate response on simulator.

c. Test forms to include, but not be limited to: 1) PLC and panel number. 2) I/O type. 3) I/O tag name. 4) Panel terminal block numbers. 5) Rack/slot/number of I/O point. 6) Check-off for correct response for each I/O point. 7) Space for comments. 8) Initials of individual performing test. 9) Date test was performed. 10) Witness’ signature lines.

7. System configuration test: a. Demonstrate and test the setup and configuration of all operator stations,

servers, development stations, and peripherals. b. Demonstrate all utility software and functions, such as virus protection,

backup, optical drive burning, network monitoring, etc. c. Demonstrate the proper operation of all peripheral hardware. d. Demonstrate all general SCADA functions.


e. Demonstrate proper operation of log-on and other access security functions.

f. Demonstrate the proper operation of all historical data storage, trend, display, backup, and report functions.

g. Test automatic fail over of redundant equipment. h. Demonstrate the proper operation of the alarm display and

acknowledgement functions. i. Test forms:

1) For each test, list the specification page and paragraph of the function demonstrated, and provide a description of the function.

2) List the specific tests and steps to be conducted. 3) For each function, list all of the different sub-functions or ways the

function can be used, and provide a test check-off for each: a) Include signature and date lines.

8. Control logic test: a. The purpose of this test is to verify that all software functions and logic

work as specified, along with any hardwired logic or functions in the tested control panels.

b. Testing requirements: 1) . Demonstrate in detail how each function operates under a variety of

operating scenarios. Test to verify the application of each general control strategy function to each specific control strategy or loop description.

2) Demonstrate the proper operation of the programming and configuration for each control strategy or loop description. Test each strategy or loop description on a sentence by sentence and function by function basis. Loops with similar or identical logic must each be tested individually.

3) Demonstrate the proper operation of all digital communication links and networks. Verify each digital communication I/O point.

4) Failure testing: In addition to demonstrating correct operation of all specified features, special effort shall be made to demonstrate how the system responds to and recovers from abnormal conditions including, but not limited to: equipment failure, operator error, communications subsystem error, communications failures, simulated/forced software lockups, power failure (both utility power and power to SCADA hardware), process equipment failure, and high system loading conditions.

c. Test forms: 1) Include the fully revised and approved control strategy for the loop

being tested. 2) Identify the cause and effect as each I/O point is toggled through the

simulator. Check boxes shall be provided to track proper and/or improper operation of the loop.

3) Any deficiencies or operational changes shall be noted on the forms for correction and documentation: a) Include signature and date lines.

B. Owner Training: 1. Complete Owner training as specified in Section 40_61_00.

C. Installation Testing:


1. General: a. The Owner reserves the right to test any specified function, whether or not

explicitly stated in the test submittals. b. Failure testing:

1) In addition to demonstrating correct operation of all specified features, demonstrate how the system reacts and recovers from abnormal conditions including, but not limited to: a) Equipment failure. b) Operator error. c) Communications sub-system error. d) Power failure. e) Process equipment failure. f) High system loading conditions.

c. Conduct testing Monday through Friday during normal working hours for no more than 8 hours per day. 1) Testing at other times requires approval of the Engineer.

2. Sequencing: a. See additional requirements specified in the Sequencing article of

Section 40_61_00. 3. Calibration:

a. After installation but before starting other tests, calibrate and adjust all instruments, devices, valves, and systems, in conformance with the component manufacturer's instructions and as specified in these Contract Documents.

b. Components having adjustable features are to be set carefully for the specific conditions and applications of this installation. Test and verify that components and/or systems are within the specified limits of accuracy.

c. Replace either individually or within a system, defective elements that cannot achieve proper calibration or accuracy.

d. Calibration points: 1) Calibrate each analog instrument at 0 percent, 25 percent,

50 percent, 75 percent, and 100 percent of span, using test instruments with accuracies traceable to NIST.

e. Field verify calibration of instruments that have been factory-calibrated to determine whether any of the calibrations are in need of adjustment.

f. Analyzer calibration: 1) Calibrate and test each analyzer system as a workable system after

installation. Follow the testing procedures directed by the manufacturers' technical representatives.

g. Complete instrument calibration sheets for every field instrument and analyzer.

h. Calibration tags: 1) Attach a calibration and testing tag to each instrument, piece of

equipment, or system. 2) Sign the tag when calibration is complete.

4. LAN cable post-testing: a. After installing the cable and connectors, test all cables using the LAN

certification to confirm the installation meets the requirements of the specification.

b. Provide test documentation that includes the cable number, total length of cable, a permanent hard copy, as well as a-USB or CD copy of all traces: 1) After installing connectors.


2) Perform cable end-to-end testing on all installed cables from both ends of the cable. Test shall include cable system performance tests and confirm the absence of wiring errors.

3) Submit a signed test report presenting the results of the cable testing.

4) Repair or replace any portions of the system not meeting ANSI/TIA/EIA standards for a Category 5e or Category 6 installation. Repaired sections shall be retested.

c. Submit 3 copies of all final documentation (including traces), using the approved test form, to the Engineer upon successful completion of the testing.

D. Functional Testing: 1. General:

a. Commence Functional tests after completion of all loop check/validation tests: 1) As specified in Section 40_61_00, Sequencing and Scheduling

article. b. Functional to demonstrate proper operation of all systems with process

equipment operating over full operating ranges under conditions as closely resembling actual operating conditions as possible.

c. Additional tests are specified in other Instrumentation and Control Sections.

d. Follow approved detailed test procedures and check lists for Functional Test activities.

2. Control logic operational validation: a. The purpose of control logic validation is to field test the operation of the

complete control system, including all parts of the SCADA system, all control panels (including vendor control panels), all control circuits, all control stations, all monitored/controlled equipment, and final control elements.

b. Demonstrate all control functionality shown on the P&IDs, control schematics, and other drawings, and specified in the loop descriptions, control strategies, Electrical Specifications, and Mechanical Equipment Specifications.

c. Test in detail on a function-by-function and sentence-by-sentence basis. d. Thoroughly test all hardware and software functions:

1) Including all hardwired and software control circuit interlocks and alarms.

e. Test final control elements, controlled equipment, control panels, and ancillary equipment under startup, shut down, and steady-state operating conditions to verify all logic and control is achieved.

f. Control logic validation tests to include, but not limited to: a repeat of all control logic tests from the FAT, modified and expanded to include all field instruments, control panels, circuits, and equipment.

3. Loop tuning: a. Optimally tune all electronic control stations and software control logic

incorporating proportional, integral, or derivative control. Apply control signal disturbances at various process variable levels and adjusting the gain, reset, or rate settings as required to achieve proper response.

b. Verify the transient stability of final control elements operating over the full range of operating conditions, by applying control signal disturbances,


monitoring the amplitude and decay rate of control parameter oscillations and making necessary controller adjustments as required to eliminate excessive oscillatory amplitudes and decay rates. As a minimum, achieve 1/4 wave amplitude decay ratio damping (subsidence ratio of 4) under the full range of operating conditions.

c. If excessive oscillations or system instability occur, as determined by the Engineer, continue tuning and parameter adjustments, or develop and implement any additional control algorithms needed to achieve satisfactory control loop operation.

4. Functional validation sheets: a. Document each Functional test on an approved test form. b. Document loop tuning with a report for each loop, including two-pen chart

recordings showing the responses to step disturbance at a minimum of 3 setpoints or process rates approved by the Engineer. Show tuning parameters on the charts, along with time, date, and sign-off by Contractor and Engineer.

c. Include on the form, functions which can be demonstrated on a loop-by-loop basis: 1) Loop number and P&ID number. 2) Control strategy, or reference to specification tested. 3) Test procedures: Where applicable, use the FAT function-by-

function, sentence-by-sentence loop test checklist forms modified to meet the requirements of the Functional test. Otherwise, create new forms.

d. For functions that cannot be demonstrated on a loop-by-loop basis (such as overall plant power failure), include on the test form a listing of the specific steps and tests to be conducted. Include with each test description the following information: 1) Specification page and paragraph of function demonstrated. 2) Description of function and/or text from specification. 3) Test procedures: use the FAT loop test checklist forms modified to

meet the specific testing conditions of the Functional test. 5. Functional certification:

a. Provide Manufacturer’s Certificate of Installation and Functionality Compliance as specified in Section 01_75_17: 1) Including all test forms with test data entered, submitted to the

Engineer with a clear and unequivocal statement that all Functional test requirements have been satisfied.

E. Instrumentation and Controls Performance Testing: 1. After the Process Operational Period, test PCIS system for additional 60 days

as specified in this Section to identify issues and make corrections, as needed. 2. General:

a. The performance test is part of the Work that must be completed as a condition of substantial completion and final completion for the entire Project.

b. The complete PLC control and SCADA system must run continuously for the duration of the performance test.

c. Test and use the entire process control system under standard operating conditions.

d. Exercise all system functions.


e. Log failure, any system interruption and accompanying component, subsystem, or program failure including time of occurrence, duration of each failure, failure classification, and cause: 1) Provide a competently trained technician or programmer on call for

the Project Site during all normal working days and hours from the start of the performance test until final acceptance of the system: a) Response time to the Project Site: 24 hours or less, for a major

failure. 3. SCADA system testing:

a. Exercise each system function, e.g., status report, alarms, logs, and displays several times at a minimum, and in a manner that approximates "normal" system operation.

b. Failure of the SCADA system during testing shall be considered as indicating that the programs and operating system do not meet the requirements of the specifications: 1) Corrective action is required before restarting the performance test.

c. Only those components, sub-systems, and systems covered in this Section and supplied under this Contract shall be considered for this acceptance test. Problems and failures of other systems shall not be considered as part of this test, except as they display the capabilities of this system to detect failures.

4. Failures: a. Classify failures as either major or minor:

1) Minor failure: a) A small and non-critical component failure or software problem

that can be corrected by the Owner's operators. b) Log this occurrence but this is not a reason for stopping the test

and is not grounds for non-acceptance. c) Should the same or similar component failure occur repeatedly,

this may be considered as grounds for non-acceptance. d) Failure of one printer or operator station is considered a minor

failure providing all functions can be provided by backup equipment, i.e., alternate printers and operator station, and repairs can be made and equipment returned to service within 3 working days.

2) Major failure: a) Considered to have occurred when a component, subsystem,

software control, or program fault causes a halt in or improper operation of the system and/or when a technician's work is required to make a repair or to re-initiate operation of the system.

b) Cause termination of the performance test. c) Start a new acceptance test when the causes of a major failure

have been corrected. d) A failure is also considered major when failure of any control

system that results in an overflow, underflow, overdose, or underdose condition occurs.

5. Technician report: a. Each time a technician is required to respond to a system malfunction,

they must complete a report, which includes details concerning the nature of the complaint or malfunction and the resulting repair action required and taken.


b. If a malfunction occurs which clears itself or which the operator on duty is able to correct, no report is required or logged as specified above.

c. If a technician has performed work but no report is written, then a major failure is considered to have occurred.

d. Each report shall be submitted within 24 hours to the Engineer and the Owner, or its representative.





3.12 SCHEDULES

A. Example test forms: 1. Example test forms are attached at the end of this Section. They may be used

as a starting point for the development of Project-specific test forms for this Project.

2. The example test forms are not intended to be complete or comprehensive. Edit and supplement the forms to meet the requirements for testing and test forms specified in this Section and other Contract Documents.

END OF SECTION


FACTORY ACCEPTANCE TEST – CONTROL PANELS

1. GENERAL INSPECTION A. Structural Inspection

Verify Lifting Lugs Installed Verity enclosure has lock and lock is functional Confirm that seismic bracing components are provided per manufacturer’s installation instructions

B. Exterior Inspection Cabinet exterior is clean, scratch, and dent free Inspect externally for corrosion and damage Verify enclosure door opens and closes easily Verify enclosure has a 3-point latch Verify enclosure has a flange mounted disconnect (where voltages greater than 120 VAC enter the cabinet) Verify enclosure has the appropriate NEMA rating (1, 1G, 12, 3R, 4, 4X, etc.) Verify enclosure is the appropriate size (not grossly larger than design, and will still fit in the plant)

Nameplates Cabinet has identification nameplate

All door labels are straight, spelled correctly, and match the tagging defined in the Contract

Cabinet has a nameplate that includes the following:

Power source(s) Integrator’s Logo Circuit ID(s) Short Circuit KAIC ratings If labels are screwed to door, silicone was utilized to cover screw holes (Labels screwed to the door of a

NEMA 4/4X panel technically violates the NEMA rating.) Door Devices All devices penetrating the outside of panel have gaskets, silicone or both All door devices are installed (HMIs, Pilot Devices, etc.) Door mounted equipment is mounted straight and square All exterior or door mounted equipment present and accounted for, installed and securely fastened NEMA classification has not been violated due to penetrations Door mounted equipment has the same NEMA rating as the panel All door mounted equipment installed at the correct height All door mounted equipment installed in the correct positions and order (layout of door mounted equipment

is grouped properly and in a logical manner) Doors with multiple penetrations have adequate bracing (if needed) Visually check condition of indicators , controllers and annunciators Check that pilot lights illuminate correctly Check the Push-To-Test function Ensure correct pilot light color Peripheral Devices Horn / Beacon is installed (where required) Silence and Reset pushbutton PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



1. GENERAL INSPECTION (continued) C. Interior Inspection

Cabinet is cleaned of marks and dirt. Inspect internally for corrosion and damage. Back panel is clean of marks and dirt. Interior of panel vacuumed and shall be free of all debris. Check that the panel roof is clean and clear of foreign materials. Bottom of panel has been cut out (where bottom entry is required), with angle iron welded around the bottom

perimeter. Re-painting has been performed. If internal light door limit switch is provided, ensure the light automatically turns "on" when the doors are open. Intrusion alarms (where required).

Interior Labeling All panel mounted equipment has identification labeling, by using either a Brothers or Phenolic type tags. Verify that door mounted components are mounted square and symmetrical. Verify that nameplates are straight, legible, and spelled correctly. All terminal blocks are identified/labeled with permanent labels including tight end blocks and caps. All wiring shrink labeled and or phased correctly to the specifications. All wire labels shrunk completely rotated and aligned alike for easy identification. All fuses and circuit breakers are labeled with ID and current rating. System Integrator’s label or labels installed on door. Panel manufacturer model/serial number tag is present. All required safety/warning tags installed and straight. Correct UL (typically UL 508) or cUL tag installed and registered and all other associated tags installed and

straight (the UL tag might not be installed in the panel at the factory test. If the panel is modified due to changes during the factory test or a punch list generated from the factory test, the UL labeling would need to be re-applied. Some UL shops do not apply the UL label until the panel is released to be shipped.).

Wireways Plastic wire way covers installed properly. Plastic wireways have no sharp edges. No wire Ties inside the wireways. No sharp edges on wire ties. Separation: White duct is used for DC voltages, Gray duct is used for AC voltages. Ensure wiring duct is not over-full, includes provision for 20% more wiring and the cover may easily be

installed. Panduit recommends 50% duct fill, but 40% is a better practice. PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



1. GENERAL INSPECTION (continued) C. Interior Inspection (continued) Wiring Visually check terminals and condition of internal wirings Verify that the control panel has been assembled and wired as designed Verify that all components are operational and perform the functions intended Verify that all components are sized appropriately for the application Verify that equipment control circuits function as intended Back of door wiring is labeled and neatly formed Back panel to door wiring has sufficient bending radius with spiral wrap Wire connection has been verified wired to correct points within the panel Individual wires have been given a pull test to verify a good terminal connection Wire and cable minimum bending radius have not been violated All equipment installed straight and square to back panel Wire colors are correct: Black and White > AC hot and neutral, respectively Red > AC control signals Blue > DC power and control (Blue w/White stripe for DC ground) Yellow > Foreign voltages (those still present when panel power is disconnected) Green > AC equipment ground Black > TSP (+) White> TSP(-) Analog wiring shields are continuous (connected by a dedicated terminal block for such shields) Analog shield wires are grounded within the panel, where not otherwise grounded at the transmitter itself Discrete inputs are separately fused or protected by a circuit breaker on a “per loop” basis Intrinsic Safety Wiring Ensure wiring associated with intrinsic safety circuits or intrinsic safety barriers is kept away from all

other wiring by UL minimum distances or by a physical (grounded metal) barrier preventing non-intrinsically safe wiring from coming in contact with intrinsically safe circuits or wiring

Verify all spare terminals are installed according to the percentage listed in the specifications Grounding Equipped with “Blackburn” or other grounding type lug Lug is securely fastened to the panel structure Verify Grounding bar is installed Verify Isolated ground bar is installed PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



2. POWER TEST A. AC Power

AC Power is routed correctly within the panel, and is isolated from DC and network wiring . All fuses are installed and sized properly. All breakers are installed and sized properly. 24 VDC Power Supplies are functional. 24 VDC Power fail contacts are functional. 24 VDC power supplies are redundant, and have diode modules enabling the hot swap-over between supplies.

24 VDC supplies are equipped with dry contact failure alarms, wired as PLC inputs to signal failure of any DC power supply. Such alarm inputs to the PLC have been tested as being functional.

Dedicated receptacle is wired to receive a dedicated AC supply. Verify continuity for all DC commons, ground and AC neutrals. Verify that the CP temporary input power is connected correctly and is the correct voltage. Close the CP main circuit breaker(s). Verify that voltages at subsequent circuit breakers are correct. Close circuit breakers. Verify that power feeding interruptible and uninterruptible power supplies is correct. Turn on power supplies if they are not already on. Verify that voltages at distribution terminals are correct. Energize any remaining hardware such as the PLC.

B. Uninterruptible Power Supply (UPS) Mounted appropriately within the cabinet, on a dedicated shelf, or rear of a swing-out sub panel. Is equipped with maintenance bypass switch (or at least plug/receptacle means for bypassing the unit). Test all UPS alarms (on inverter, failure, battery failure etc.) Turn off the AC power supply and verify that the UPS will be switched on to supply the designated vital loads in

the control panel. 3. CONTROLS & AUXILIARY DEVICES TEST

Verify all interposing and auxiliary relays are functioning.

Verify panel lights are functioning. Ventilation and Heating

If ventilation fans are fitted , check the fans operate correctly any associated air filters are clean and not blocked. Verify components are installed in the correct orientation for proper air flow.

4. HARDWIRED INTERLOCK AND SAFETY TEST Verify that hardwired interlocks through the control panel as shown on schematic drawings are functioning. For

example, outlet high pressure switch interlock to a pump. Verify that all hardwired safety devices through the control panel is functioning. For example, the pull cord

emergency stops of conveyors. PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



5. PLC TEST A. Components

PLC interior High Temperature alarm is installed, wired to the PLC, and is shown to be functional. Relays have transient suppression across their coils. This is particularly important for DC coil relays, where

diodes in reverse polarity are often used. TVSS is installed across the main incoming 120 VAC.

PLC and PLC Rack Verify all cards are securely seated. Ensure clearance around PLC rack has been met, such that convective heat transfer is not impeded by

devices erroneously mounted in the “no encroachment” area. Confirm with manufacturer clearance recommendations.

B. PLC I/O Test Furnish I/O test forms and test all the listed input and output points as follows:

Discrete Inputs: Simulate a field contact closure by “shorting” across the appropriate terminal blocks. Observe the transition between a logical “0” and “1” in the PLC software.

Discrete Outputs: Force the output bit to toggle between logical “0” and logical “1” using the PLC software. Measure contact resistance at the wired terminal blocks using a digital meter selected for the “ohms” setting.

Analog Inputs: Connect a signal generator to the appropriate terminal blocks. Tailor the connection depending on whether a 2-wire or 4-wire simulation is required. Modulate the 4-20mA signal. Observe the associated PLC internal memory register to transition between 0-65535 or if scaled in engineering units, between 0 and the maximum scaled engineering unit. The latter method is preferred.

Analog Outputs: Force the output register to a value between 0-65535 or 0-100%, if the scaling block can be manipulated. Observe the measured 4-20mA value increment and decrement using a digital ammeter.

C. Redundant Controllers (where required) Test Remove Communication cable from PLC-1 to verify switching to PLC-1A Remove Communication cable from PLC-1A to verify switching back to PLC-1 Remove Power from PLC-1 to verify switching to PLC-1A Remove Power from PLC-1A to verify switching to PLC-1 Remove Communication cable from PLC-1 to I/O rack and verify switching to PLC-1A Remove Communication cable from PLC -1A to I/O rack and verify switching to PLC-1

D. PLC Control Logic Verification The PLC control strategy is verified by following the Control Logic Verification Form based on the specifications.

Each control strategy will be verified by simulating the process and checking the state or value of PLC outputs. The results of equipment status and alarms and process instrument values and trends shall also be verified on the Plant SCADA graphic screens stored in a temporary SCADA computer. Since all PLC input and output wiring has been verified and some field devices are not available during Factory Acceptance Testing, certain inputs will be simulated either by means of additional hardware and/or software as described below.

DI states are either simulated by hardwired switches or forced inputs using a programming terminal. For example, when starters and drives are not provided as part of the contract, jumpers may be installed

from the output call relays to the running confirmation inputs to simulate the running state of the motors. AI values are either simulated by an external source or within software using a programming terminal. For example, when a level transducer is not provided as part of the contract the level transducer loop

current may be simulated with a loop powered potentiometer and adjusted manually for the level input. PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



5. PLC TEST (continued) D. PLC Control Logic Verification (continued) Typical Fault Logic If the fault input is high and the disable (if applicable) for the fault is not high and the common disable (if

applicable) is not high begin timing. If any of these conditions changes, stop timing and reset the timer. If the timer reaches its preset, activate the alarm output. If the fault alarm is a shutdown alarm stop the associated motor and latch the alarm so that it remains present even if the condition clears.

The fault condition must return to normal and the alarm must be reset for a latched alarm to clear. Typical Fail to Start Logic If the motor is called to run (call output high) and no running feedback is received (running input is low) and

the fail to start and common alarm disables (if applicable) are not high start timing. If any of these conditions changes, stop timing and reset the timer. If the timer reaches its preset, activate the alarm output, stop calling the motor and latch the alarm.

6. HMI OR OIT TEST HMI / OIT Functionality Communication with PLC Screen Layouts Screen Navigation Set Point Entry Animation Color Correctness (Green=Run, Red=Off, Amber=Alarm, or the agreed upon convention) Alarms Acknowledge and Reset Security / Access Levels / Passwords 7. NETWORK COMMUNICATION TEST A. Network Components Fiber optic cabling terminates in a patch panel Media converters are installed and functional Terminating resistors have been installed for trunk/tap topologies or where required Wire and cable bending limitations have not been violated B. Networking Functions Verify data transfer via the network to different PLCs as shown on the Network Block Diagrams Verify network traffic rate and error margin is acceptable PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:



8. FAT DOCUMENTATION AND RECORD Panel Documentation As-built panel drawings showing actual panel construction and devices arrangement and c/w Bill of

Material. Panel schematic and interconnection drawings. P&ID drawings and schematic drawings for the process area controlled by the panel that is to be tested. I/O list test forms of the process area to be tested. FAT procedure of the process area to be tested. Test record forms of the process area to be tested. Forms shall include area for signature of responsible

test personnel. Hard copy of the PLC application program of the process area to be tested. Hard copy of the HMI/OIT graphic screens of the process area to be tested. 9. FAT TOOLS AND SOFTWARE

Simulation software if required Digital volt meter Fluke 87 Process meter Fluke 787 Laptop computer with PLC application program Temporary SCADA computer with HMI software and applicable graphic screens Jumper wires

PROJECT NAME: TEST DATE: FACILITY NAME: TESTED BY: PROCESS AREA: COMPANY: NETWORK ID: PAGE: WITNESSED BY: SIGNATURE:


INSTALLATION AND CERTIFICATION CHECKLIST DOCUMENTATION

INSTRUMENT LOOP NO.

SERVICE DESCRIPTION

A COPY OF LATEST ISSUE OF THE FOLLOWING DOCUMENTS ARE INCLUDED IN THIS INSTRUMENT INSTALLATION CERTIFICATION FILE:

INSTRUMENT SPECIFICATION SHEETS (FOR ALL INSTRUMENTS IN THE LOOP)

INSTRUMENT INSTALLATION DETAILS (FOR ALL INSTRUMENTS IN THE LOOP)

INSTRUMENT LOOP WIRING DIAGRAMS

INSTRUMENT INSTALLATION CERTIFICATION CHECKLIST

SIZING CALCULATIONS

INSTRUMENT INSTALLATION SCHEDULE (APPLICABLE PART)

NAMEPLATE SCHEDULE (APPLICABLE PART)

VENDOR LITERATURE CALIBRATION INFORMATION

INSTRUMENT LOOP IS PART OF EQUIPMENT START-UP/SHUTDOWN INTERLOCKS? No Yes

REMARKS:

CHECKED BY (COMPANY) ACCEPTED BY (COMPANY)

SIGNATURE SIGNATURE

DATE DATE


SWITCHES INSTALLATION AND CALIBRATION CHECKLIST

INSTRUMENT LOOP NO.

SERVICE DESCRIPTION

CHECK BELOW, WHEN COMPLETED:

BENCH CALIBRATED PER SPECIFICATION SHEET NO.

VERIFIED PER P&ID NO.

CORRESPONDS TO SPECIFICATION SHEET NO.

WIRING CORRECT PER INSTRUMENT LOOP DRAWING NO.

INSTALLATION CORRECT PER DETAIL NO.

ACCESSORIES ARE PRESENT AND PROPERLY INSTALLED

INSTRUMENT IS ACCESSIBLE FOR MAINTENANCE OR REMOVAL

ENGRAVED LAMINATED NAMEPLATE (NO SPELLING ERRORS) PERMANENTLY INSTALLED


FIELD CALIBRATION CHECK

CONTACT NO. FUNCTION

FOR SIGNAL

CONTACT IS TO AT SPECIFIED VALUE FOR ACTUAL TRIP POINT WAS

1 ALARM INCR OPEN SET PT = SET PT =

S/D PERM DECR CLOSE RESET = RESET =







NOTE: PERM IS ABBREVIATION FOR PERMISSIVE


SWITCHES INSTALLATION AND CALIBRATION CHECKLIST

REMARKS:


SIGNATURE SIGNATURE

DATE DATE


TRANSMITTER/CONTROLLER/INDICATOR INSTALLATION AND CALIBRATION CHECKLIST


INSTRUMENT TYPE INDICATOR

TRANSMITTER CONTROLLER

OTHER DESCRIPTION

INSTRUMENT TAG NO. SERIAL NO.

SERVICE DESCRIPTION

BENCH CALIBRATION CHECK

INPUT RANGE = OUTPUT RANGE =

HEAD CORRECTION = LINEAR

CALIBRATED SPAN = SQUARE ROOT % CALIB

SPAN DESIRED VALUE ACTUAL VALUE EXPECTED VALUE ACTUAL VALUE

0

50

100

CHECK BELOW, WHEN COMPLETED:









FIELD CALIBRATION CHECK

INPUT RANGE =

OUTPUT RANGE =

% CALIB SPAN DESIRED VALUE ACTUAL VALUE EXPECTED VALUE ACTUAL VALUE

0

50

100


TRANSMITTER/CONTROLLER/INDICATOR INSTALLATION AND CALIBRATION CHECKLIST

DIRECT REVERSE

ACTION VERIFIED AT 50% SPAN

ACTION VERIFIED AT SPAN

CONTROLLER SETTINGS

SETTING GAIN PB RESET

(INTEGRAL) DERIV. (RATE)

HIGH LIMIT

LOW LIMIT

ELEV. ZERO

ZERO SUPP

PRE-TUNE

POST-TUNE

PRE-TUNE SETTINGS

GAIN PB RESET (REPEAT/MIN) RESET (MIN/REPEAT) DERIVATION (MINUTES)

FLOW 1.0 100 10 0.1 N/A

LEVEL 1.0 100 MIN. MAX. N/A

PRESSURE 2.0 50 2.0 0.5 N/A

TEMP. 4.0 25 0.1 10 OFF

REMARKS


SIGNATURE SIGNATURE

DATE DATE


ANALYZERS INSTALLATION AND CALIBRATION CHECKLIST


TYPE OF INSTRUMENT

INSTRUMENT TAG NO. SERIAL NO.

SERVICE DESCRIPTION

CHECK BELOW, IF TRUE









REMARKS


SIGNATURE SIGNATURE

DATE DATE


CONTROL VALVES

INSTALLATION AND CALIBRATION CHECKLIST


VALVE TAG NO. SERIAL NO.

TRANSDUCER TAG NO. SERIAL NO.

SOLENOID TAG NO. SERIAL NO.

VOLUME BOOSTER TAG NO.

SERIAL NO.

POSITIONER SERIAL NO.

SERVICE DESCRIPTION

TRANSDUCER CHECK

INPUT RANGE = OUTPUT RANGE =

CALIBRATED SPAN = CALIBRATED SPAN =

BENCH

SPAN DESIRED ACTUAL SPAN EXPECTED ACTUAL

0% 0%

50% 50%

100% 100%

FIELD

SPAN DESIRED ACTUAL SPAN EXPECTED ACTUAL

0% 0%

50% 50%

100% 100%

CHECK BELOW, IF TRUE:

BENCH CALIBRATED PER ABOVE



VALVE SPECIFICATION NO.

TRANSDUCER SPECIFICATION NO.

SOLENOID SPECIFICATION NO.


INSTALLATION CORRECT PER INSTRUMENT INSTALLATION DETAILS

VALVE DETAIL NO.

TRANSDUCER DETAIL NO.

SOLENOID DETAIL NO.


CONTROL VALVES INSTALLATION AND CALIBRATION CHECKLIST




VALVE CHECK

FLOW CHECK PROCESS FLOW DIRECTION THROUGH THE VALVE IS CORRECT

SAFETY CHECK

ON LOSS OF AIR VALVE FAILS ON LOSS OF POWER SOLENOID FAILS OPEN CLOSE TO VENT TO VALVE

TRAVEL CHECK

FULL OPEN AT FULL CLOSED AT MEASURED TRAVEL

PSI PSI INCHES

SEATING CHECK

ON BENCH RESULTS ACTUATOR BENCH SET

IN-LINE

POSITIONER CHECK

VALVE FULL OPEN AT PSI TO POSITIONER

VALVE FULL CLOSED AT PSI TO POSITIONER

VOLUME BOOSTER CHECK

BYPASS VALVE (GAIN) ADJUSTING SCREW BACKED OUT TURNS FROM CLOSED TO ENSURE QUICK BUT

STABLE OPERATION (TYPICALLY 1-1/2 TO 2 TURNS)

REMARKS


SIGNATURE SIGNATURE

DATE DATE




SECTION 40_94_33

LOCAL OPERATOR INTERFACES

PART 1 GENERAL

1.01 DESCRIPTION

A. Work included: 1. Furnish and install Local Operator Interfaces (LOIs). 2. Local Operator Interfaces and related equipment has been specified on a “no

or equal” basis in order to match existing District control equipment. No hardware and software products other than the exact model numbers specified will be acceptable.

B. Related sections: 1. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. 2. Section 40_61_05 - Packaged Control System. 3. Section 40_80_01 - Testing, Calibration, and Commissioning. 4. Section 40_94_43 - Programmable Logic Process Controllers. 5. Section 40_95_13 - Process Control Panels and Hardware.

1.02 SUBMITTALS

A. Submittals shall be made in accordance with Section 01_33_00 Submittal Procedures and Section 40_61_00 Common Work Results for Process Control and Instrumentation Systems.

B. The Contractor shall furnish submittals for approval as outlined below: 1. Product data.


A. Local Operator Interfaces shall be fully installed in the control panel prior to shipping to the site from the factory.

1.04 REFERENCES

A. Applicable codes and standards: design, fabricate, assemble, and test equipment so that upon installation and operation in accordance with manufacturer's recommended procedures for this application the equipment will conform with all applicable codes and standards. The date of issue or version shall be the current version at time of bid: 1. NFPA Standard 70 National Electrical Code. 2. IEEE Standard 472 Electrical Surge Protection. 3. EIA Standard RS-232-C Interface between data terminal equipment and

data communication equipment employing serial binary data interchange. 4. NEMA ICS6 Enclosures for Industrial Controls and Systems.


1.05 JOB CONDITIONS

A. Environmental: 1. Ambient temperature range: 0 to +47 degrees Celsius. 2. Ambient humidity range: 5 percent - 95 percent RH non-condensing. 3. Atmosphere: No corrosive gases.

PART 2 PRODUCTS

2.01 LOCAL OPERATOR INTERFACE (LOI)

A. Local Operator Interfaces shall be provided as indicated on the drawings.

B. The LOI shall have the following features and characteristics: 1. 256 MB of Flash memory. 256 MB of RAM. 2. Have the ability to communicate to the Programmable Logic Process

Controllers via Ethernet 10/100 Base-T and RS-232. 3. 15 inch active matrix TFT color LCD touch screen display with 1024x768

resolution. 4. Include keypad and touch screen input. 5. Operating Temperature: 5 to 50 degree Celsius with a relative humidity of 10 to

80 percent non-condensing. 6. NEMA 4X enclosure. 7. Power: 24 vdc. 8. LOI hardware shall be: Maple Systems HMI5150P with connecting cable and

USB configuration cable. No substitutions. 9. LOI Programming Software: Maple Systems EZware configuration software.

No substitutions.

PART 3 EXECUTION


A. General: 1. Process Control System Supplier service personnel shall perform all factory

tests, inspections, and adjustments as specified in section 40_80_01.

END OF SECTION


SECTION 40_94_43

PROGRAMMABLE LOGIC PROCESS CONTROLLERS

PART 1 GENERAL

1.01 DESCRIPTION

A. Work included: 1. Furnish and install Programmable Logic Controllers (PLC). 2. PLC and related equipment has been specified on a “no or equal” basis in

order to match existing District control equipment. No hardware and software products other than the exact model numbers specified will be acceptable.

B. Related sections: 1. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. 2. Section 40_61_05 - Packaged Control System. 3. Section 40_80_01 - Testing, Calibration, and Commissioning. 4. Section 40_94_33 - Local Operator Interfaces. 5. Section 40_95_13 - Process Control Panels and Hardware.

1.02 REFERENCES

A. Codes and Standards: Unless otherwise specified herein, or shown on the drawings, work under this Specification shall be performed in accordance with the following codes, standards, and publications to the extent indicated by the references herein. Any conflict among these standards shall be brought to the attention of the District for clarification and final ruling. The date of issue or version shall be the current version at time of bid: 1. NFPA Standard 70 National Electrical Code. 2. IEEE Standard 472 Electrical Surge Protection. 3. EIA Standard RS-232-C Interface between data terminal equipment and data

communication equipment employing serial binary data interchange. 4. EIA Standard RS-422-A.Electrical characteristics of balanced voltage digital

interface circuits. 5. NEMA ICS6 Enclosures for Industrial Controls and Systems. 6. SAMA PMC-33.1 Electromagnetic Susceptibility of Process Control

Instrumentation. 7. IEEE 519 Recommended Practices and Requirements for Harmonic Control in

Electric Power Systems. 8. ISA S5.1 Instrumentation Symbols and Identification. 9. ISA S20 Specification Forms for Process Measurement and Control

Instruments, Primary Elements and Control Valves.


1.03 SUBMITTALS

A. Submittals shall be made in accordance with Section 01_33_00 and Section 40_61_00.

B. In addition to submittal requirements in Section 01_33_00 and Section 40_61_00, the contractor shall furnish submittals for approval as outlined below: 1. Drawings showing any modifications or additional details as may be required to

supplement the Contract Documents and adequately define the installation of the Programmable Logic Process Control System elements.

2. Physical drawings showing equipment arrangement and terminal block locations.


A. Programmable Logic Process Control System shall be fully installed in the control panel prior to shipping to the site from the factory.

1.05 MANUFACTURER’S FIELD SERVICES

A. General: 1. Manufacturer’s field services and testing shall be performed in accordance with

Section 40_80_01.

1.06 JOB CONDITIONS

A. Environmental: 1. Ambient temperature range: 0 to +47 degrees Celsius. 2. Ambient humidity range: 5 percent - 95 percent RH non-condensing. 3. Atmosphere: No corrosive gases.

PART 2 PRODUCTS

2.01 PROGRAMMABLE LOGIC CONTROLLER (PLC)

A. General: 1. PLCs and remote I/Os shall be provided as indicated on the drawings. 2. The PLC programming software system shall be manufactured by PLC

hardware manufacturer. a. PLC programming software: Rockwell Software RSLogix 5000.

3. Provide one licensed copy of the PLC programming software under this specification.

B. PLC hardware shall be: 1. Rockwell Automation Logix family: ControlLogix or CompactLogix. No

substitutions. 2. The Main and Hot-standby PLCs for the MOCP shall be ControlLogix.

C. Programmable logic controller: 1. Construction:

a. Furnish plug-in modular system.


b. Provide PLCs capable of operating in a hostile industrial environment without fans, air conditioning, or electrical filtering: 1) Temperature: 0 to 60 degrees Celsius. 2) RFI: 80 to 1,000 MHz. 3) Vibration: 10 to 500 Hertz. 4) Humidity: 0 to 95 percent.

c. Provide internal power supplies designed to protect against overvoltage and frequency distortion characteristics frequently encountered with the local power utility.

d. Design the PLC system to function as a stand-alone unit that performs all of the control functions described herein completely independent from the functions of the SCADA system PC-based operator interfaces: 1) Failure of the SCADA system shall not impact data acquisition,

control, scaling, alarm checking, or communication functions of the PLC.

2. CPU: a. Configure each CPU so that it contains all the software relays, timers,

counters, number storage registers, shift registers, sequencers, arithmetic capability, and comparators necessary to perform the specified control functions.

b. Capable of interfacing with all discrete inputs, analog inputs, discrete outputs, analog outputs, and communication cards to meet the specified requirements.

c. Capable of supporting and implementing closed loop floating-point math and PID control that is directly integrated into the CPU control program.

3. Memory: a. Non-volatile memory: On-board complementary metal oxide semi-

conductor (CMOS), electrically erasable programmable read-only memory (EEPROM), PCMCIA, compact flash card, or SD card.

b. Supply with sufficient memory to implement the specified control functions plus a reserve capacity as specified with the requirements of this Section: 1) Reserve capacity:

a) Totally free from any system use. 2) Programmed in a multi-mode configuration with multiple series or

parallel contacts, function blocks, counters, timers, and arithmetic functions.

4. Programming: a. Provide a system where processors are programmed by:

1) Portable laptop computer both locally and via the PLC control network.

5. PLC power supply: a. Input: 120 VAC. b. Mounted in the PLC housing. c. Sized to power all modules mounted in that housing including an average

module load for any empty housing slots plus 50 percent above that total. 6. PLC input/output, I/O modules:

a. General: 1) Compatible with all of the PLCs being furnished under the contract

and by the same manufacturer as the PLCs. 2) Provide I/O modules that:

a) Isolate in accordance with IEEE Surge Withstand Standards and NEMA Noise Immunity Standards.


b) Provide A/D and D/A converters with optically or galvanically isolated inputs and outputs.

c) Accept dual-ended inputs. 3) The use of common grounds between I/O points is not acceptable. 4) Provide modules that are removable without having to disconnect

wiring terminals: a) Utilize a swing-arm or plug-in wiring connector.

5) Provide at each PLC the I/O modules for the following: a) Designated future I/O points contained in the I/O Lists and/or

shown on the P&IDs, control schematics, or described in the control strategies.

b) Installed spare capacity in accordance with the requirements of this Section.

c) Wire all spares provided to the field terminal strip. 6) Condition, filter, and check input signals for instrument limit

conditions. 7) Filter, scale, and linearize the raw signal into an engineering-units-

based measurement. 8) Alarm measurements for high, low, rate-of-change limits, and alarm

trends. 9) Provide external fuses mounted on the field connection terminal block

for all discrete input, discrete output, and analog input I/O points. 10) When multiple cards of the same I/O type are provided and parallel

equipment, instrumentation, or redundant processes exist, distribute I/O among cards to ensure that a single card failure will not render an entire process unavailable.

b. Discrete input modules: 1) Defined as contact closure inputs from devices external to the input

module. 2) Provide inputs that are optically isolated from low-energy common-

mode transients to 1,500 volts peak from users wiring or other I/O modules.

3) Individually isolated inputs. 4) With LED's to indicate status of each discrete input. 5) Input signal level: As indicated in the schematics and as required to

interface with the equipment and instruments. It is most desirable to stick with a signal voltage level where possible.

6) Provide input module points that are individually fused with blown-fuse indicator lights, mounted external of the module on the output terminal strip: a) Coordinate external fuse size with the protection located on the

module, so that the external fuse opens first under a fault condition.

c. Discrete output modules: 1) Defined as contact closure outputs for ON/OFF operation of devices

external to the output module: a) Triac outputs may be used, with the permission of the Engineer.

Care must be used in applying this type of module to ensure that the leakage current through the output device does not falsely signal or indicate an output condition.

2) Optically isolated from inductively generated, normal mode and low-energy common-mode transients to 1,500 volts peak.

3) LEDs to indicate status of each output point.


4) Each output point: Individually isolated. d. Analog input modules:

1) Signal type: Provide 4-20 mA for most applications; other levels are acceptable to interface to vendor control panels.

2) Analog-to-digital conversion: Minimum 12-bit precision with the digital result entered into the processor.

3) The analog-to-digital conversion updated with each scan of the processor. Individually isolated each input. Coordinate the size of the external fuse with the protection located on the module, so that the external fuse opens first under a fault condition.

e. Analog output modules: 1) Signal type: Provide 4-20 mA for most applications; other levels are

acceptable to interface to vendor control panels. 2) Individual isolated output points each rated for loads of up to

1,200 ohms. f. Specialty I/O modules:

1) Resistance temperature detector (RTD) input module: a) Channels per module: 4 minimum. b) RTD types accepted:

(1) 100-ohm platinum. (2) 200-ohm platinum. (3) 500-ohm platinum. (4) 1,000-ohm platinum. (5) 100-ohm nickel. (6) 200-ohm nickel. (7) 500-ohm nickel. (8) 10-ohm copper.

c) Provide input module that accepts 2, 3, or 4-wire RTD. 2) Thermocouple input module:

a) Channels per module: 4 minimum. b) Thermocouple types accepted:

(1) Type J. (2) Type K. (3) Type E. (4) Type T. (5) Type S. (6) Type R. (7) Type B.

c) Individually isolate each channel. 7. Communications modules:

a. Remote I/O adapter module: 1) For any PLC location requiring more than 1 housing to mount all of

the I/O modules or that is identified as a RIO, provide the appropriate remote I/O adapter module for communication with the secondary housing(s).

2) Install the RIO adapter module in the PLC backplane and the RIO backplane.

3) Provide adapter modules that support all available types of I/O modules required.

4) Provide all network taps, connectors, termination resistors, drop cables, and trunk cables necessary for remote I/O communications.

5) Complete diagnostic LEDs. b. Network communications modules:


1) General: a) Install communications modules external to the PLC housing.

2) Ethernet: a) Ports: RJ-45 or Fiber optic, as shown on the drawings. b) Minimum number of ports as shown on the drawings. c) Communication rate: 10 Mbit/s.

3) Provide all network taps, connectors, termination resistors, drop cables, and trunk cables necessary for remote I/O communications.

8. PLC backplane housing: a. Mount the PLC power supply, CPU, communications module, and I/O

modules in a suitable standard PLC backplane or housing. b. Provide spare slots in each PLC and RIO location in accordance with the

requirements of this Section. c. Provide a blank slot filler module for each spare slot.

9. Hot standby modules: a. Hot standby configuration requires 2 PLC processors installed in

2 separate PLC backplanes, with each processor containing the identical PLC logic application.

b. Provide a hot standby synchronization module in each of the 2 PLC backplanes, linked via fiber optic cable.

c. Configure the PLC processors as primary and standby controllers, with each controller running the PLC logic program and scanning associated I/O simultaneously. 1) In the event of a primary controller failure, automatically switch over

to the standby controller. d. The associated I/O signals, as a result of an automatic hot standby

switchover, are to remain continuous and unaffected. e. Alarm at the SCADA system and locally with LED indication of failure of

the primary controller.

D. Remote inputs and outputs (RIOs): 1. Compatible with all of the PLCs being furnished under this Contract and shall

be by the same manufacturer as the PLCs, and as a minimum, includes: a. Power supply. b. Rack. c. Backplane. d. Communications module. e. I/O modules. f. Enclosure.

2. Provide all cables and software needed for a complete and operational RIO system as specified in the Contract Documents.

3. Provide a group of pre-assigned diagnostic registers to report RIO system faults to the driver PLC.

4. The control system must continue operation should a fault occur on a single RIO drop: a. Upon clearing the fault, restart communications to that drop automatically.

E. Installed spare requirements: 1. I/O points:

a. 15 percent spare capacity for each type of I/O signal at the MOCP. b. 15 percent spare capacity for each type of I/O signal at the local control

panels.


c. Wire all spare I/O points to field terminal blocks in the corresponding panel.

d. Space shall be available in the MOCP to support the future addition of 25 percent additional spare I/O.

2. PLC backplane capacity: a. At the MOCP, 25 percent or 3 spare backplane slots, whichever is greater. b. At the local control panels, 1 spare backplane slot.

3. PLC memory: a. 50 percent spare memory.

F. PLC Memory Module: Provide one memory module for each Logix family PLC supplied in this specification. Rockwell Automation Memory Module 1766-MM1. No Substitutions.

PART 3 EXECUTION


A. Refer to specification Section 40_80_01 for all PLC Factory commissioning and testing requirements.

3.02 INSTALLATION

A. Install equipment specified above as shown on the drawings. Follow all manufacturers’ instructions when installing PLCs, networks, and accessories.


A. Refer to specification Section 40_80_01 for all PLC field commissioning and testing requirements.

END OF SECTION




SECTION 40_95_13

PROCESS CONTROL PANELS AND HARDWARE

PART 1 GENERAL

1.01 DESCRIPTION

A. Work included: 1. Furnish control panel as shown on the drawings and specified herein.

B. Related sections: 1. Section 01_81_02 - Seismic Design Criteria. 2. Section 26_05_19 - Low-Voltage Electrical Power Conductors and Cables. 3. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. 4. Section 40_61_05 - Packaged Control System. 5. Section 40_80_01 - Testing, Calibration, and Commissioning. 6. Section 40_94_33 - Local Operator Interfaces. 7. Section 40_94_43 - Programmable Logic Process Controllers.

1.02 SUBMITTALS

A. The Contractor shall furnish submittals for approval : 1. All process control panels and hardware submittals shall be provided in

accordance with Section 40_61_00 requirements.


A. Control panels shall be shipped directly to the site from the factory. Before the control panels are shipped, remove all case-mounted instruments from the face of the panels, and repack in their original shipping cartons for shipment to the site with the control panel.

1.04 REFERENCES

A. Codes and Standards: Unless otherwise specified herein, or shown on the drawings, work under this specification shall be performed in accordance with the following codes, standards, and publications to the extent indicated by the references herein. Any conflict among these standards shall be brought to the attention of the District for clarification and final ruling. The date of issue or version shall be the current version at time of bid: 1. NFPA Standard 70 National Electrical Code. 2. IEEE Standard 472 Electrical Surge Protection. 3. EIA Standard RS-232-C Interface between data terminal equipment and data

communication equipment employing serial binary data interchange. 4. EIA Standard RS-422-A Electrical characteristics of balanced voltage digital

interface circuits. 5. NEMA ICS6 Enclosures for Industrial Controls and Systems. 6. SAMA PMC-33.1 Electromagnetic Susceptibility of Process Control

Instrumentation.


7. IEEE 519 Recommended Practices and Requirements for Harmonic Control in Electric Power Systems.

8. IEEE 472 Electrical Surge Protection. 9. ISA S5.1 Instrumentation Symbols and Identification. 10. ISA S20 Specification Forms for Process Measurement and Control

Instruments, Primary Elements and Control Valves.

1.05 JOB CONDITIONS

A. Environmental: 1. Ambient temperature range: 0 to +47 degrees Celsius. 2. Ambient humidity range: 5 percent - 95 percent RH non-condensing.

B. Atmosphere: No corrosive gases, however, there is a possibility of exposure to ozone gas should a leak occur.

PART 2 PRODUCTS

2.01 GENERAL

A. Unless otherwise approved by the Engineer, the control panels shall be constructed with external dimensions as shown on the drawings. The panel construction and all interior wiring shall be in strict accordance with the standards listed in part 1.2, Quality Assurance. Instrument arrangement shall be as shown, with minor modifications as may be required for the particular equipment furnished. Modifications shall be subject to the approval of the Engineer.

B. The construction of the control panels shall be by a UL listed Industrial Control Panels Fabricator. An entire control panel shall be completely fabricated, instruments installed, wired, and plumbed at the Fabricator’s factory. Multiple Control Panel Fabricators may be used, however, they all must be UL listed. Unless otherwise indicated, provide all new materials and equipment, free from any defects, and suitable for the space provided. Provide materials and equipment listed by UL wherever standards have been established by that agency.

C. The control panels shall conform to UL listing 508 and bear a UL 508 label stating "suitable for use as an industrial control panel", or built by an UL listed shop.

D. Where two or more units of the same class of materials or equipment are required, provide products of a single manufacturer. Component parts of materials or equipment need not be products of the same manufacturer.

E. Standard products: Unless otherwise indicated, provide material and equipment that is the standard product of manufacturers regularly engaged in the production of such materials and equipment. Provide the manufacturer's latest standard design that conforms to the specifications.

2.02 TYPICAL EQUIPMENT

A. Construction: 1. For cabinets located indoors, cabinet shall be NEMA Type 12, manufactured

with 12-gauge steel, with ANSI 61 gray polyester powder paint external finish.


Cabinet dimensions are as shown on the design drawings. Include back panels and side panels as shown on the drawings.

2. For cabinets located outdoors, cabinet shall be NEMA Type 4X, manufactured with 14-gauge Type 316L stainless steel, complete with back panel. Cabinet dimensions are as shown on the design drawings. Include back panels and side panels as shown on the drawings. Cabinets located outdoors shall be supported by a unistrut metal frame and mounted at the height shown on the design drawings.

3. Seams shall be continuously welded and ground smooth without holes or knockouts.

4. The enclosure shall have a single hinged door. When facing the front of the enclosure, the hinge shall be on the left-hand side and the door latch on the right-hand side: a. Door shall have heavy-duty continuous hinges, with lockable three-point

latch. b. Door gaskets shall be of oil resistant material and shall be attached with

oil-resistant adhesive. 5. Each enclosure shall be provided with a print pocket 12-inch wide x 12-inch

high x 2-inch deep provided on door. 6. Acceptable products: For wall mounted enclosures, Hoffman Concept wall-

mount enclosure, with Hoffman Concept back panel, or equal as approved by the Engineer.

7. Acceptable products: For pad mounted enclosures, Hoffman free standing type 12 enclosure, with Hoffman side and back panels, or equal as approved by the Engineer.

B. Wiring: 1. Single conductor wiring shall be No. 14 AWG stranded copper with 600 volt

Type MTW insulation unless otherwise specified.

Color Coding: Function Gauge Color Remarks Instrument DC Power (+) 14 Light Blue Instrument DC Power (-) 14 Gray HVAC DC Power(+) 12 Dark Blue HVAC DC Power (-) 12 Gray DC Control 16 Violet AC Control 16 Red AC Common 16 White AC Power 14 Black AC Ground 14 Green

2. Wiring to receptacles shall be No. 14 AWG stranded black (line), white (grounded neutral), and green (ground).


3. Instrumentation cables shall be 300 volt twisted shielded pairs, No. 18 AWG stranded copper conductors, 105 degrees C PVC insulation and jacket, color coded black and white, with aluminum/mylar shield overlapped to provide 100 percent coverage, and stranded copper drain wire.

4. No more than 2 wires shall be connected to one terminal. 5. Wires carrying instrument and control D.C. signals shall be physically

separated a minimum of 6" from wires carrying A.C. (120 VAC). 6. All wiring shall be neatly routed in wiring ducts and labeled with their assigned

wire numbers. Wire labels shall be machine printed, permanent type heat shrinkable polyolefin labels, Brady Permasleeve printable wire markers, or equal as approved by the Engineer.

7. Instruments with grounding terminals shall be grounded to the panel steel. Provide grounding lug for grounding the console to earth ground.

8. Wire termination: a. Screw type terminals: wires terminated on screw type terminal blocks shall

be made of 105 degrees C nylon insulated, crimp-on terminals with fork-type tongue for screw-type terminals, AMP, Inc., or Thomas & Betts Co. Sta-Kon, or equal as approved by the Engineer.

b. Screw clamp terminals: wires terminated on screw clamp terminal blocks such as relays, switches, control units and devices, and power supplies shall be made with plastic insulating color coded collar ferrules. Use twin plastic insulated ferrules for connecting two wires to a single terminal block. Acceptable products: Phoenix Contact Type AI and AI-TWIN, or equal as approved by the Engineer.

Ferrule Color Coding:

AC, Power and Controls Gray

DC, Controls and Instruments Blue

DC Power Black

Use only manufacturer approved crimping tool designed specifically for the type of ferrule provided.

9. Open-slot-wiring duct sized for the application shall be provided to hold the

wires neatly in place. Wiring duct covers shall be hinged. Provide one-inch minimum wire bending radius to prevent wires from being kinked or stressed at the wiring duct junctions. Wiring duct sizes shown on the drawings are minimum sizes; wiring duct fill shall not exceed 50 percent.

10. Whenever there is any discrepancy between wiring drawings and the control schematic, the control schematics shall take precedence.

C. Control units and devices: 1. Terminal blocks: Shall be tubular clamp rated 600 VAC/VDC minimum and as

specified on drawings. If fuse terminal blocks are specified, they shall be with built-in puller and with fuse size as shown on drawings. Provide 20 percent spare terminals for every terminal strip, space permitting. Terminals shall be clearly and permanently labeled with embossed numbers as shown on drawings.


2. Terminal block jumpers: Where indicated on the drawings, terminal block jumpers shall be pre-made specifically designed for the application. Jumpers designed to screw in on top of terminal blocks are preferred.

3. Provide all necessary accessories, partition plates, separating plates, end cover, group markers, etc., as required for proper installation of the terminal blocks.

4. Standard control terminal blocks: a. Standard control terminal blocks shall be designed to accept No. 22 to No.

12 AWG wires. Terminal blocks shall be gray colored and rated for 30 amperes, 600 VAC/VDC.

b. Terminal blocks for analog 4-20mA circuits shall be knife-style isolation (circuit disconnect) type.

c. Acceptable products (Allen-Bradley part numbers are listed; or equal as approved by the Engineer is acceptable): 1) End Anchor: Allen Bradley 1492-EA35. 2) End Barrier (Single Circuit Terminal Blocks): Allen-Bradley 1492-EB3. 3) End Barrier (Two Circuit Terminal Blocks): Allen-Bradley 1492-EBD3. 4) End Barrier (Grounding Terminal Blocks): Allen-Bradley 1492-EB3-Y. 5) Group Marker: Allen-Bradley 1492-GM35. 6) Fuse Block: Allen-Bradley 1492-H5. 7) Single Circuit Terminal Block: Allen-Bradley 1492-W4. 8) Two Circuit Terminal Block (For digital I/O field wiring interface

applications only): Allen-Bradley 1492-WD4. 9) Knife-Style Isolating Terminal Block (For analog 4-20mA or 1-5VDC

applications only): Allen-Bradley 1492-WKD3. 10) Grounding Terminal Block: Allen-Bradley 1492-WG4. 11) Side Jumpers: Allen-Bradley 1492-N49. 12) Center Jumpers: Allen-Bradley 1492-CJ6-XX (where XX is the

number of poles). 13) Marking Systems (1492-W4 and 1492-WG4 terminal blocks): Allen-

Bradley 1492-SM6X12 (snap-in marker cards) or Allen-Bradley 1492-MP-X (individual marker tabs where X is the number, letter, or symbol required).

14) Marking Systems (1492-WD4 terminal blocks): Allen-Bradley 1492-SM6X9 (snap-in marker cards) or Allen-Bradley 1492-MP-X (individual marker tabs where X is the number, letter, or symbol required).

15) Marking Systems (1492-WKD3 terminal blocks): Allen-Bradley 1492-SM5X9 (snap-in marker cards) or Allen-Bradley 1492-MP5-X (individual marker tabs where X is the number, letter, or symbol required).

16) Marking Systems (1492-H5 fuse blocks): Allen-Bradley 1492-SM8X12 (snap-in marker cards).

5. Heavy Duty Terminal Block shall be designed to accept wires up to No. 10 AWG. Terminal blocks shall be gray colored and rated for 30 amperes, 600 VAC/VDC. Acceptable products: Allen Bradley 1492 W6, Phoenix Contact Universal “UK” Terminal Blocks, or equal as approved by the Engineer.

6. Din rail mounted circuit breakers shall be the high density, 2-pole, energy limiting type rated 250VAC or 120VDC, with current ratings as shown on the drawings. Acceptable products: Allen Bradley 1492-GH (250VAC) and 1492-CB Series B (120VDC), or equal as approved by the Engineer.


7. Molded case circuit breakers shall be panel mountable, 2-pole, energy limiting type rated 250VAC or 120VDC, with current ratings as shown on the drawings. The molded case circuit breaker shall have an integral padlockable handle which will allow the circuit breaker to be locked in the off position. The manufacture of the locking device shall be the same manufacture of the molded case circuit breaker. Molded case circuit breaker shall be in accordance with requirements and type specified in Section 26 24 16 Panelboards.

8. Selector Switches: a. LOCAL/OFF/REMOTE Selector Switch:

1) Selector control. 2) Black knob. 3) Electronic-duty gold contacts. 4) White insert with black letters for “LOCAL” selector. 5) White insert with black letters for “REMOTE” selector. 6) Provide contact blocks and engraving as shown on the drawings.

b. Acceptable Products: Honeywell or Senasys CMC Series, or equal as approved by the Engineer.

9. Control Relays: a. DIN rail mounted PLC discrete output interposing relay with 24VDC coil,

DPDT contact rating of 10 amperes at 250VAC, and on/off indicator light: 1) Acceptable products:

a) Control Relay: Phoenix Contact No. 2967620, or equal as approved by the Engineer.

b) Plug-In Jumper: Phoenix Contact No. 2966838 (length as required), or equal as approved by the Engineer.

c) Separation Plate: Phoenix Contact No. 2966841, or equal as approved by the Engineer.

10. Time Delay Relays: a. DIN rail mounted discrete output on time delay relay with 120VAC coil,

DPDT contact rating of 10 amperes at 250VAC, and on and timing out LED indicator light.

b. Adjustable time delay from 1 sec to 10 hours. c. Acceptable products:

1) Time Delay Relay: IDEC RTE analog timer Part no. RTE-B12-AC120V, or equal as approved by the Engineer.

11. Cabinet Door Switch: a. Cabinet door switch shall be rated for 15 amperes at 120 VAC and 0.5

amperes at 24 VDC, plunger-type door switch, SPST. b. Acceptable products: Honeywell Microswitch Model 1AC2, or equal as

approved by the Engineer. 12. Cabinet Light:

a. Energy efficient fluorescent luminaire with one F15 T8 lamp, white baked enamel housing, white acrylic diffuser, and UL listed for damp locations. The luminaire shall be undercabinet style for surface mounting at the top inside of a control panel.

b. The light shall turn on and off via the integral plunger switch. c. Acceptable products: Hoffman model ALF16D18R, or equal as approved

by the Engineer.


13. Convenience Receptacle: a. Fully enclosed, DIN-rail mounted, GFI duplex utility receptacle, suitable for

either vertical or horizontal mounting, rated 15A at 120VAC. b. Acceptable products: Phoenix Contact Model EM-DUO-120/15/GFI, or

equal as approved by the Engineer. 14. Instrument Power Supply (120VAC to 24VDC):

a. Single-phase DIN-rail mounted, switched-mode power supply with 120VAC input, 24VDC nominal output. Output shall be adjustable and regulated over the range 22.5 to 28.5 VDC. Output current capability of 12 A at 60 Deg C.

b. The power supply shall have an efficiency greater than 87 percent with maximum peak-to-peak voltage ripple of less than 100mV.

c. Where shown on the design drawing schematic, the power supply shall be provided in a redundant configuration with two identical power supplies connected in parallel with blocking diodes on the 24VDC (+) terminals.

d. Power supply shall have the following status signals: 1) DC “OK” LED which remains lit during normal power supply

operation, flashes when the output voltage has dropped by more than 10 percent, and is off when no input voltage is present.

2) A “sourced” DC “OK” contact rated 24VDC and up to 40mA. 3) An isolated DC “OK” relay contact rated 1A at 30V.

e. Acceptable products: Sola SFL12-24-100RED, or equal as approved by the Engineer.

15. Instrument Power Supply, DC to DC Converter (120VDC to 24VDC): a. DIN-rail mounted, switched-mode DC to DC converter, power supply with

90VDC to 350VDC input, 24VDC nominal output. Output shall be adjustable and regulated over the range 22.5 to 28.5 VDC. Output current capability of 10 A at 60 Deg C.






e. Acceptable products: Phoenix Contact 2938604 QUINT-PS-100-240AC/24DC/10, or equal as approved by the Engineer.

16. HVAC Power Supply (120VAC to 24VDC): a. Single-phase DIN-rail mounted, switched-mode power supply with

120VAC input, 24VDC nominal output. Output shall be adjustable and regulated over the range 22.5 to 28.5 VDC. Output current capability of 24 A at 60 Deg C.







e. Acceptable products: Sola SFL24-24-100RED, or equal as approved by the Engineer.

17. Blocking Diode: a. Blocking diode to provide battery isolation from power supplies shall be

rated for a minimum If = 30A, minimum Vrrm= 200 V, maximum Vf = 1.3 V. b. Acceptable products: International Rectifier, input rectifier diode or equal

as approved by the Engineer. 18. EMI/RFI Filter:

a. Main incoming interference filter, DIN-rail mounted, rated 10A at 264VAC maximum voltage, for use on a 120VAC system.

b. Differential mode (symmetrical) (DM) and common mode (asymmetrical) (CM) input attenuation shall be no less than: 1) 100kHz: 20dB DM, 20dB CM. 2) 500kHz: 70dB DM, 40dB CM. 3) 1MHz: 90dB DM, 40dB CM. 4) 5MHz: 60dB DM, 40dB CM. 5) 10MHz: 40dB DM, 50dB CM.

c. Acceptable products: Phoenix Contact Model 2788977, or equal as approved by the Engineer.

19. Signal Isolators (4-20 ma loop Isolators): a. Signal Isolators shall be UL listed and powered from 24VDC. Terminals to

accept wire sizes from No. 20 AWG to No. 12 AWG. Units shall be DIN-rail mounted. Single 4-20 ma input and two isolated 4-20 ma outputs. Outputs shall track input current.

b. Acceptable products: Phoenix Contact MINI Analog Model No. MINI MCR-SL-UI-21.

20. Alarm Horn: a. Alarm Horn shall be UL listed and 120 VAC powered. b. Produce 100db audible signal at 10 feet. c. External panel mountable. d. Acceptable products: Federal Signal model 350, 120VAC.

21. Alarm Flasher: a. Alarm Flasher shall be UL listed and consist of a removable plug and a

hardwired base element that accepts wire sizes from No. 20 AWG to No. 2 AWG. Units shall be DIN-rail mounted.

b. Units shall be solid state 120 VAC, DPDT isolated contacts rated at 10 A. c. Variable flash rate adjustable from 10 to 120 flashes per minute. d. Acceptable products: Amperite DFV model 120A F10-120DFV.

22. Rotating Warning Light (Beacon): a. Lamp type: 100 Watt, sealed beam, incandescent lamp. b. Lamp life: 2,000 hours. c. Beam angle: Adjustable though 90 degree from horizontal to vertical. d. Mounting: Pipe or surface mount. e. Rotation rate: 60 times per minute. f. Operating voltage: 120VAC. g. Material of construction: Cast Aluminum housing with Lexan dome. h. Dome color: As specified on drawings.


i. Acceptable products: Federal Signal Corp. Model 371L, or equal as approved by the Engineer.

23. Surge Suppressor: a. Surge suppressors shall be UL listed and consist of a removable plug and

a hardwired base element that accepts wire sizes from No. 20 AWG to No. 2 AWG. Units shall be DIN-rail mounted.

b. Units shall be rated for 120 VAC nominal, 150 VAC maximum and 15kA nominal, 40kA maximum surge current (8/20us).

c. Acceptable products: Phoenix Contact Valvetrab or equal as approved by the Engineer. Valvetrab system part numbers are listed below: 1) Line-Neutral: 120VAC to neutral plug VAL-MS 120 ST Model

2807586; Base element VAL-MS-BE Model 2817741. 2) Neutral-Ground Base and Plug: F-MS 12/FM Model 2817974.

24. Fuses: a. Time delay glass tube construction with nickel plated brass endcaps, 1/4”

x 1-1/4” size, for use in Allen-Bradley 1492-H5 fuse blocks. b. Provide fuse sizes as shown on the drawings. c. Acceptable products: Bussman MDL or equal as approved by the

Engineer. 25. Grounding and Ground Bar:

a. Ground bars shall be UL listed and have suitable number and size of terminals necessary for terminating stranded copper ground wires.

b. Provide control panels with a signal ground bus, isolated from the power ground bus: 1) Provide multiple panels in one location with a common point for signal

ground bus connection to ground. c. Ground single point ground shields and measurement loops at the source

panel external terminals, unless otherwise noted, by bonding to the control panel signal ground bus.

d. Provide isolating amplifiers within control panels for field equipment possessing a grounded input or output, except when the panel circuit is galvanically isolated.

e. Acceptable products: Square D Ground Bar Kits, or equal as approved by the Engineer.

26. Battery Box: a. Battery box shall be a lockable NEMA 4X enclosure, with a minimum

dimension of 12” x 12” x 12”. b. Acceptable products: Hoffman NEMA 4X enclosure, or equal as approved

by the Engineer. 27. Battery Charger:

a. Battery charger shall be UL listed, Single-phase DIN-rail mounted, switched-mode battery charger 120VAC input, with the capability to charge 24VDC sealed lead-acid, absorbent glass mat battery.

b. Minimum output current 4 Amps, automatic float charge upon completion of battery charging.

c. Acceptable products: Curtis model 1604CS-AVS/24/04, or equal as approved by the Engineer.

28. Backup Battery: a. Back up batteries shall be 12 VDC, 18 Amp Hrs capacity, sealed lead-acid

battery. Provide sufficient quantity of batteries to obtain a backup voltage of 24VDC.

b. Absorbent glass mat (AGM) technology. c. Valve regulated, spill proof and can be operated in any position.


d. Acceptable products: Power Sonic PS-12180, or equal as approved by the Engineer.

29. Panel Exhaust Fan and Fan Thermostat: a. Panel exhaust fan shall be UL listed and powered form 120VAC. b. Shall have integrated cover grill and removable filter. c. Shall include external thermostat with an adjustable range from 30 DEGF

to 140 DEGF. d. Panel exhaust fan shall be sized according to panel cooling requirements. e. Acceptable products (Fan): Hoffman Series SF-05 filter fan package,

catalog No. SF0516002, or equal as approved by the Engineer. f. Acceptable products (Thermostat): Hoffman Temperature Control Switch.

Hoffman catalog No. ATEMNO, or equal as approved by the Engineer. 30. Control Net T-Taps at connection points for Control Net modules. Rockwell

Automation catalog number 9904-TPYS, or equal as approved by the Engineer.

31. Panel Heater: a. Panel heater shall be UL listed and powered from 120VAC. b. Integrated thermostat adjustable from 0 DEGF to 90 DEGF. c. 200 watt heating capacity. d. Acceptable products: Hoffman electric heater, catalog No. DAH2001A, or

equal as approved by the Engineer. 32. Nameplates:

a. Nameplates shall be provided.

2.03 JUNCTION TERMINAL BOXES

A. Refer to Section 26_05_33 Raceway and Boxes for Electrical Systems for junction terminal box construction requirements.

2.04 SPARES, AND EXPENDABLES

A. General: 1. In addition to the items noted below and in the other specification sections, the

OSS shall provide suitable spare parts and expendable items for each water treatment plant in sufficient quantities to sustain each ozone system for a period of 1 year after acceptance. All spare parts shall be delivered to the site before testing begins.

2. The following tabulation of spare parts and maintenance equipment is presented as a minimum of suitable types and quantities to be provided. The OSS shall review the ozone system and submit to the District for approval a specific list. The District’s decision as to both types and quantities to be provided shall be final: a. Provide the following spares:

1) Fuses: 20 percent spares of each size and type used, but no less than 10 of each size and type.

2) Relays: 20 percent spares of each type used, but no less than five of each type.

3) Indicating Light Bulb: 20 percent spares of each size and type used, but no less than 10 of each size and type.

4) 24v Loop Dc Power Supplies: 20 percent spares of each size and type used, but no less than three of each size and type.

5) PLC Modules: PLC spare parts shall be provided as listed in Section 40_94_43.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install equipment specified above as shown on the drawings. Follow all manufacturers’ instructions when installing PLCs, networks, and accessories.

3.02 Factory QUALITY CONTROL

A. All factory testing shall be in accordance with Sections 01_75_17 Field Testing and Startup and 40_80_01.


A. All field testing shall be in accordance with Sections 01_75_17 and 40_80_01.

END OF SECTION




SECTION 40_96_15

SCHEDULES: I/O LIST

PART 1 GENERAL

1.01 SUMMARY

A. The ozone system supplier shall refer to specifications section 40_61_16 - Specific Control Strategies to determine the complete I/O list for the MOCP and other vendor supplied control panels.

PART 2 PRODUCTS

Not used.

PART 3 EXECUTION

3.01 I/O LIST

A. Not used.

END OF SECTION




SECTION 46_05_94

MECHANICAL EQUIPMENT TESTING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Testing of mechanical equipment and systems.




3. The following sections are related to the Work described in this Section. This list of related sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents. a. Section 01_75_17 - Commissioning and Process Start-Up. b. Section 26_05_83 - Low Voltage Motors up to 500 Horsepower. c. Section 40_05_00.09 - Piping Systems Testing.

1.02 REFERENCES

A. American National Standards Institute (ANSI): 1. S1.4 Specification for Sound Level Meters.

B. Hydraulic Institute (HI).

C. National Institute of Standards and Technology (NIST).

1.03 SUBMITTALS

A. Schedule of source (factory) tests, Owner training, installation testing, functional testing, clean water facility testing, closeout documentation, process start-up and process operational period as specified in this Section and in Section 01_75_17 and equipment sections.

B. Test instrumentation calibration data.

C. Operation and maintenance manual:

D. Commissioning and Process Start-up Plan: As specified in Section 01_75_17.

E. Test plan as specified in Section 01_75_17 and equipment sections.

F. Test reports as specified in this Section and in Section 01_75_17 and equipment sections.



PART 3 EXECUTION

3.01 GENERAL

A. Commissioning and process start-up of equipment as specified in: 1. This Section. 2. Section 01_75_17. 3. Equipment sections.

a. If testing requirements are not specified, provide Level 1 Tests.

B. Comply with latest version of applicable standards.

C. Test and prepare piping as specified in Section 40_05_00.09.

D. Operation of related existing equipment: Owner will operate related existing equipment or facilities necessary to accomplish the testing. Schedule and coordinate testing as required by Section 01_75_17.

E. Provide necessary test instrumentation that has been calibrated within 1 year from date of test to recognized test standards traceable to the NIST or approved source. 1. Properly calibrated field instrumentation permanently installed as a part of the

Work may be utilized for tests. 2. Prior to testing, provide signed and dated certificates of calibration for test

instrumentation and equipment.

F. Test measurement and result accuracy: 1. Use test instruments with accuracies as recommended in the appropriate

referenced standards. When no accuracy is recommended in the referenced standard, use 1 percent or better accuracy test instruments. a. Improved (lower error tolerance) accuracies specified elsewhere prevail

over this general requirement. 2. Do not adjust results of tests for instrumentation accuracy.

a. Measured values and values directly calculated from measured values shall be the basis for comparing actual equipment performance to specified requirements.

G. Report features: 1. Report results in a bound document in generally accepted engineering format

with title page, written summary of results compared to specified requirements, and appropriate curves or plots of significant variables in English units.

2. Include appendix with a copy of raw, unmodified test data sheets indicating test value, date and time of reading, and initials of person taking the data.

3. Include appendix with sample calculations for adjustments to raw test data and for calculated results.

4. Include appendix with the make, model, and last calibration date of instrumentation used for test measurements.


5. Include in body of report a drawing or sketch of the test system layout showing location and orientation of the test instruments relative to the tested equipment features.

H. Prepare and submit test reports as specified.

I. Testing levels: 1. Level 1 Tests:

a. Level 1 General Equipment Performance Test: 1) For equipment, operate, rotate, or otherwise functionally test for

15 minutes minimum after components reach normal operating temperatures.

2) Operate at rated design load conditions. 3) Confirm that equipment is properly assembled, equipment moves or

rotates in the proper direction, shafting, drive elements and bearings are installed and lubricated in accordance with proper tolerances, and that no unusual power consumption, lubrication temperatures, bearing temperatures, or other conditions are observed.

b. Level 1 Pump Performance Test: 1) Measure flow and head while operating at or near the rated

condition; for factory testing, testing may be at reduced speeds with flow and head corresponding to the rated condition when adjusted for speed using the appropriate affinity laws.

2) Use of a test driver is permitted for factory tests when actual driver is given a separate test at its point of manufacture as specified in Section 26_05_83 or the applicable equipment section. Use actual driver for field tests.

3) Record measured flow, suction pressure, discharge pressure, and make observations on bearing temperatures and noise levels.

c. Level 1 Vibration Test: 1) Test requirement:

a) Measure filtered vibration spectra versus frequency in 3 perpendicular planes at each normally accessible bearing housing on the driven equipment, any gears and on the driver; 1 plane of measurement to be parallel to the axis of rotation of the component.

b) Vibration spectra versus frequency shall be in accordance with Vibration Acceptance Criteria.

2) Equipment operating condition: Test at specified maximum speed. d. Level 1 Noise Test:

1) Measure unfiltered overall A-weighted sound pressure level in dBA at 3 feet horizontally from the surface of the equipment and at a mid-point of the equipment height.

2. Level 2 Tests: a. Level 2 General Performance Test:

1) For equipment, operate, rotate, or otherwise functionally test for at least 2 hours after components reach normal operating temperatures.

2) Operate at rated design load conditions. 3) Confirm that equipment is properly assembled, equipment moves or

rotates in the proper direction, shafting, drive elements and bearings are installed and lubricated in accordance with proper tolerances,


and that no unusual power consumption, lubrication temperatures, bearing temperatures, or other conditions are observed.

b. Level 2 Pump Performance Test: 1) Test 2 hours minimum for flow and head at the rated condition; for

factory testing, testing may be at a reduced speeds with flow and head corresponding to the rated condition when adjusted for speed using the appropriate affinity laws.

2) Use of a test driver is permitted for factory tests when actual driver is given a separate test at its point of manufacture as specified in Section 26_05_83. Use actual driver for field tests.

3) Test for flow and head at 2 additional conditions; 1 at 25 percent below the rated flow and 1 at 10 percent above the rated flow.

4) Record measured flow, suction pressure, discharge pressure, and observations on bearing temperatures and noise levels at each condition.

c. Level 2 Vibration Test: 1) Test requirement:

a) Measure filtered vibration spectra versus frequency and measure vibration phase in 3 perpendicular planes at each normally accessible bearing housing on the driven equipment, any gears and on the driver; 1 plane of measurement to be parallel to the axis of rotation of the component; measure actual rotational speeds for each vibration spectra measured using photometric or other tachometer input connected directly to the vibration data collector.

b) Vibration spectra versus frequency shall be in accordance with Vibration Acceptance Criteria.

2) Equipment operating condition: Repeat test requirements at design specified maximum speed and at minimum speed for variable speed equipment.

3) Natural frequency test of field installed equipment: a) Excite the installed equipment and support system in

3 perpendicular planes, use same planes as operating vibration measurement planes, and determine the as-installed natural resonant frequency of the driven equipment, the driver, gears and supports.

b) Perform test at each bearing housing, at each support pedestal, and for pumps on the suction and discharge piping.

c) Perform with equipment and attached piping full of intended service or process fluid.

d. Level 2 Noise Test: 1) Measure filtered A-weighted overall sound pressure level in dBA for

each of 8 octave band mid-points beginning at 63 hertz measured at 3 feet horizontally from the surface of the equipment at mid-point height of the noise source.

3. Level 3 Tests: a. Level 3 General Equipment Performance Tests:



2) Operate at rated design load conditions for 1/2 the specified time; operate at each of any other specified conditions for a proportionate share of the remaining test time.

3) Confirm that equipment is properly assembled, equipment rotates in the proper direction, shafting and bearings are installed and lubricated in accordance with proper tolerances, and that no unusual noise, vibration or temperatures are observed.

4) Take appropriate capacity, power or fuel consumption, torque, revolutions per minute, pressure and temperature readings using appropriate test instrumentation to confirm equipment meets specified performance requirements at the design rated condition.

5) Bearing temperatures: During maximum speed or capacity performance testing, measure and record the exterior surface temperature of each bearing versus time.

b. Level 3 Pump Performance Test: 1) Test 4 hours minimum for flow and head at or near the rated

condition; for factory testing, testing may be at a reduced speeds with flow and head corresponding to the rated condition when adjusted for speed using the appropriate affinity laws.

2) Use of a test driver is permitted for factory tests when actual driver is given a separate test at its point of manufacture as specified in Section 26_05_83. Use actual driver for field tests.

3) Test each specified flow and head condition at the rated speed and test at minimum as well as maximum specified speeds; operate at each test condition for a minimum of 15 minutes; for factory testing, test at other speeds may be omitted if test driver at reduced speeds is used for rated condition testing.

4) Record measured shaft revolutions per minute, flow, suction pressure, discharge pressure; record measured bearing temperatures (bearing housing exterior surface temperatures may be recorded when bearing temperature devices are not required by the equipment section) and record observations on noise levels.

c. Level 3 Vibration Test: 1) Requirements: Same as Level 2 vibration test except data taken at

each operating condition tested and with additional requirements below.

2) Perform High Frequency Enveloping Analysis for gears and bearings. a) Measure bearing element vibration directly on each bearing cap

in a location close as possible to the bearing load zone that provides a smooth surface and direct path to the bearing to detect bearing defects.

b) Report results in units of acceleration versus frequency in cycles per minute.

3) Perform Time Wave Form analysis for gears, low speed equipment and reciprocating equipment; plot true peak amplitude velocity and displacement versus time and label the period between peaks with the likely cause of the periodic peaks (relate the period to a cause).

4) Plot vibration spectra on 3 different plots; peak displacement versus frequency, peak acceleration versus frequency and peak velocity versus frequency.

d. Level 3 Noise Test: Measure filtered, un-weighted overall sound pressure level in dB at 3 feet horizontally from the surface of the equipment at mid-


point height and at 4 locations approximately 90 degrees apart in plain view; report results for each of 8 octave band mid-points beginning at 63 hertz.

4. Level 4 Tests: a. Level 4 General Equipment Performance Test:


2) Operate at rated design load conditions for 1/2 the specified time; operate at each of any other specified conditions for a proportionate share of the remaining test time.

3) Confirm that equipment is properly assembled, equipment rotates in the proper direction, shafting and bearings are installed and lubricated in accordance with proper tolerances, and that no unusual noise, vibration or temperatures are observed.

4) Take appropriate capacity, power or fuel consumption, torque, revolutions per minute, pressure and temperature readings using appropriate test instrumentation to confirm equipment meets specified performance requirements at the design rated condition.

5) Bearing temperatures: During maximum speed or capacity testing, measure and record the exterior surface temperature of each bearing versus time.

b. Level 4 Pump Performance Test: 1) Test 8 hours minimum for flow and head; begin tests at or near the

rated condition; for factory and field-testing, test with furnished motor at full speed.

2) Test each specified flow and head condition at the rated speed and test at minimum as well as maximum specified speeds; operate at each test condition for a minimum of 20 minutes or longer as necessary to measure required performance, vibration and noise data at each test condition.

3) Record measured shaft revolutions per minute, flow, suction pressure, discharge pressure; record measured bearing temperatures (bearing housing exterior surface temperatures may be recorded when bearing temperature devices not required by the equipment section) and record observations on noise levels.

4) Bearing temperatures: During maximum speed or capacity testing, measure and record the exterior surface temperature of each bearing versus time.

5) Perform efficiency and/or Net Positive Suction Head Required (NPSHr) and/or priming time tests when specified in the equipment section in accordance with the appropriate HI standard and as follows: a) Perform NPSHr testing at maximum rated design speed, head

and flow with test fluids at ambient conditions; at maximum rated speed, test at 15 percent above rated design flow, and 25 percent below rated design flow.

b) Perform efficiency testing with test fluids at maximum rated speed.

c) Perform priming time testing with test fluids at maximum rated speed.

c. Level 4 Vibration Test: Same as Level 3 vibration test.


d. Level 4 Noise Test: Same as Level 3 Noise Test except with data taken at each operating condition tested.

J. Variable speed equipment tests: 1. Establish performance over the entire speed range and at the average

operating condition. 2. Establish performance curves for the following speeds:

a. The speed corresponding to the rated maximum capacity. b. The speed corresponding to the minimum capacity. c. The speed corresponding to the average operating conditions.

K. Pump tests, all levels of testing: 1. Test in accordance with the following:

a. Applicable HI Standards. b. This Section. c. Equipment sections.

2. Test tolerances: In accordance with appropriate HI Standards, except the following modified tolerances apply: a. From 0 to plus 5 percent of head at the rated design point flow. b. From 0 to plus 5 percent of flow at the rated design point head. c. No negative tolerance for the efficiency at the rated design point. d. No positive tolerance for vibration limits. Vibration limits and test methods

in HI Standards do not apply, use limits and methods specified in this or other Sections of the Specifications.

L. Drivers tests: 1. Test motors as specified in Section 26_05_83. 2. Test other drivers as specified in the equipment section.

M. Noise requirements and control: 1. Perform noise tests in conjunction with vibration test analysis. 2. Make measurements in relation to reference pressure of 0.0002 microbar. 3. Make measurements of emitted noise levels on sound level meter meeting or

exceeding ANSI S1.4, Type II. 4. Set sound level meter to slow response. 5. Unless otherwise specified, maximum free field noise level not to exceed

85 dBA measured as sound pressure level at 3 feet from the equipment.

N. Pressure testing: 1. Hydrostatically pressure test pressure containing parts at the appropriate

standard or code required level above the equipment component specified design pressure or operating pressure, whichever is higher.

O. Inspection and balancing: 1. Statically and dynamically balance each of the individual rotating parts as

required to achieve the required field vibration limits. 2. Statically and dynamically balance the completed equipment rotating assembly

and drive shaft components. 3. Furnish copies of material and component inspection reports including

balancing reports for equipment system components and for the completed rotating assembly.


P. Critical speed of rotating equipment: 1. Satisfy the following:

a. The first lateral and torsional critical speed of all constant and variable driven equipment that is considered rigid such as horizontal pumps, all blowers and air compressors shall be at least 25 percent above the equipment’s maximum operating speed.

b. The first lateral and torsional critical speed of all constant and variable driven equipment that is considered flexible or flexibly mounted and fans shall at least 25 percent below the equipment’s lowest operating speed.

c. The second lateral and torsional critical speed of all constant and variable equipment that is considered flexible or flexibly mounted shall be at least 25 percent above the maximum operating speed.

Q. Vibration tests: 1. Definitions:

a. Root mean square: for pumps operating at speeds greater than 600 rpm, the vibration measurement shall be measured as the overall velocity in inches per second root mean square (RMS).

b. Peak-to-peak displacement: The root mean squared average of the peak-to-peak displacement multiplied by the square root of 2.

c. Peak velocity: The root mean squared average of the peak velocity multiplied by the square root of 2.

d. Peak acceleration: The root mean squared average of the peak acceleration multiplied by the square root of 2.

e. High frequency enveloping: A process to extract very low amplitude time domain signals associated with impact or impulse events such as bearing or gear tooth defects and display them in a frequency spectrum of acceleration versus frequency. 1) Manufacturers: One of the following or equal as approved by the

Engineer: a) Rockwell Automation, Entek Group, "Spike Energy" analysis. b) CSI, "PeakVue."

f. Low speed equipment: Equipment or components of equipment rotating at less than 600 revolutions per minute.

g. High speed equipment: Equipment and equipment components operating at or above 600 revolutions per minute.

h. Preferred operating range: Manufacturer’s defined preferred operating range (POR) for the equipment.

i. Allowable operating range: Manufacturer’s defined allowable operating range (AOR) for the equipment.

2. Vibration instrumentation requirements: a. Analyzers: Use digital type analyzers or data collectors with anti-aliasing

filter, 12 bit A/D converter, fast fourier transform circuitry, phase measurement capability, time wave form data storage, high frequency enveloping capabilities, 35 frequency ranges from 21 to 1,500,000 cycles per minute, adjustable fast fourier transform resolution from 400 to 6,400 lines, storage for up to one hundred 3,200 line frequency spectra, data


output port, circuitry for integration of acceleration data to velocity or double integration to displacement. 1) Manufacturers: One of the following or equal as approved by the

Engineer: a) Computational Systems Inc., (CSI) Division of Emerson Process

Management, Model 2120A, Data Collector/analyzer with applicable analysis software.

b) Pruftechnik, VIBXPERT II. b. Analyzer settings:

1) Units: English, inches/second, mils, and gravitational forces. 2) Fast fourier transform lines: Most equipment 1,600 minimum; for

motors, enough lines as required to distinguish motor current frequencies from rotational frequencies, use 3,200 lines for motors with a nominal speed of 3,600 revolutions per minute; 3,200 lines minimum for High Frequency Enveloping; 1,600 lines minimum for low speed equipment.

3) Sample averages: 4 minimum. 4) Maximum frequency (Fmax): 40 times rotational frequency for rolling

element bearings, 10 times rotational frequency for sleeve bearings. 5) Amplitude range: Auto select but full scale not more than twice the

acceptance criteria or the highest peak, whichever is lower. 6) Fast fourier transform windowing: Hanning Window. 7) High pass filter: Minus 3 dB at 120 cycles per minute for high speed

equipment. Minus 3 dB at 21 cycles per minute for low speed equipment.

3. Vibration acceptance criteria: a. Testing of rotating mechanical equipment: Tests are to be performed by

an experienced, factory trained, and independent authorized vibration analysis expert.

b. Vibration displacement limits: Unless otherwise specified, equipment operating at speeds 600 revolutions per minute or less is not to exhibit unfiltered readings in excess of following:

Operating Conditions & Application Data Overall Peak-to-Peak Displacement

Field, mils Factory, mils Operation within the POR 3.0 4.0 Operation within the AOR 4.0 5.0

Additive value when measurement location is greater than 5 feet above foundation. 2.0 2.0 Additive value for solids-handling pumps 2.0 N/A Additive value for slurry pumps 2.0 N/A

c. Vibration velocity limits: Unless otherwise specified, equipment operating at speeds greater than 600 revolutions per minute is not to exceed the following peak velocity limits:

HI Pump Type Horsepower

Field Test Factory Test

Overall RMS Overall RMS

Between 33 and 100 HP 0.28 0.31


HI Pump Type Horsepower

Field Test Factory Test

Overall RMS Overall RMS

Horizontal and Vertical In-Line Centrifugal Pumps

100 HP and above 0.31 0.34

Below 33 HP 0.30 0.33

100 HP and above 0.34 0.35 Non-Solids Handling Centrifugal Pumps HI Types BB1, BB2, BB3, BB4, BB5, OH1, OH2, OH3, OH4, OH5, and OH7

Below 268 HP 0.15 0.19

268 HP and above 0.19 0.22

Gear Reducers, Radial 268 HP and above 0.17

Motors See Applicable Motor Specification

See Applicable Motor

Specification

Gear Reducers, Radial

Not to exceed AGMA 6000-B96 limits

Not to exceed AGMA 6000-

B96 limits

Other Reducers, Axial 0.1 N/A d. Equipment operation: Measurements are to be obtained with equipment

installed and operating within capacity ranges specified and without duplicate equipment running.

e. Additional criteria: 1) No narrow band spectral vibration amplitude components, whether

sub-rotational, higher harmonic, or synchronous multiple of running speed, are to exceed 40 percent of synchronous vibration amplitude component without manufacturer's detailed verification of origin and ultimate effect of such excitation.

2) The presence of discernable vibration amplitude peaks in Test Level 2 or 3 vibration spectra at bearing inner or outer race frequencies shall be cause for rejection of the equipment.

3) For motors, the following shall be cause for rejection: a) Stator eccentricity evidenced by a spectral peak at 2 times

electrical line frequency that are more than 40 percent of the peak at rotational frequency.

b) Rotor eccentricity evidenced by a spectral peak at 2 times electrical line frequency with spectra side bands at the pole pass frequency around the 2 times line frequency peak.

c) Other rotor problems evidenced by pole pass frequency side bands around operating speed harmonic peaks or 2 times line frequency side bands around rotor bar pass frequency or around 2 times the rotor bar pass frequency.

d) Phasing problems evidenced by 1/3 line frequency side band spectral peaks around the 2 times electrical line frequency peak.


4) The presence of peaks in a High Frequency Enveloping spectra plot corresponding to bearing, gear or motor rotor bar frequencies or harmonics of these frequencies shall be cause for rejection of the equipment; since inadequate lubrication of some equipment may be a cause of these peaks, lubrication shall be checked, corrected as necessary and the high frequency envelope analysis repeated.

4. Vibration testing results presentation: a. Provide equipment drawing with location and orientation of measurement

points indicated. b. For each vibration measurement take and include appropriate data on

equipment operating conditions at the time vibration data is taken; for pumps, compressors, and blowers record suction pressure, discharge pressure, and flow.

c. When Vibration Spectra Data required: 1) Plot peak vibration velocity versus frequency in cycles per minute. 2) Label plots showing actual shaft or part rotation frequency, bearing

inner and outer race ball pass frequencies, gear mesh frequencies and relevant equipment excitation frequencies on the plot; label probable cause of vibration peaks whether in excess of specification limits or not.

3) Label plots with equipment identification and operating conditions such as tag number, capacity, pressure, driver horsepower, and point of vibration measurement.

4) Plot motor spectra on a log amplitude scale versus frequency. d. For low speed equipment, plot peak vibration displacement versus

frequency as well as velocity versus frequency. e. Provide name of manufacturer and model number of the vibration

instrumentation used, including analyzer and accelerometer used together with mounting type.

3.02 PLANNING PHASE

A. Submit test plans as specified in Section 01_75_17 and this Section. 1. Indicate test start time and duration, equipment to be tested, other equipment

involved or required; temporary facilities required, number and skill or trade of personnel involved; safety issues and planned safety contingencies; anticipated effect on Owner's existing equipment and other information relevant to the test.

2. Provide locations of all instruments to be used for testing. Provide calibration records for all instrumentation.

3.03 COMMISSIONING PHASE

A. Source testing: 1. Witnessing not required unless specified otherwise in equipment section. 2. Witnessed tests: Schedule test date and notify Engineer at least 30 days prior

to start of test. 3. Test equipment as specified in Section 01_75_17 and equipment sections. 4. Test fluids as specified in Section 01_75_17. 5. Submit reports as specified in Section 01_75_17.


B. Installation testing: 1. Test equipment as specified in Section 01_75_17 and equipment sections.

C. Functional testing: 1. Witnessing required as specified in Section 01_75_17. 2. Schedule test date and notify Engineer at least 7 days prior to start of test. 3. Test equipment as specified in equipment sections. Test fluids as specified in

Section 01_75_17. 4. Submit reports as specified in Section 01_75_17.

D. Clean Water Facility Testing: 1. Test equipment as specified in Section 01_75_17 and equipment sections.

E. Closeout documentation: 1. Provide closeout documentation as specified in Section 01_75_17 and

equipment sections.

3.04 PROCESS START-UP PHASE

A. Process start-up: 1. Process start-up equipment as specified in Section 01_75_17 and equipment

sections.

B. Process Operational Period: 1. Operate equipment as specified in Section 01_75_17 and equipment sections.

END OF SECTION


SECTION 46_31_52

OZONE SYSTEMS: GENERAL

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Specifications for providing the equipment and services associated with the

Ozone Systems by the Contractor and Ozone System Supplier. 2. This specification covers equipment to be provided at two water treatment

plants. The two plants are approximately a 30-minute drive apart without traffic delays and are both within 30 minutes of the Oakland International Airport. a. Sobrante Water Treatment Plant. b. Upper San Leandro Water Treatment Plant.

3. Unless otherwise noted, the Ozone System equipment will be identical for each water treatment plant.

4. The delivery dates for the equipment at the two water treatment plants shall be as indicated in Section II of the Request for Proposal.

5. Specifications for Contractor installation of equipment provided by the Ozone System Supplier and other Contractor responsibilities associated with the Ozone System.


binding as if called for by all. 2. The following Sections are related to the Work described in this Section. This

list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Ozone System Supplier to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 01_75_17 - Commissioning and Process Start-Up. c. Section 01_78_23 - Operation and Maintenance Data. d. Section 01_81_01 - Project Design Criteria. e. Section 01_81_02 - Seismic Design Criteria. f. Section 05_05_24 - Mechanical Anchoring and Fastening to Concrete. g. Section 46_31_54 - Supplemental Nitrogen Equipment. h. Section 46_31_55 - Ozone Generating Equipment. i. Section 46_31_57 - Ozone Destruction Equipment. j. Section 46_31_58 - Cleaning for Oxygen and Ozone Service. k. Section 46_31_59 - Ozone System Testing. l. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. m. Section 40_61_05 - Packaged Control Systems. n. Section 40_61_16 - Specific Control Strategies. o. Section 40_80_01 - Testing, Calibration, and Commissioning. p. Request for Quotation for Sobrante and Upper San Leandro Water

Treatment Plants Ozone Systems Equipment


1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. Boiler and Pressure Vessel Code, Section VIII, Rules for Construction of

Pressure Vessels, Division 1.

B. American Water Works Association (AWWA): 1. B304 - Liquid Oxygen for Ozone Generation for Water, Wastewater, and

Reclaimed Water Systems.

C. Institute of Electrical and Electronics Engineers (IEEE): 1. 519 - Recommended Practices and Requirements for Harmonic Control in

Electrical Power Systems.

D. National Electrical Manufacturers Association (NEMA).

1.03 DEFINITIONS

A. Ozone System: A complete system for producing and destroying ozone at each project facility. The Contractor shall have overall responsibility for providing complete and operable Ozone Systems as specified in this Section and indicated on the Drawings.

B. Ozone System Supplier (OSS or Supplier): Manufacturer of ozone generators and power supplies, supplemental nitrogen system, and ozone destruct systems to supply the Ozone System, defined in this Section, based on the Drawings, Specifications and the specific requirements of the Manufacturer's equipment. The OSS shall furnish the following major equipment and services for each Ozone System including, but not limited to, the following: 1. Ozone Generators and Power Supplies. 2. Ozone Destruct Systems. 3. Supplemental Nitrogen System. 4. Closed Loop Cooling Water Pumps and ancillary dielectric cooling loop

equipment as required by OSS. 5. Master Ozone Control Panel. 6. Remote I/O (RIO) Panels for the LOX area and Ozone Destruct Room. 7. Interconnecting piping, valving, and safety relief devices as specified and

indicated on the Drawings for the above major equipment items. Interconnecting piping and wiring provided by the OSS shall be limited to piping located on the equipment skids provided by the OSS.

8. Instrumentation as specified in the Contract Documents for the above major equipment items.

9. Programming of the PLC equipment within the Ozone System control panels: a. Provide a copy of the application program to the Owner.

10. Spare parts for the above equipment items at each water treatment plant. 11. Other services as specified in this Section including but not limited to testing,

installation responsibilities, training, O&M manuals, and record drawings.

C. Ozone Generator Design Production Capacity (DPC): Design ozone production capacity of one generator and its associated power supply unit at a specific cooling water temperature and at three specific ozone product gas concentrations as specified in this Section.


D. Average Rate of Energy Consumption (AVE-kW): The average value of the rate of energy consumption over a specific period of operation, measured in kilowatts (kW).

E. Ozone Generator Specific Energy Consumption (SEC): The amount of energy consumed per pound of ozone produced (kWh/pound) during operation under a specific set of operating conditions.

F. Supplier Agreement: Agreement between OSS and District for procurement of ozone equipment.


A. General design criteria: 1. Design the Ozone System components to operate continuously as specified

throughout the full range of ambient environmental conditions as specified.

B. Power supply to the ozone generator power supply units: 480-volt, 3-phase, 60 hertz.

C. Gaseous oxygen production: 1. Gaseous oxygen with a maximum dew point of minus 80 degrees Fahrenheit,

produced by vaporization of liquid oxygen (LOX) and supplemental nitrogen shall serve as the only feed gases to the Ozone System. Design the ozone systems to be compatible with liquid oxygen procured with AWWA Standard B304, latest edition.

D. Ozone system operation: 1. The ozone product gas concentration of the Ozone System shall range

between 3.0 to 12.0 percent, by weight.

E. Cooling water system: 1. Provide ozone generator and power supply cooling by a closed-loop circulation

system where the heat is ultimately rejected to plant water as specified in Section 46_31_55 and indicated on the Drawings.

F. Harmonic mitigation systems: 1. Provide harmonic mitigation evaluations and equipment with each ozone

generator power supply system, as required, to meet the requirements as specified in Section 46_31_55.

2. Provide written certification, signed by a representative of the Ozone System Supplier, that the Ozone System is in conformance with the harmonic standards specified.

1.05 OZONE GENERATOR PERFORMANCE CRITERIA

A. Ozone generator design production capacity: 1. As specified in Section 46_31_55.


B. Ozone system design production capacity: 1. The ozone system design production capacity shall be 3,500 pounds per day

at an ozone product gas concentration of 10.0 percent, by weight at each water treatment plant: a. The ozone system design production capacity is based on any two ozone

generators operating under the same conditions specified for the ozone generator design production capacity at an ozone product gas concentration of 10.0 percent, by weight as specified in Section 46_31_55.

C. Energy consumption efficiency criteria: 1. Each ozone generator and power supply required to produce ozone, shall

have an average Specific Energy Consumption (SECAVE) of no more than the value stated in the Energy Consumption Bid Form in units of Kilowatt hours per pound of ozone at a concentration of 10.0 percent, by weight, under the operating conditions given for the Energy Consumption Efficiency Test as specified in Section 46_31_59.

2. If the actual ozone generator Specific Energy Consumption, SECACT, determined during the energy consumption efficiency performance testing as specified in Section 46_31_59, is greater than the value of SECAVE stated in the Energy Consumption Form, the Ozone System Supplier shall pay the Owner the penalties defined by the following equation for each water treatment plant: a. Penalty = Actual Present Worth Energy Cost – Proposed Present Worth

Cost b. Where:

1) Actual Present Worth Cost = Cost using equation and terms in the Bid Form (Part B) of the RFQ, except SECACT is substituted for SECAVE

2) Proposed Present Worth Cost = Bid cost provided by OSS in Bid Form (Part B)

c. This amount corresponds to the additional cost that the Owner shall bear over a 20-year operating life of the plant.

3. If SECACT is less than or equal to SECAVE, the penalty is $0.

D. Ozone generator design production capacity criteria: 1. The maximum allowable Specific Energy Consumption (SECMAX) under the

ozone generator design production capacity testing operating conditions as specified in Section 46_31_59 shall be 5.0 kilowatt hours per pound. The value of SECMAX shall include all energy consumption associated with the power supply units but not the closed loop cooling water pumping energy consumption.

2. The Actual Production Capacity (APC) measured under the Ozone Generator Design Product Capacity Performance Test as specified in Section 46_31_59, shall be greater than or equal to the ozone generator design production capacity corresponding to each specified ozone product gas concentration in Section 46_31_55.

3. If either the SECACT measured during the Design Production Capacity test exceeds the SECMAX or the APC is less than the ozone generator design production capacity for an ozone generator and power supply, the Ozone System Supplier shall modify that equipment and perform the Design


Production Capacity Test until the criteria are met, at no additional cost to the Owner.

1.06 SUBMITTALS

A. Submittals to the Engineer as specified and in accordance with the individual equipment specifications, and as specified in Section 01_33_00.

B. All submittal information shall be provided in the English language using US standard symbology.

C. Operations and Maintenance Manuals as specified in Section 01_78_23.

D. Documentation to describe any deviations from the design indicated on the Drawings and in the Specifications.

E. Submittal information as specified in Section 40_61_00 for the instrumentation and controls portion of the ozone system work.

F. Structural and seismic design calculations for the system: 1. All structural calculations shall be signed and stamped by a Civil or Structural

Engineer registered in the State of California.


A. Ozone System Supplier Qualifications: 1. Refer to Request for Qualifications (RFQ) documents.

1.08 WARRANTIES AND GUARANTEES

A. Warranties and guarantees: As specified in RFQ documents.

1.09 SITE CONDITIONS

A. Ambient environmental conditions: 1. Design Ozone System components to operate in indoor environments

throughout the entire range of ambient temperature conditions specified in Section 01_81_01.

B. Project elevations: As specified in Section 01_81_01.

C. Cooling water temperature and quality: 1. Design the ozone systems to operate with the raw water temperature and

quality conditions specified in Section 01_81_01.

PART 2 PRODUCTS

2.01 OZONE SYSTEM

A. Ozone System Supplier: 1. Refer to Request for RFQ documents for Ozone System Supplier

qualifications.


B. Materials: 1. Unless otherwise specified in this Section, all Ozone System equipment and

appurtenances from the generators and off-gas destruct units shall be compatible for continuous contact with up to 12 percent by weight concentration ozone and 98 to 99 percent pure oxygen: a. Compatible non-metallic materials for gaskets and seals include the

appropriate grades of Viton or Teflon. b. Metallic components shall be AISI Type 316L stainless steel (ozone and

gaseous oxygen). c. Anchor bolts: As specified in Section 05_05_24.

2. Ozone System equipment and appurtenances of the ozone destruct systems shall be compatible for continuous contact with ozone in saturated air and high concentrations of oxygen: a. Compatible non-metallic materials for gaskets and seals include the

appropriate grades of Viton or Teflon. b. Metallic components shall be AISI Type 316L stainless steel.

3. All equipment and materials that may contact oxygen or ozone shall be cleaned and certified as specified in Section 46_31_58: a. Cleaned equipment and materials shall be protected from environmental

exposure. b. The OSS shall be responsible for all recleaning of OSS-provided

equipment required as a result of contamination due to OSS actions. 4. All equipment, piping and other materials provided as part of the Ozone

System shall be sized in accordance with US standards and dimensioned using US standard units.

C. Master Ozone Control Panels (MOCPs) (505-OGS-VCP-100 at Sobrante WTP and 503-OGS-VCP-100 at USL WTP): 1. Provide Vendor Control Panels (VCPs) that will serve as the Master Ozone

Control Panel for the Ozone System at each WTP. 2. Provide full access to all programming on the Master Ozone Control Panels to

District personnel. 3. Each VCP shall perform monitoring and controls as indicated on the Drawings,

as specified in Section 40_61_16 and as described in the individual ozone equipment sections.

4. The control panels and their components shall meet the requirements as specified in Section 40_61_05: a. The panel shall be rated for NEMA 12 construction.

5. Network component requirements: As specified in Section 40_61_05. 6. HMI and programming requirements: As specified in Section 40_61_16. 7. Provide a PLC inside the MOCP as specified in Section 40_61_05:

a. Program the PLC as specified in Section 40_61_16, for a complete functioning system.

b. Provide remote I/O and network communication modules as required, as indicated on the Drawings, and as specified in Sections 40_61_05, for a complete functioning system.

8. The VCP shall communicate with the plant control system over Ethernet IP communication protocol using media as shown on the drawings : a. Provide a minimum of 4 usable fiber optic multi-mode strands for

redundant connection to the plant control system. 9. Provide and configure Managed Ethernet Switches inside the VCP as

required, to isolate the VCP’s communication with the plant control system,


and the VCP’s communication with other Ozone System Supplier -furnished equipment and control panels: a. Managed Ethernet Switches shall be provided in accordance with Owner’s

standards. 10. Provide all other electrical and instrumentation hardware and software in

accordance with the Contract Documents, for a complete functioning system.

D. Remote I/O (RIO) Panels: 1. Provide Vendor Control Panels (VCPs) that will serve as the RIOs at each

WTP. 2. Each RIO shall perform the functions as indicated on the Drawings and as

described in the individual ozone equipment sections. 3. Each RIO and its components shall meet the requirements as specified in

Section 40_61_05: a. The RIO in the Ozone Destruct Room at each WTP shall be rated NEMA

12 and be of stainless steel construction. b. The RIO in the LOX Area at each WTP shall be rated for outdoor service

and be rated NEMA 4X and be of stainless steel construction. 4. Each RIO shall communicate with a Master Ozone Control Panel as indicated

on the Drawings and specified in Section 40_61_05.

PART 3 EXECUTION

3.01 PLC PROGRAMMING

A. The Ozone System Supplier shall provide PLC programming for the following PLCs as indicated on the Drawings and as specified in Section 40_61_16: 1. PLCs provided with the ozone generator power supplies. 2. PLCs located in the Master Ozone Control Panels.

3.02 SOFTWARE TESTING

A. The Ozone System Supplier shall prepare software and hardware to test the Ozone System control software in accordance with 40_80_01.


A. See factory testing requirements as specified herein and in Section 46_31_59.

3.04 OZONE SYSTEM PROVISION RESPONSIBILITY

A. All communication shall be through the District or the Contractor as specified in the Supplier Agreement.

B. Ozone System Supplier: Furnish the following equipment: 1. Instruments indicated on the instrumentation drawings and/or indicated in the

specification sections related to the Ozone System Supplier’s equipment. 2. Supplemental nitrogen generation systems as specified in Section 46_31_54. 3. Skid-mounted ozone generators, including on-skid interconnecting piping,

valving, instrumentation, and pressure relief valves, and separate power supplies as specified in Section 46_31_55.


4. Closed-loop cooling water pumps and ancillary equipment to meet any specific cooling requirements as specified in Section 46_31_55.

5. Ozone destruct systems as specified in Section 46_31_57. 6. Master Ozone Control Panels, as indicated on the Drawings and specified

herein and in Section 40_61_05. 7. Remote I/O Panels as indicated on the Drawings and specified herein and in

Section 40_61_05. 8. Programming of the PLCs and panel-mounted HMIs in control panels provided

by the Ozone System Supplier: a. The programming shall implement the control strategies as specified in

Section 40_61_16. 9. Miscellaneous process and control equipment specifically required for the

Ozone System Supplier equipment.

C. Contractor-provided equipment: The Contractor will provide all equipment not supplied by the Ozone System Supplier including the following: 1. Instrumentation equipment, including valves, pressure regulating and relief

valves, analyzers, switches, gauges and transmitters. 2. Interconnecting piping and flanging for gaseous oxygen, ozone, off-gas, closed

loop cooling water, and open loop cooling water. 3. Cooling water equipment including valves, instruments, expansion tanks, and

chemical pot feeders. Existing open loop cooling water pumps and heat exchangers will continue to be utilized with the modified system.

4. LOX storage, vaporization, and handling equipment. 5. Anchor bolts for anchoring the skids provided by the Ozone System Supplier. 6. All power and signal wiring and conduits, with the exception of the high-voltage

cable between the ozone generators and power supplies. 7. Power distribution equipment. 8. Valves except those specifically in the nitrogen generation system, ozone

generator skids, or the ozone destruct unit skids or specifically indicated to be provided by the OSS.

9. Oxygen cleaning services not already specified for piping and equipment.

3.05 OZONE SYSTEMS INSTALLATION RESPONSIBILITY

A. The Contractor has overall responsibility for installation of the equipment provided by the Supplier: 1. All communications by the Supplier, District, and Contractor shall be in

accordance with the Supplier Agreement..

B. Ozone System Supplier: 1. Provide installation oversight services to ensure that the equipment is installed

in accordance with the Specifications and the specific requirements of the Ozone System Supplier. Provide a minimum of 80 hours at each water treatment plant of installation oversight services. Assume that a total of five trips by at least one employee to the area of the District's WTPs is required for installation oversight services. More than one WTP can be visited during each trip.

2. Provide service by qualified personnel as specified in the RFQ. 3. Include cost of all wages, taxes, benefits, insurance, travel and living expenses

associated with the installation oversight services.


C. Contractor will install all equipment, piping, and power and signal connections of the Ozone Systems, except as specified in this Section, in accordance with the Contract Documents and the requirements of the Ozone System Supplier.

3.06 OZONE SYSTEM START-UP AND TESTING

A. Perform all system start-up and testing as specified in Section 01_75_17.

B. Ozone System Supplier: 1. Provide qualified personnel to start-up and operate the Ozone Systems per the

RFQ. 2. Provide qualified personnel to conduct the Ozone System performance tests

as specified in Section 46_31_59. 3. Include cost of all wages, taxes, benefits, insurance, travel, and living

expenses associated with the Ozone System start-up and testing services.

C. Contractor: 1. Will provide qualified personnel to correct installation deficiencies defined by

the Ozone System Supplier Representative during start-up and testing. 2. Will make corrections in a timely fashion.

3.07 OPERATION TRAINING SERVICES

A. All training shall be the responsibility of the Ozone System Supplier. Provide training in accordance with the requirements specified in Section 01_75_17.

B. The Ozone System Supplier shall provide classroom and field training to the Owner’s supervisory, operation and maintenance personnel covering the operation and maintenance of the Ozone System at each WTP. General requirements of the training follow: 1. Minimum 44 hours of classroom training at each WTP. 2. Minimum 44 hours of field instruction at each WTP.

C. A minimum of 40 hours of the training at each WTP shall be completed prior to Functional Testing as defined by Section 01_75_17: 1. The scope of the initial training shall include sufficient information for the

operational personnel such that they can successfully operate the Ozone System without the supervision of the Ozone System Supplier.

2. Provide the balance of the training within 90 days after the Process Operational Period of the project. Include additional travel and living expenses for the balance of the training over and above the initial travel and living expenses for the initial training.

D. A minimum of 10 hours of the total training time at each WTP shall cover safety issues related to the Ozone System. Of this minimum 10 hours of safety training, four hours shall be related to the safety related to liquid and gaseous oxygen facilities.

E. Include cost of all wages, taxes, benefits, insurance, travel, and living expenses associated with the training services.

F. At the direction of the Engineer, classes may be repeated so that all staff may attend the training:


1. Repeated class time counts toward the minimum total of 80 hours at each WTP.

3.08 OPERATION AND MAINTENANCE MANUALS

A. The Ozone System Supplier shall supply the minimum number of hard copy manuals and an electronic version of the Ozone System Operation and Maintenance Manual as specified in Section 01_78_23 for each WTP. The O&M manuals for each WTP shall reflect any specific ozone system characteristics that are unique to that WTP.

B. Include the operation and maintenance information written by the Ozone System Supplier as well as a compilation of the equipment manuals for each piece of equipment provided as an element of the Ozone System.

C. At the minimum, include the following Ozone System information in the O&M manuals: 1. Description of the entire system. 2. Drawing list and functional Design Specification. 3. P&IDs, wiring diagrams, and control panel drawings in 11" x 17" format. 4. Programming: Copies of all OSS-furnished programming. 5. Start-up procedures. 6. Shutdown procedures under normal and emergency conditions. 7. Standard operating procedures, including a sample daily operating log and

laboratory procedures. 8. System control, including alarms, process control and system efficiency and

optimization considerations. 9. Troubleshooting. 10. Maintenance, corrective and preventive. 11. Ozone generator cleaning instructions: Directions for disassembly, inspection,

cleaning and repair and reassembly of the equipment; safety precautions; and recommended tolerances, critical bolt torques, and special tools that are required.

12. Glossary of terms. 13. Vendor contact list. 14. Parts list: Complete parts list of all equipment being provided including catalog

data. 15. Recommended spare parts inventory. 16. Valve schedule for valves one inch in size and above. 17. Safety. 18. Summary of Ozone System equipment suppliers with addresses and phone

numbers. 19. Emergency phone numbers, including that of the Ozone System Supplier

representatives.

D. Include sections in the Manual to cover the following information for each component of the Ozone System: 1. Description of the component. 2. Disassembly and reassembly instructions. 3. Troubleshooting. 4. Maintenance, preventive and corrective. 5. Parts list including recommended spare parts.


6. Piping and instrumentation diagrams, including logic summary if applicable. 7. Electrical wiring schematic. 8. Accessory literature. 9. Safety.

E. Include manufacturer equipment manuals for each component of the Ozone System, including, but not limited to, the following: 1. Nitrogen generation system. 2. Ozone generators and power supply units. 3. Gaseous oxygen and ozone flowmeters. 4. Ozone destruct units. 5. Ozone process analyzers. 6. Other instrumentation equipment. 7. Closed-loop cooling water pumps.

3.09 PROJECT RECORD DRAWINGS

A. The Ozone System Supplier shall provide record drawings for the Ozone Systems as defined in the following: 1. Provide 5 sets of complete record drawings of the Ozone System (P&IDs,

layouts, and piping drawings) for each water treatment plant. 2. Provide 1 set of reproducible record drawings of the Ozone System for each

water treatment plant. 3. Provide all drawings in 11 inch x 17 inch format. 4. Provide 1 complete set of Drawings in a digital format compatible with

AutoCAD for each water treatment plant.

B. Provide the record drawings to the Engineer within 60 days after initiation of Functional Testing as defined by Section 01_75_17.

C. The Ozone System Supplier under the direction of the Contractor shall be responsible for modifying the record drawings to reflect any changes made during the first year acceptance of the Ozone System installation.

D. Comply with the requirements as specified in Section 01_33_00.

END OF SECTION




SECTION 46_31_54

SUPPLEMENTAL NITROGEN EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. The supplemental nitrogen equipment shall meet the overall system requirements specified in this Section and as indicated on the Drawings. The supplemental nitrogen equipment shall be supplied by the Ozone System Supplier and be mounted on a single skid for each plant. The supplemental nitrogen equipment shall be installed by the Contractor inside the Ozone Building at each water treatment plant. Each water treatment plant shall be provided with one supplemental nitrogen system. The supplemental nitrogen system equipment shall be identical for the two water treatment plants.

B. Each supplemental nitrogen system shall include the following: 1. Rotary scroll oil-less air compressors: 2 units. 2. ASME-rated and stamped air receiver tank: 1 unit. 3. Coalescing filter: 2 units. 4. Desiccant dryer: 2 units. 5. Particulate filter: 2 units. 6. Pressure regulator: 1 unit. 7. Solenoid valves: 7 units. 8. Dewpoint analyzer: 1 unit. 9. Air flow meter with integral flow control valve: 1 unit. 10. Vendor control panel. 11. Associated piping, valves, instruments, accessories, and appurtenances. 12. Skid mounting for this equipment and panel.



list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Ozone System Supplier to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 – Submittal Procedures. b. Section 01_82_02 - Seismic Design Criteria. c. Section 40_05_23.01 - Stainless Steel Pipe and Tubing. d. Section 26_05_83 - Low Voltage Motors. e. Section 26_05_53 - Identification for Electrical Systems. f. Section 29_29_13.13 - Across-The-Line Motor Controllers. g. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. h. Section 40_61_05 - Packaged Control Systems. i. Section 40_61_16 - Specific Control Strategies. j. Section 40_73_13 - Pressure/Vacuum Measurement: Gauges. k. Section 40_75_85 - Analyzers: Dew Point. l. Section 40_95_13 - Process Control Panels and Hardware.


m. Section 46_31_52 - Ozone Systems: General.

D. The equipment for each plant specified in this Section shall be fabricated, shop tested and shipped as a fully assembled, complete, stand-alone skid requiring a minimum of field installation labor. The maximum dimensions for the skid shall be 168" long, 96" wide, and 120" tall.

E. The Contractor shall furnish all equipment, pipe, fittings, wire, conduit, and accessories not on the skid but required for a complete operational supplemental nitrogen equipment as specified in this Section.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME).

B. Instrumentation, Systems, and Automation Society (ISA): 1. Standard 20 - Specification Forms for Process Measurement and Control

Equipment.

C. National Electrical Code (NEC).

D. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

E. Underwriters Laboratories, Inc. (UL).

1.03 DEFINITIONS

A. NEMA Type 12 enclosure: in accordance with NEMA 250.


A. The skid-mounted supplemental nitrogen equipment will be used to provide a clean, dry, pressurized, continuous source of nitrogen-in-air gas to the oxygen feed system.

1.05 SUBMITTALS

A. Product data: General: 1. All submittals shall be in accordance with Section 01_33_00:

a. Process design criteria in terms of percentage of air flow relative to oxygen flow and design nitrogen percentage.

b. Provide an equipment summary data sheet for each piece of equipment including equipment manufacturer, model number, capacity, dimensions (length, width, height), weight (full and empty), inlet and outlet connections, pressure drop and power draw.

2. Complete drawings and data are required to describe the overall system and indicate full compliance with these Specifications: a. As a minimum, this shall include data sheets or annotated catalog cuts on

all system components. 3. Literature and drawings describing all of the supplemental nitrogen equipment

components in sufficient detail, including parts list, materials and details of construction to indicate full compliance with these Specifications.


4. Dimensional drawings of each item of equipment and auxiliary apparatus to be furnished including full and empty center of gravity, installation drawings, and details.

5. ISA Standard 20 data sheets and manufacturer’s data for all instrumentation devices, including manufacturer, model number, size, type, materials, ranges, spares, control panel layouts, wiring diagrams, etc. as specified in Section 40_61_00.

6. List of spare parts. 7. Anchorage calculations completed and stamped by a civil or structural

engineer registered in the state of California: a. Anchorage locations and size, including template showing anchorage

locations. 8. Internal piping schematic.

B. Product data: Air compressor additional information: 1. Maximum noise level. 2. Motor size, enclosure type, service factor, and other material to demonstrate

compliance with the specification requirements in this Section.

C. Product data: Air receiver tank additional information: 1. Maximum allowable operating pressure. 2. Coating system. 3. Pressure relief valve. 4. Solenoid-actuated drain valve.

D. Product data: Desiccant dryer additional information: 1. Nominal outlet flow capacity. 2. Outlet flow to purge flow ratio. 3. Maximum allowable operating pressure. 4. Outlet dewpoint rating. 5. Pressure drop. 6. Desiccant Material Safety Data Sheets. 7. Minimum operating pressure. 8. Switching cycle.

E. Product data: Dewpoint analyzer, and controls additional information: 1. Dew point rating. 2. Calibration certification.

F. Quality assurance/control: 1. Factory test reports. 2. Field test reports. 3. Manufacturer installation certification.

G. Documentation: 1. Operation and maintenance manuals. 2. Training plan.


1.06 MAINTENANCE

A. Spare parts: 1. Spare parts for the supplemental nitrogen equipment shall include at a

minimum at each plant: a. Air compressor intake filter elements: 2 sets. b. Air compressor drive belts: 1 complete set. c. Dryer desiccant media charges: 1 set. d. Desiccant dryer switching valves: 1 set. e. Coalescing filter: 1 unit. f. Particulate filter elements: 2 sets. g. Solenoid valve: 1 unit of each type supplied. h. Moisture trap: 1 unit of each type supplied. i. Pressure relief valve: 1 unit of each type supplied.

2. Spares for the control panel shall include: a. Fuse: 1 set of each type supplied. b. Relay: 1 of each type supplied. c. Pilot indicating lights: 2 lamp replacements.

1.07 ANCHORAGE CALCULATIONS

A. The Ozone System Supplier shall complete anchorage calculations for the supplemental nitrogen equipment skid assembly using the criteria as specified in Section 01_81_02: 1. Calculations shall be completed and stamped by a civil or structural engineer

registered in the state of California. 2. Anchorage shall be designed to work with the foundation concrete thickness of

12 inches and a concrete compressive strength of 4,000 pounds per square inch. Assume epoxy anchors will be set into existing concrete.

PART 2 PRODUCTS

2.01 GENERAL

A. The supplemental nitrogen equipment shall be a fully functional, redundant, skid mounted system: 1. The system shall be configured to deliver clean, dry, pressurized, ambient air

at the specified rate to the oxygen feed system.

B. The supplemental nitrogen equipment on the skid shall be designed and constructed so that it can be installed with a maximum of 5 feet clearance around all sides without impeding access for operation and maintenance for any component.

2.02 AIR COMPRESSORS

A. The air compressors shall be single stage, air-cooled, oil-free rotary scroll type and shall include motor, air intake filters, aftercoolers, cooling fans, and associated controls.


B. Air compressors shall meet the following design criteria:

Parameter Value Nominal Flow Capacity By Ozone System Supplier Operating Discharge Pressure Range 105 to 125 psig Maximum Temperature Rise 36 degrees Fahrenheit Maximum Ambient Cooling Temperature 104 degrees Fahrenheit Maximum Noise Level 85 dBA Maximum Motor Size 10 HP

C. The compressor units shall operate via a single orbiting helical scroll that meshes with a fixed scroll inside the compressor housing via an eccentric crankshaft connection: 1. The compressor scrolls shall be of anodized aluminum construction. 2. Compressor scroll sealing shall be accomplished using replaceable composite

plastic tip seals, including a PTFE composite low-pressure seal and graphite filled composite high-pressure seal on both the orbiting and fixed scrolls.

3. The compressors shall be completely oil free internally and shall operate with absolutely no lubricants or oils within the compressor housing and chamber.

4. Bearings shall be of the high precision, tight clearance type. A 3-micron absolute compressor air intake filter and air-cooled finned copper tube after cooler shall be included with each unit.

5. The compressors shall include a single crankshaft driven radial flow cooling fan to provide ambient airflow cooling for both the compressor housing and after cooler.

6. Provide noise reduction provisions as required to meet the maximum noise level criteria above.

D. Compressors shall be mounted inside of a sound enclosure with vibration isolation.

E. Air compressors shall be provided with a pressure relief valve on the outlet prior to the first isolation valve: 1. Pressure relief valve shall be as specified in this Section.

F. Air compressor air-cooled aftercoolers shall be mounted inside the enclosure and be sized for a 20 degree Fahrenheit approach temperature.

G. Air compressor motors shall be constant-speed, 480V, 3-phase, 60 hertz, 40 degrees Celsius ambient, have a 1.15 service factor, Class F insulation with Class B temperature rise, and a TEFC enclosure as specified in Section 26_05_83: 1. Provide motor with a nominal efficiency of at least 92 percent.

H. Air compressors: 1. Manufacturers: The following or equal as approved by the Engineer:

a. Atlas Copco: SF Series with high-pressure option.

I. Air compressor motor starter: 1. Manufacturers: As specified in Section 26_29_13.13. 2. Requirements:

a. Mounted in a local control panel on the skid.


J. Vendor control panel configuration: 1. Mount motor starters and alternator in a local control panel that allows one

480-volt feeder to supply both compressors. 2. Provide interlock that will not allow both compressors to be operational at one

time. 3. In conformance with Section 40_61_05 and Section 40_95_13.

2.03 AIR RECEIVER TANK

A. A vertical, carbon steel ASME pressure vessel air receiver tank shall be provided to ensure that the system delivers a continuous flow of gas without surges: 1. Manufacturers: The following or equal as approved by the Engineer:

a. Campbell Hausfeld.

B. Air receiver shall be made of A-36 carbon steel and painted with an acrylic polyurethane painting system with a total dry film thickness of 10 mils.

C. Air receiver tank shall be sized based upon the projected load/unload cycles of the air compressors to limit air compressor starts to no more than 5 per hour or the minimum volume stated below, whichever is larger.

D. Air receiver tank shall include a tap for moisture drainage through solenoid valve operation: 1. The solenoid valve shall operate through a timer in the supplemental nitrogen

equipment control panel where both open duration and frequency can be adjusted from 0 to 10 seconds and 0 to 60 minutes, respectively.

2. The solenoid valve shall be normally closed, stainless steel body, 120-volt AC, 1/2-inch NPT connections, ASCO Series 8210 or equal as approved by the Engineer with muffler for sound attenuation.

E. Air receiver tank shall meet the following design criteria:

Parameter Value Minimum Volume 240 gallons Discharge Pressure Range 100 to 125 psig Maximum Allowable Operating Pressure 200 psig

F. Air receiver tank shall include pressure switches for compressor start, compressor stop and low-low and high-high pressure indications: 1. Pressure switches:

a. Manufacturer: The following or equal as approved by the Engineer: 1) Ashcroft B Series Type 400 with Buna-N actuator seal.

G. Tank shall also include separate fittings for pressure relief valve, temperature and pressure gauges: 1. Pressure relief valve, pressure switches and gauges shall be as specified in

this Section and as indicated on the Drawings.


2.04 COALESCING FILTERS

A. The coalescing filters shall be equipped with particulate filter to remove solid particles of 0.5 microns or greater, shall remove greater than 99.99 percent of oil and water particles of 0.01 microns or greater, and shall be equipped with automatic drain with solenoid valves. Solenoid valves shall be provided with discharge mufflers to reduce noise.

B. Coalescing filters shall be rated to operate with no more than 2.0 pounds per square inch pressure drop under design conditions.

C. The coalescing filters shall be as manufactured and/or provided by the desiccant dryer manufacturer, shall be rated for operation under the same conditions as the desiccant dryer, and shall be provided with the desiccant dryer as part of a complete dryer system.

2.05 DESICCANT DRYERS

A. Manufacturers: The following or equal as approved by the Engineer: 1. Hankison DHW Series.

B. Design requirements: 1. Heatless compressed air dryers. 2. Utilize pressure swing adsorption technology and include 2 identical desiccant

chambers, and integrated pressure orifices, control valves, and solid-state timer.

3. Designed for wall-mounting but installed on the supplemental nitrogen equipment skid.

4. The desiccant dryers shall function by passing the compressed air through a desiccant chamber that contains an adsorbent material with strong affinity for moisture.

5. Each desiccant dryer shall contain 2 desiccant chambers and automatic switch over such that 1 desiccant chamber is continuously on-line while the second chamber is regenerated in order to supply a continuous supply of dry air.

6. A portion of the dried air from the on-line desiccant chamber shall be purged through an orifice to regenerate the off-line chamber.

7. A solid-state timer shall switch the flow through the desiccant chambers on a timed cycle by opening and closing control valves within the desiccant dryer.

8. The adsorbent desiccant employed by the desiccant dryer shall be either activated alumina or synthetic zeolite media.

9. Reactivation of the desiccant shall be accomplished automatically without the application of heat: a. Heat reactivated desiccant dryers, refrigeration type dryers, or

deliquescent/chemical dryers where moisture is absorbed by desiccant salts that are dissolved and consumed shall not be acceptable.

10. The desiccant dryers shall be capable of drying air to dew points below minus 100 degrees Fahrenheit, offer continuous self-regenerating operation, and be rated for maximum compressed air pressures of at least 150 pounds per square inch gauge: a. The dryers shall be capable of operation without airflow (other than to the

purge outlet) on startup to dry each desiccant chamber before it is placed into service.


11. The desiccant dryers shall operate on 120V, single phase, 60 hertz power from the supplemental nitrogen equipment skid control panel, VCP-30.3020.

12. The desiccant dryer shall include integral discharge moisture indicators that change color on high dew point, and purge gas discharge mufflers to quiet purge gas noise.

C. Design criteria:

Parameter Value Minimum Ratio of Maximum Output Flow to Purge Flow 3.5:1 Rated Operating Pressure 100 psig Rated Maximum Dew Point -100 degrees Fahrenheit Maximum Outlet Dew Point -70 degrees Fahrenheit Inlet Air Temperature at Rated Maximum Dew Point 100 degrees Fahrenheit Inlet Air Relative Humidity 100 percent Maximum Pressure Drop 10 psi

2.06 PARTICULATE FILTERS

A. Manufacturers: The following or equal as approved by the Engineer: 1. Hankison model HF-12.

B. The particulate filters shall remove particles of 1 micron absolute or greater size.

C. Particulate filters shall be rated to operate with no more than 2 pounds per square inch pressure drop under design conditions.

D. Particulate filters shall be rated for operation under the same conditions as the desiccant dryer, and shall be provided with the desiccant dryer as part of a complete system.

2.07 DEW POINT ANALYZER

A. Provide a dew point analyzer as specified in Section 40_75_85 for sampling of the dried air: 1. Moisture sensor shall be mounted in a stainless steel sample cell on a side

stream from the main airflow. 2. Maximum sample flow shall be 10 standard cubic feet per hour. 3. Exhaust from the sample cell shall vent to atmosphere. 4. Analyzer shall be internal pressure and temperature compensated.

2.08 VENDOR CONTROL PANEL FOR THE SUPPLEMENTAL NITROGEN SYSTEM

A. Provide a control panel for the skid-mounted supplemental nitrogen equipment as specified in Section 40_61_05 and Section 40_95_13 and as shown on the drawings: 1. Control panel shall be sized to mount the manufacturer’s recommended

controls and functions and the instruments indicated on the Drawings and specified in this Section.


2. The control panel shall be mounted on the skid so that the minimum NEC clearance requirements are achieved from the skid location: a. Provide two additional junction boxes mounted on the skid to transition

signals from the Supplemental Nitrogen System Control Panel to the Master Ozone Control Panel as indicated on the Drawings: 1) One junction box shall be used for all analog signal (4-20 mA) wiring. 2) One junction box shall be used for all discrete control (<120VAC)

wiring. 3. All wire connections to the skid shall route through terminal strips in the control

panel.

B. The vendor control panel shall consist of a minimum of 2 enclosures: 1. One enclosure (power panel) shall contain all devices operating at voltages

above 120 volts. 2. The second enclosure (control panel) shall contain voltages of 120 volts and

lower. 3. Control panels shall be of NEMA 12 construction. 4. Use stainless steel door hardware. 5. Properly ground control panel to the skid and ground the skid in accordance

with NEC requirements.

C. The vendor control panel shall include a flange mounted main power disconnect, interlocked to the enclosure doors, a combination starter for each compressor, and a fused control power transformer: 1. A 480 volt, 3-phase, 30 amp circuit will be provided to this panel. 2. All system power shall be derived from this single power feed. 3. Minimum UL short circuit rating of 42,000 RMS symmetrical Amperes.

D. Vendor control panel shall include front panel mounted controls and indicators. PLC (if provided), Remote I/O, timers, wiring terminals, wire way, etc., shall be included on an internal mounting panel.

E. Provide control strategies as specified in Section 40_61_16.

2.09 PIPING, APPURTENANCES, AND EQUIPMENT SKID

A. Provide supplemental nitrogen equipment skid mounted on a common A-36 structural steel skid with the following piping and appurtenances, as indicated on the Drawings: 1. Provide Type 316 stainless steel pipe, schedule 40, or stainless steel tubing as

specified in Section 40_05_23.01 for all piping on the skid: a. All fittings shall be threaded. b. Size pipe in order to deliver the compressed, dried nitrogen at a minimum

pressure of 85 pound per square inch gauge at the outlet connection of the skid.

c. Dissimilar metals of any valves or fittings shall be protected with insulation kits to avoid corrosion.

d. Provide unions such that valves with screwed connections can be removed from skid as required for replacement or repair.


2. Check valves: a. Manufacturers: The following or equal as approved by the Engineer:

1) Swagelok C series stainless steel poppet style with tubing connections.

b. Sized for a maximum headloss of 1.0 pounds per square inch at air compressor nominal flow capacity.

3. Pressure relief valves: a. Manufacturers: The following or equal as approved by the Engineer:

1) Kunkle Model 917 with stainless steel body and NPT connections. b. ASME-stamped and designed for relief at the pressures determined by

the OSS. c. Able to accommodate the design flow capacity of the air compressor at

100 pounds per square inch gauge with no more than 5 percent pressure increase.

d. Pipe away relief valve discharge to a minimum of 10 feet above bottom of skid.

4. Pressure sustaining valve: a. Manufacturers: The following or equal as approved by the Engineer:

1) Fisher Controls 98H Series with stainless steel body and PTFE elastomeric parts.

b. Sized to accommodate the design flow capacity of the air compressor at 100 pounds per square inch gauge with no more than a 5 pounds per square inch headloss through the valve.

5. Ball valves: a. Manufacturers: The following or equal as approved by the Engineer:

1) Jamesbury, Series 3000 screwed NPT. b. Materials: Stainless steel body with PTFE seats.

6. Solenoid valves: a. Manufacturers: The following or equal as approved by the Engineer:

1) ASCO Series 8210. b. Shall be normally closed, stainless steel body, 120-volt AC, NPT

connections. 7. Pressure gauges:

a. Provide as specified in Section 40_73_13, with stainless steel wetted materials and connection.

8. Temperature gauges: a. Manufacturers: The following or equal as approved by the Engineer:

1) Ashcroft Type EL Series. 9. Flow meter with integral flow control valve shall be thermal mass type:

a. Accuracy: +/- 1.0% of full scale. b. Repeatability: +/- 0.2% of full scale. c. Valve response shall be capable of being tuned on-site. d. Power supply: 24-volt DC provided from control panel on Supplemental

Nitrogen System control panel. e. Output signal for flow: 4-20 mA. f. Wetted parts material: Stainless steel with Viton seals and gaskets g. Sierra Smart-Trak 100 Series, or equal as approved by the Engineer.

B. Provide single points of connection for the following items: 1. Supplemental nitrogen gas discharge. 2. Waste drains. Coordinate location of discharge with nearest floor drain. 3. 480V, 3-phase, 60 hertz power shall be wired to the power panel.


C. Lay out in a neat and orderly manner to maintain required clearances and provide free and ready access to equipment and appurtenances as required for operation and maintenance of associated equipment.

D. Conform to code requirements, including the NEC.

E. Properly support and design equipment, piping, and appurtenances to withstand seismic forces as specified in Section 01_81_02.

F. Shop weld skid mounted piping except at connections to valves and equipment where flanges shall be used.

G. Provide wetted components on the skid as cleaned for oxygen service and pneumatically factory tested.

2.10 FACTORY TESTS

A. Perform factory testing to ensure the proper operation of skid components in advance of shipment to the Work site: 1. Simulate all inputs and outputs and provide reading.

B. Factory test wiring for continuity.

C. Perform functionality factory tests on power, instrumentation, and control wiring from the skid mounted control panels.

2.11 SURFACE PREPARATION AND SHOP PRIMING

A. The structural steel skid shall be prepared, primed, and finish painted with an acrylic polyurethane painting system with a total dry film thickness of 10 mils: 1. Finish color shall be light gray, dark blue, or dark green. 2. The air compressor baseplate and the air receiver color shall match the color

selected for the structural steel skid. 3. All coating shall be completed at manufacturer's facility prior to deliver to the

site.

PART 3 EXECUTION

3.01 INSTALLATION AND COORDINATION

A. Contractor will be responsible for installation of all equipment as specified in this Section and as directed by the Ozone System Supplier: 1. Contractor will mount supplemental nitrogen skid on an equipment pad. 2. Contractor will provide anchor bolts as sized by the Ozone System Supplier to

anchor the supplemental nitrogen equipment as indicated on the Drawings. 3. Contractor will provide flange bolts and gaskets or fittings as required to

connect piping to the Ozone System Supplier provided equipment. 4. Contractor will provide the wire and conduit as necessary to connect all power

and signal terminations for the supplemental nitrogen equipment: a. Ozone System Supplier's Work inside the local control panels shall

comply with the electrical identification requirements as specified in Section 26_05_53.


3.02 ON-SITE INSPECTION AND TESTING

A. The Contractor will test the supplemental nitrogen equipment under actual start-up and operating conditions to determine that the operation is satisfactory.

B. If the equipment performance does not meet the Specification, corrective measures shall be taken by the Ozone System Supplier or the equipment shall be removed and replaced at no additional cost to the Owner.

3.03 TRAINING

A. The Ozone System Supplier shall provide a minimum of 8 hours of on-site training to the plant operations and maintenance staff specific to the supplemental nitrogen system. This training shall be included in the total training requirements specified in Section 46_31_52. 1. The training shall cover both operations and maintenance topics and

consistent of both classroom and field instruction of about equal durations. 2. The trainer shall expect to be on-site and available for training over a

consecutive 2-day period selected by the Owner.

END OF SECTION


SECTION 46_31_55

OZONE GENERATING EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Equipment specifications for the ozone generators and power supplies. The generators and power supplies shall be supplied as part of the Ozone System by the Ozone System Supplier as specified in Section 46_31_52. The ozone generating equipment shall be identical for the two water treatment plants.



list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Ozone System Supplier to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 01_75_17 - Commissioning and Process Start-Up. c. Section 01_78_23 - Operation and Maintenance Data. d. Section 01_81_01 - Project Design Criteria. e. Section 01_81_02 - Seismic Design Criteria. f. Section 05_05_24 - Mechanical Anchoring and Fastening to Concrete and

Masonry. g. Section 09_96_56.05 - High-Build Epoxy Coatings. h. Section 26_05_53 - Identification for Electrical Systems. i. Section 26_05_83 - Low Voltage Motors. j. Section 26_09_13 - Electrical Power Monitoring and Control. k. Section 26_28_16 - Enclosed Switches and Circuit Breakers. l. Section 40_05_23.01 - Stainless Steel Pipe and Tubing. m. Section 40_05_57.23 - Electric Actuators. n. Section 40_05_67.37 - Pressure Reducing and Pressure Relief Valves. o. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. p. Section 40_61_05 - Packaged Control System. q. Section 40_61_16 - Specific Control Strategies. r. Section 40_71_23.21 - Flow Measurement: Orifice Plate. s. Section 40_71_79 - Flow Measurement: Switches. t. Section 40_73_13 - Pressure/Vacuum Measurement: Gauges. u. Section 40_73_23 - Pressure/Vacuum Measurement: Direct. v. Section 40_73_29 - Pressure/Vacuum Measurement: Differential. w. Section 40_73_36 - Pressure/Vacuum Measurement: Switches. x. Section 40_74_66 - Temperature Measurement: Temperature Switch. y. Section 40_74_13 - Temperature Measurement: RTD. z. Section 40_74_43 - Temperature Measurement: Temperature Gauge. aa. Section 40_76_13_1 - Analyzers: Gas Monitors. bb. Section 46_31_52 - Ozone System - General.


cc. Section 46_31_58 - Cleaning for Oxygen and Ozone Service. dd. Section 46_31_59 - Ozone System Testing. ee. February 2016 Request for Quotation (RFQ) Documents

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B 16.5 - Steel Pipe Flanges, Flanged Valves and Fittings.

B. ASTM International (ASTM): 1. A 240 - Standard Specification for Chromium and Chromium-Nickel Stainless


C. Institute of Electrical and Electronics Engineers (IEEE): 1. Standard 519: Recommend Practice and Requirements for Harmonic Control

in Electric Power Systems.

D. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

1.03 DEFINITIONS

A. NEMA Type 12 enclosure in accordance with NEMA 250.

1.04 DESIGN REQUIREMENTS

A. General: Corona discharge, medium frequency (up to 12 kHz), water cooled, horizontal tube ozone generator(s). 1. Each ozone generator shall be skid-mounted with all the components included

on the skid and provided by the Ozone System Supplier as indicated on the Drawings.

2. Each generator shall be provided with an individual power supply unit (PSU) mounted on a separate skid.

3. All generators and power supply units shall be identical.

B. Ozone production requirements: Design each generator and power supply system in accordance with the following design condition performance requirements: 1. Ozone generator design production capacity: 1,750 pounds per day under the

following conditions: a. Ozone product gas concentration: 10.0 percent, by weight. b. Design temperature of closed loop cooling water supplied to the

generator: 80 degrees Fahrenheit. c. Feed gas composition range: 97 to 99 percent oxygen and 0.2 to

3 percent nitrogen, as required by the Ozone System Supplier. d. Maximum oxygen feed gas dew point: -80 degrees Fahrenheit.

2. Ozone generator design production capacity: 2,100 pounds per day under the following conditions: a. Minimum ozone product gas concentration: 6.0 percent, by weight. b. Design temperature of closed loop cooling water supplied to the

generator: 80 degrees Fahrenheit. c. Feed gas composition range: 97 to 99 percent oxygen and 0.2 to

3 percent nitrogen, as required by the Ozone System Supplier.


d. Maximum oxygen feed gas dew point: -80 degrees Fahrenheit. 3. Ozone generator design product capacity: 150 pounds per day under the

following conditions: a. Ozone product gas concentration: 3.0 percent by weight. b. Design temperature of open loop cooling water supplied to the generator:

50 degrees Fahrenheit. c. Feed gas composition range: 97 to 99 percent oxygen and 0.2 to

3 percent nitrogen, as required by the Ozone System Supplier. d. Maximum oxygen feed gas dew point: -80 degrees Fahrenheit.

C. PSU Power Supply Equipment: 1. PSU power supplies shall incorporate harmonic mitigation equipment on the

front end of the PSU connection to the distribution system. Mitigation equipment shall be provided to meet the harmonic criteria for voltage and current distortion as specified herein.

2. Details of the specific mitigation equipment shall be determined by the OSS as required to ensure compatibility with the OSS design, meet all specified production requirements, maintain warranty, and achieve the performance criteria specified.

3. At a minimum PSU technologies based on at least 18-pulse inverters (higher pulse counts are acceptable) or active front end power electronics only shall be acceptable. Other alternatives such as lower pulse count inverters with filters shall not be acceptable.

1.05 PERFORMANCE REQUIREMENTS

A. Each generator shall be capable of continuous operation at any point from 8 to 100 percent of its maximum ozone production capacity at an ozone product concentration range of 3.0 to 10.0 percent by weight. The generators shall conform with the following performance criteria throughout the entire range of operation: 1. Maximum product gas temperature: 120 degrees Fahrenheit as measured at

the generator ozone outlet pipe with the cooling water temperature as specified for the raw water in Section 01_81_01.

B. Cooling requirements: 1. Each generator and its associated power supply shall be cooled by the closed

loop cooling water system. The closed loop cooling water system shall include closed loop cooling water pumps mounted separately from the ozone generator skid and any required auxiliary closed loop cooling equipment. The closed loop cooling water pumps will be manifolded so that any pump can serve any ozone generator/PSU. Two existing redundant closed loop/open loop heat exchangers and open loop cooling water pumps will serve all the closed loop cooling water demands of the system.

2. No heat shall be rejected to the ambient air. 3. The closed loop cooling water flow through each generator shall be constant

regardless of generator operating level: a. Maximum cooling water flow for each generator shall be 350 gallons per

minute. b. Maximum closed loop cooling water temperature differential across an

ozone generator and PSU shall be 10 degrees Fahrenheit over the entire range of generator production capacity.


4. Design the closed loop cooling water pumps for a minimum pressure drop of 15 psi through the closed loop/open loop heat exchangers and the closed loop cooling water piping provided by the Contractor.

C. Control system requirements: 1. Ozone production shall be controlled by regulating the oxygen feed gas flow

rate and the generator power input from the power supply. 2. The Ozone System Supplier shall provide programming of the control system

for the Ozone System as specified in Sections 40_61_16 and 46_31_52, and the control panels shall be provided as specified in Section 40_61_05 and as shown on the drawings.

D. Power quality: 1. Ozone Power Supply Units shall be certified compatible with the Sobrante and

USL electrical distribution systems as shown on the reference documents provided, without generation of voltage or current distortion in excess of that specified for total distortion or distortion of individual harmonic orders.

2. For the purposes of the power quality performance parameters specified herein. The power quality parameter measurement points shall be defined as: a. The 480V secondary substation A and B bus directly feeding the

individual PSU with the associated tie breaker open b. The 12 kV primary bus serving both substations A and B.

3. The Ozone System Supplier shall note that the power quality measurement location as established under these Procurement Documents does not necessarily meet the formal definition of the PCC found in IEEE Recommended Practice 519 (2014). Further, the specified maximum values of voltage and current distortion and harmonic limits in these Documents are being applied within the WTP distribution systems again, not as defined formally under IEEE 519. The Contractor shall meet the specified distortion limits as defined within these Contract Documents regardless of the definitions and recommendations outlined in IEEE 519.

4. Voltage distortion at the indicated locations shall meet the specified requirements as follows: a. At the 480V secondary substation bus:

1) 5% maximum harmonic distortion on individual integer multiples of the fundamental frequency

2) Total harmonic distortion less than 8%. b. At the 12 kV primary bus:

1) 3% maximum harmonic distortion on individual integer multiples of the fundamental frequency

2) Total harmonic distortion less than 5%. 5. Current Distortion:

a. All values shall be calculated in percent of the maximum fundamental demand current.

b. At the 480V secondary substation buses and 12 kV primary bus:: 1) 3rd to 9th order: 4.0% maximum harmonic distortion 2) 11th to 15th order: 2.0% maximum harmonic distortion 3) 17th to 21st order: 1.5% maximum harmonic distortion 4) 23rd to 33rd order: 0.6% maximum harmonic distortion 5) 35th to 50th order: 0.3% maximum harmonic distortion 6) Even harmonics are limited to 25% of the odd harmonics limits

shown


7) Current distortions that result in a DC offset, e.g., half-waveconverters, are not allowed

8) Total harmonic demand distortion (TDD) less than 5%.

1.06 SUBMITTALS

A. Product data: Ozone generator manufacturer data to show conformance with generator and power supply equipment specifications, as specified in Section 01_33_00.

B. Shop drawings: Include the following information: 1. Detailed drawings to include equipment dimensions.2. Anchor bolt layout requirements.3. Piping connection details.4. Control panel layouts.5. Instrumentation diagrams to document all signals sent and received by the

generators and power supplies.

C. Calculations: 1. Submit calculations to show that pressure relief devices that protect ASME

Code vessels are designed in accordance with ASME Code Standards.Include capacity and set point of each pressure relief valve.

2. Submit anchorage calculations for sizing of the anchor bolts of the ozonegenerator/power supply skids to resist forces specified in Section 01_81_02:a. Calculations shall be signed by a civil or structural engineer registered in

the State of California.3. Submit seismic certification for electrical equipment as specified in Section

01_81_02.

D. Operation and maintenance data: 1. As specified in Section 01_78_23.2. Include detailed maintenance procedures and projected schedules as

specified in Section 01_78_23.3. Include copies of standard manufacturer operation and maintenance manual.

E. Certification to document successful completion of all equipment testing as specified in this Section.

F. Power Quality Data: 1. The data and analyses specified in 46_31_55 - 1.06F at the 480V level shall

be submitted by all prospective OSS' in their response to the RFQ, as described in Exhibit A of the RFQ. The selected OSS shall submit data and analyses at the 480V and 12kV level at a later date as part of their equipment submittals.

2. Submit PSU harmonic spectrum data for individual harmonic current distortionfrom the 0 (DC) component, fundamental, and individual frequencies up to the50th harmonic. Submit current distortion values as a percent of thefundamental and including the phase angle for each harmonic constituent.


3. Electrical harmonic analysis: Submit detailed electrical computer simulation calculations demonstrating compliance with the harmonic requirement specified in this Section: a. For the purposes of the harmonic analysis, assume three ozone

generators are operating concurrently, each at the indicated operating levels.

b. Electrical parameters for the simulation shall be as shown on Table 46_31_55-A

c. Analyses shall be performed for operation under utility power only. d. Parameters, system configuration, and assumptions including magnitude

of total linear loads based on the OSS proposed system shall be clearly indicated.

4. The harmonic analysis shall include: 1) All input data and assumptions. Provide an impedance diagram

illustrating the simulated system. 2) Explanation of methods used to perform the study. 3) Explanation of study results with specific recommendations on harmonic

mitigation measures that will be implemented to achieve the specified limits.

4) All calculations and computer printouts used to arrive at the conclusions and recommendations.

5) Individual PSU harmonic content and the combined total drives harmonic content reflected in the system supply voltage as a percent of the 60 hertz fundamental under actual load conditions from no-load to full load in 10 percent load increments.

6) A detailed description of the field tests, procedures, and supporting calculations that will be performed to verify that the installed systems comply with the specified THD and TDD limits. Include recommended test equipment, test conditions including other OSS equipment operating, and test durations.

7) Analyses submitted in response to the RFQ shall be stamped and signed by a registered Professional Electrical Engineer in their State of practice within the United States. The selected OSS shall submit analyses at a later date that are stamped and signed by a registered Professional Electrical Engineer in the State of California.

TABLE 46_31_55-A ELECTRICAL PARAMETERS FOR HARMONIC ANALYSIS

LOCATION PARAMETER

SOBRANTE WTP Substation 480V BUS A ISC = 35,000 A Substation 480V BUS B ISC = 35,000 A

12 kV Feeder (at 12 kV Bus) ISC = 5,100 A Feeder Gage and Length: PSU 1 to 480V Bus A 2-#3/0 per phase, 70' Feeder Gage and Length: PSU 2 to 480V Bus B 2-#3/0 per phase, 70' Feeder Gage and Length: PSU 3 to 480V Bus A 2-#3/0 per phase, 70'

Feeder Gage and Length: 480V Bus A to Xfmr A Secondary 4,000A Bus Duct, 5 ft Feeder Gage and Length: 480V Bus B to Xfmr B Secondary 4,000A Bus Duct, 5 ft


TABLE 46_31_55-A ELECTRICAL PARAMETERS FOR HARMONIC ANALYSIS

LOCATION PARAMETER

Substation Xfmr A Impedance 5.9% Substation Xfmr B Impedance 5.7%

Feeder Gage and Length: Xfmr A Primary to 12 kV Bus 1/0, 25 ft Feeder Gage and Length: Xfmr A Primary to 12 kV Bus 1/0, 25 ft

USL WTP Substation 480V BUS A ISC = 45,600 A Substation 480V BUS B ISC = 45,600 A

12 kV Feeder (at 12 kV Bus) ISC = 2,500 A Feeder Gage and Length: PSU 1 to 480V Bus A 2-#3/0 per phase, 70' Feeder Gage and Length: PSU 2 to 480V Bus B 2-#3/0 per phase, 70' Feeder Gage and Length: PSU 3 to 480V Bus A 2-#3/0 per phase, 70'

Feeder Gage and Length: 480V Bus A to Xfmr A Secondary 4,000A Bus Duct, 5 ft Feeder Gage and Length: 480V Bus B to Xfmr B Secondary 4,000A Bus Duct, 5 ft

Substation Xfmr A Impedance 5.6% Substation Xfmr B Impedance 5.7%

Feeder Gage and Length: Xfmr A Primary to 12 kV Bus 4/0, 25 ft Feeder Gage and Length: Xfmr B Primary to 12 kV Bus 4/0, 25 ft

The feeders from the 480V secondary substation to the PSU will be copper, installed in galvanized steel conduit.

G. Submit information as specified in Division 40 for the instrumentation and controls portion of the ozone generators and power supplies work.


A. Provide warrantees as specified in the Supplier Agreement.


A. Factory cleaning: Prior to shipping, all items to be wetted with oxygen or ozone shall be cleaned as specified in Section 46_31_58.

B. Packing, delivery and unpacking: Deliver all components in factory packaging and protect all components from environmental exposure before installation.

C. Site acceptance: All items shall be unpacked under the supervision of an Ozone System Supplier representative.


1.09 MAINTENANCE

A. Provide the following spare parts for each set of ozone generating equipment for the two water treatment plants: 1. Dielectrics, including tube, fuse, electrode, and other accessories (as

required): 5 percent of total dielectric count for all ozone generators. 2. Glass view ports and associated gaskets: 2 of each type and design provided. 3. Bolts, nuts, and washers: 1 set of each type and size for each generator

provided. 4. Power supply relays and timers: 1 of each type and scale. 5. Power supply fuses and power factor capacitors: 5 of each type and scale. 6. Plug-in circuit boards: 1 of each type. 7. Control transformers: 1 of each type. 8. Amplifiers: 1 of each type. 9. Generator bulkhead gaskets: 1 set for each ozone generator provided. 10. Closed loop cooling water pump: 1 of each type.

B. Accessories: 1. Provide wheeled racks specifically designed to vertically hold dielectrics from

the ozone generators. Sufficient racks shall be provided to hold 100 percent of the dielectrics from 1 generator.

2. Provide a set of stainless steel washdown dams to facilitate cleaning of the ozone generator if necessary for the cleaning process.

3. Provide 1 set of dielectric removal and insertion tools.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Ozone generators and power supplies: Ozone System Supplier as specified in Section 46_31_52.

2.02 OZONE GENERATORS

A. Generator characteristics: Horizontal tubular corona discharge cells mounted inside a pressurized casing: 1. Design and stamp the horizontal, cylindrical generator vessels in accordance

with ASME standards for a minimum operating pressure of 50 pounds per square inch gauge.

2. All metallic components of each generator potentially in contact with gaseous oxygen or ozonated feed gas shall be constructed with ASTM A 240 Type 316L stainless steel: a. With the exception of the dielectrics, all non-metallic components in

contact with oxygen gas or ozone shall be, glass, hypalon or Teflon, or other suitable material acceptable to the Engineer.

3. Each generator shall have compound hinges on both ends to allow the end covers to be swung open to allow access to dielectrics.

4. Provide skid-mounted instrumentation including connections and a high ozone gas concentration analyzer as specified in Section 40_76_13_1: a. Maximum tubing size between the product gas line and the high ozone

gas concentration analyzer shall be 1/4-inch stainless steel.


5. Generator and power supply unit shall be mounted on 2 separate skids for mounting on separate equipment pads in the field: a. Maximum dimensions for ozone generator skid and power supply skid

(exclusive of any harmonic mitigation equipment) shall be as follows (all dimensions in feet - length x width x height):

Metawater Mitsubishi Ozonia Wedeco Ozone Generator

12.5 x 8.7 x 10.8 10.8 x 7.1 x 6.5 13.3 x 7.3 x 10.2 16.25 x 5.25 x 8.0

Power Supply 14.1 x 5.1 x 8.2 23.6 x 3.5 x 7.0 10.0 x 4.1 x 7.5 15.8 x 5.25 x 7.25

6. The maximum clearance required at each end of the generator to allow complete removal of the dielectrics: 5 feet.

7. The maximum clearance required around the perimeter of the power supply shall be 3.5 feet for normal operation and routine maintenance.

8. The ozone generators shall be mounted on individual skids with all of the gas and cooling water connections located at the edge of the skid.

9. The ozone cylinder shell shall be constructed of double butt welded seams in accordance with ASME standard for unfired pressure vessels.

10. Shell design corrosion allowance: 1/8 inch (minimum). 11. The design cooling water pressure in the ozone generator shell shall be at

least 2 pounds per square inch less in pressure than the design ozone/oxygen gas pressure.

12. Provide skids fabricated from ASTM A-36 structural steel. Paint structural steel in accordance with Section 09_96_56. 05. Provide lifting lugs at each corner of the skid.

B. Dielectrics: 1. Removable as individual pieces from the appropriate end of the generator. 2. Stainless steel, glass, or ceramic material.

C. Service connections: 1. All gaseous oxygen, ozonated feed gas, and cooling water inlet and outlet

connections shall be 150-pound class stainless steel flanges, in accordance with ASME B16.5.

2. Provide cooling water, gaseous oxygen, and ozonated feed gas service connections, as indicated on the Drawings.

D. Pressure relief valves: 1. Provide pressure relief valves and discharge piping for the gas and water

systems, as indicated on the Drawings, as specified herein and in Section 40_05_67.37.

2. Provide the pressure relief valves in accordance with the ASME Code and the following criteria, to prevent over-pressurization of the system: a. Gas system pressure relief valves:

1) Design relief flow: 300 standard cubic feet per minute minimum. 2) Normal operating pressure: 20 pounds per square inch gauge. 3) Relief pressure: In accordance with the design of the generator

housing. 4) Maximum overpressure: 10 percent.

b. Cooling water system pressure relief valves: 1) Design relief flow: Sized by the Ozone system Supplier for the

scenario of thermal relief from exposure to fire. Minimum relief flow: 50 gallons per minute.


2) Normal operating pressure: 10 to 20 pounds per square inch gauge. 3) Relief pressure: In accordance with the design of the generator

housing. 4) Maximum overpressure: 10 percent.

E. Cooling water system: 1. Closed loop:

a. Ozone System Supplier shall provide closed loop cooling water pumps for the supplied ozone generator equipment.

b. Design the closed loop cooling water pumps so that the design water pressure inside the ozone generator shell is at least 2 pounds per square inch less in pressure than the design gas pressure inside the ozone generator tubes. The closed loop cooling water pumps will discharge into a common manifold that will be piped directed to the three ozone generators and power supplies.

c. The cooling water pumps will pump closed-loop cooling water at a constant flow rate through the ozone generators and associated PSUs. The rated capacity of one operating pump shall be equal to 110 percent of the maximum cooling water flow required for one ozone generator plus PSU, and a maximum total discharge head (TDH) equal to the highest pressure drop of the equipment being cooled, plus the total circuit pressure drop, including piping and valves. The pumps shall be single stage, end suction, horizontal centrifugal pumps. Manufacturer’s standard cast iron bronze-fitted pumps shall be furnished unless otherwise hereinafter specified. The pumps shall be as manufactured by Allis Chalmers, Goulds or equal as approved by the Engineer: 1) Casing shall be volute type, bolted to adapter through a machined

lock fit to ensure permanent alignment and shall be close grained cast iron, ASTM A48, with flanges faced and drilled to 125 psi ANSI standard. Tapped and plugged holes shall be provided for priming, vent, drain, and gage connections. Casing design pressure shall be 125 psig, minimum.

2) Impeller shall be enclosed, single suction type of bronze, ASTM B62, dynamically balanced and keyed to the shaft.

3) Both casing and impeller wearing rings shall be provided. Impeller wearing rings shall be bronze and of a replaceable design. Casing wearing rings shall be aluminum bronze, heat treated, ASTM B148, Alloy 954. Brinnell hardness number shall be 50 units greater than the Brinnell number of the impeller wearing rings. Press fit or dowel to case and impeller and/or lock with pins, lugs, or screws to prevent rotation.

4) Mechanical seals shall be Chesterton 155 or equal as approved by the Engineer, externally mounted type with carbon to ceramic mating face. The pumped liquid shall lubricate the seal faces. Provide Type 316 stainless steel tubing from pump discharge nozzle to seals complete with shutoff valve and filter.

5) Shaft shall be Type 416 stainless steel, ground and polished. 6) Shaft sleeve shall be bronze, heat treated, ASTM B148, Grade 9C

threaded against shaft rotation and locked against reverse rotation. Sleeve shall extend beyond glands.

7) Bearings shall be steel ball or roller thrust bearing at the outboard end and steel ball or roller radial bearing at the inboard end. Rating


life shall be 50,000 hours as defined by ABMA. Bearing shall be manufacturer’s standard grease lubricated.

8) The rotating parts of each pump, coupling, and driver shall be dynamically balanced prior to final assembly. Vibration of the completed pump assembly shall not exceed a displacement of 1.0 mil.

9) Baseplate shall be cast iron or fabricated steel with drip collection chamber, tapped drain connection and holes for grouting.

10) Coupling shall have a power rating of not less than 1.25 times the motor nameplate rating when the misalignment is within the manufacturer’s tolerance limit. Coupling shall be Reynolds Type PB or equal as approved by the Engineer with all metal coupling guard per OSHA requirements.

11) Each pump shall be driven by a horizontal single speed solid shaft squirrel case induction electric motor with a maximum speed of 1800 rpm. Electric motors shall be as specified in Section 26_05_83.

F. Accessories: Provide the following accessories with each generator: 1. Dielectric viewing ports:

a. Minimum of 3 viewing ports located on the hinged end of each generator. b. Provide additional ports as required so that all dielectrics may be

inspected for operation without opening the generator shell. 2. Cooling water system inspection ports: A minimum of one 6-inch flange

connection with a Type 316 stainless steel blind flange for inspection of the internal coolant portion of each ozone generator.

3. Generator gas vent: a. Provide each generator with a vent consisting of a minimum 1/2-inch

diameter ball valve to allow depressurization and purging of the generator prior to maintenance.

b. Include vent locks to prevent accidental opening during normal operation. c. Identically key all locks. d. Connect generator gas vent to gas system pressure relief valve discharge

piping. 4. Cooling water drain:

a. Provide a drain at the low point of each generator to allow complete drainage of the cooling water from each generator.

b. Coordinate discharge pipe location on skid with drainage piping installed in the field.

5. Isolation valves: a. Motor actuated inlet and outlet gas valves. As specified in Section

40_05_57.23 for requirements of the actuator. b. Manual inlet and outlet valves.

6. Gaseous oxygen flow indicating transmitters: a. Shall be orifice plate type as specified in Section 40_71_23.21. b. Provide 2 parallel flow meters, 1 sized for the low end of the flow range

and the other sized for the high end of the flow range, with the 2 flow ranges overlapping.

7. As a minimum, provide temperature instruments on the following services: a. As specified in Sections 40_74_13, 40_74_43, and 40_74_66 for

requirements for temperature indicating transmitter, temperature indicator, and temperature switch, respectively.


b. Temperature indicating transmitter: Oxygen, ozone, closed loop cooling water supply, closed loop cooling water return from generator vessel, and closed loop cooling water return from PSU.

c. Temperature indicator: Closed loop cooling water return. d. High temperature switch: Ozone discharge.

8. As a minimum, provide pressure instruments on the following services: a. As specified in Sections 40_73_23, 40_73_29, 40_73_29, and 40_73_13

for requirements for pressure indicating transmitter, differential pressure indicators, pressure switches, and pressure gauges, respectively.

b. Pressure indicating transmitter: Oxygen (located upstream of the orifice plate flowmeters).

c. Pressure indicator: Ozone and closed loop cooling water supply., d. High pressure switch: Oxygen. e. Low pressure switch: Oxygen.

9. High range ozone gas analyzer as specified in Section 40_76_13. 10. Flow indicator with integral flow switch on the PSU cooling water supply as

specified in Section 40_71_79.

2.03 GENERATOR POWER SUPPLIES

A. Manufacturers: The generator power supplies shall be provided with the ozone generators by the Ozone System Supplier.

B. Power supply characteristics: 1. A 480 volt, 3-phase, circuit will be provided to the skid. 2. Design each power supply to convert 480-volt, 3-phase, 60-hertz input to a

higher voltage single-phase output with a frequency ranging between 1,000 and 10,000 hertz to each generator.

3. The power supply enclosure shall include a minimum 18-pulse or active front end inverter. Each inverter and output converter shall be certified for a mean time between failures of 30,000 hours when the generators are operated at design conditions.

4. The inverter shall operate at greater than 0.95 power factor throughout the normal operating range between 40 and 100 percent of the design ozone generator production capacity.

5. All components shall be rated for an ambient room temperature between 40 and 105 degrees Fahrenheit and 80 percent relative humidity.

6. All components shall be rated at not less than 125 percent of the maximum anticipated power load, on a KVA basis.

7. Each power supply shall include a main circuit breaker. a. As specified in Section 26_28_16.

8. Each power supply shall include a step down control power transformer to provide 120 VAC to power supply instrumentation and accessories: a. As specified in Section 40_95_13.

C. High voltage transformer: 1. Each power supply shall include a high voltage transformer designed to step

up voltage for the power to the ozone generator cells. 2. Design the high voltage transformer in accordance with the following criteria:

a. Minimum efficiency: 97 percent at full load. b. Maximum skin temperature: 65 degrees Celsius. c. Dry type transformer suitable for indoor installation.


d. Maximum noise level: 83 dBA at 5 feet in any direction from the transformer.

e. Provide appropriate lifting lugs on each transformer.

D. Power supply enclosures: 1. Panel and panel components shall be provided as specified in Section

40_61_05. 2. NEMA Type 12 steel enclosure completely gasketed on construction seams

and doors. All gaskets shall be constructed of material suitable for ozone service. Mount the enclosure on a skid fabricated from ASTM A-36 structural steel. Paint skid in accordance with 09_96_56.05. Provide lifting lugs at each corner of the enclosure to facilitate lifting.

3. Provide complete, self-contained power supply cooling system as recommended by the Ozone System Supplier. Connections for the cooling water shall be located on the side of the power supply that faces the ozone generator and shall be no more than 24-inches above the bottom of the power supply.

4. Provide sufficient doors to allow ready access to all components within the enclosure.

5. Clearance around each enclosure: a. Clearance:

1) Each power supply shall require a maximum of 4 feet on both ends of each enclosure.

2) Maximum required clearance for the front and back of each enclosure shall be 5 feet.

6. Install LED lights in enclosures with manually operated hand switches. a. Lights shall be powered from the control power transformer.

E. Power supply system protection: Each power supply system shall include the following protection equipment: 1. A temperature probe/switch on the high-voltage winding and in the magnetic

core that shall shut down the transformer and ozone generator in the event of high core temperature.

2. A three-phase power sensing feedback circuit to maintain power input to the generator within 1/2 percent of the set point over the entire operating range of the generator.

3. Automatic current and/or voltage limitation with annunciator to limit current and/or voltage flowing to the silicon control rectifiers independent of the ozone generator status.

4. Transient over voltage protection at the ozone generator shell, smoothing capacitor and low voltage resonant circuit capacitor. Continuous peak voltage monitoring of the silicon control rectifiers in both conducting and non-conducting direction shall be provided.

5. Overcurrent protection with alarms, lights and/or trip indicators to reveal the cause of the power supply shutdown.

6. Power supply cabinet temperature switches with dual settings. The lower temperature switch shall be for alarm purposes only while the higher temperature switch shall shut down the ozone generator unit.

7. Cooling system failure alarm to shutdown system and indicate of high cooling water temperature and/or low cooling water flow.

8. High voltage alarm and short circuit.


9. Power supply cabinet doors shall be equipped with a flanged-mounted disconnect thermal magnetic breaker interlocked with the doors. Minimum UL short circuit rating of 65,000 RMS symmetrical Amperes.

10. Maximum dielectric failure rate while maintaining ozone production shall be 10 percent of the total number of dielectrics in the generator.

11. The power supplies shall be designed with protection from temporary brownouts where inlet line voltage may vary a maximum of 10 percent of the normal line voltage.

12. Monitoring and control features supplied with each generator/power supply unit shall include, but not be limited to, the following: a. Door Ajar Indicator. b. Emergency System Trip Indicator. c. Excessive Dielectric Failure Indicator. d. Auxiliary Circuit Breaker Trip Indicator. e. Enclosure Temperature High Indicator. f. Converter Overload Indicator. g. Inverter Malfunction Indicator. h. Transformer High Temperature Indicator. i. ON/OFF indicators for all equipment. j. Alarm Acknowledge/Reset and Test Switches. k. Power Supply On/OFF/Emergency Stop Switches. l. Local/Remote Control Selector Switch. m. Local Control Set Point Dial. n. Kilowatts Meter. o. DC Voltage Meter. p. DC Current Meter. q. Kilowatt Hour Meter.

F. Provide manufacturer standard cables for high-voltage connection between the power supply unit and the ozone generator skid. Assume a cable distance of 100 feet. The Contractor will furnish the conduit for this cable and install the conduit and cable. All other signal and power conduit and conductors between the power supply unit and ozone generator skid will be provided by the Contractor.

G. Voltage distortion and current distortion shall meet the specified power quality criteria as specified herein.

H. Harmonic mitigation equipment: 1. Provide additional, harmonic filters or other equipment, as approved by the

Engineer, to meet the harmonic limitation criteria specified in this Section. 2. All harmonic mitigation equipment shall be installed within the power supply

unit and shall be fully warranted and certified compatible with the power supply units. This requirement shall be met even if mitigation equipment is installed under field retrofit conditions if found necessary to meet the specified distortion limits during acceptance testing.

I. Programmable logic controller (PLC): 1. Provide PLC hardware in each ozone generator power supply as indicated on

the Drawings and as specified in Section 40_94_43. 2. Provide PLC hardware as required to implement the control strategies as

specified in Section 40_61_16. 3. Program PLC hardware and software as specified in Section 40_61_05.


4. Provide provisions for connection of an external uninterruptible power supply for the PLC and control equipment. The external uninterruptable power supply will be provided by others. Assume that the uninterruptable power supply will provide 30 minutes of power to the control system during an outage.

5. Network hardware and connection to the Owner's DCS.

J. Local Operator Interface: 1. Provide a 15 inch local operator interface in each ozone generator power

supply as indicated on the Drawings and as specified in Section 40_94_33. 2. Provide local operator interface hardware as required to implement the control

strategies as specified in Section 40_61_16. 3. All graphic screens and logic resident in operator interface stations shall be

programmed as specified in Section 40_61_05.

K. Power meter: 1. Furnish each power supply unit with a power meter as specified in Section

26_09_13. 2. Voltage transformers:

a. ANSI B0.3 or better metering accuracy class. b. 277/120 volt. Ratio of 2.31:1. c. Wired in wye-wye configuration such that the input to the power meter is

208Y/120V, 3-phase, 4-wire. 3. Current transformers:

a. ANSI B0.3 or better metering accuracy class. b. One per phase.

L. Coordinate acceptance of all control signals from all oxygen and ozone facilities including from items outside of the Ozone System Supplier’s scope such as the LOX facilities and open-loop cooling water pumps.

2.04 ANCHOR BOLTS

A. As specified in Section 03_21_17 and 05_05_24.


A. Factory testing: 1. As specified in Section 46_31_59. 2. Subject each transformer to the following factory testing:

a. Transformer turns ratio at no load. b. Short-circuit test. c. Resistance test. d. Leakage inductance test.

B. Provide certification to document successful factory testing to the Engineer prior to installation.


PART 3 EXECUTION


A. Contractor will be responsible for installation of all equipment as specified in this Section, as indicated on the Drawings, and as directed by the Ozone System Supplier: 1. Contractor will mount each ozone generator and power supply on equipment

pads as indicated on the Drawings. 2. Contractor will provide anchor bolts as sized by the Ozone System Supplier to

anchor the ozone generators and power supplies as indicated on the Drawings.

3. Contractor will provide flange bolts and gaskets as required to connect piping to the Ozone System Supplier provided equipment:

4. Contractor will provide the wire and conduit as necessary to connect all power and signal terminations for the generators and power supply units to the destinations indicated on the Drawings.

B. Contractor will be responsible for coordination with the Ozone System Supplier.

3.02 TESTING

A. Conduct ozone system start-up testing as specified in Section 01_75_17.

B. Conduct ozone system performance testing as specified in Section 46_31_59.

END OF SECTION


SECTION 46_31_57

OZONE DESTRUCTION EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. All equipment associated with the ozone destruct equipment. The ozone

destruction equipment shall be supplied as part of the Ozone System by the Ozone System Supplier as specified in Section 46_31_52. The ozone destruction equipment shall be identical for the two water treatment plants.

2. The ozone destruction equipment includes the ozone destruct units to treat off-gas from the ozone contactors.

3. The ozone destruction equipment shall be installed by the Contractor.



list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Ozone System Supplier to see that the completed Work complies accurately with the Contract Documents: a. Section 01_33_00 - Submittal Procedures. b. Section 01_75_17 - Commissioning and Process Start-Up. c. Section 01_78_23 - Operation and Maintenance Data. d. Section 01_81_01 - Project Design Criteria. e. Section 05_05_24 - Mechanical Anchoring and Fastening To Concrete

and Masonry. f. Section 26_05_83 - Low Voltage Motors. g. Section 26_29_13.13 - Across the Line Motor Controllers. h. Section 26_29_23 - Low Voltage Variable Frequency Motor Controllers. i. Section 33_12_01 - Basic Mechanical Materials and Methods. j. Section 40_05_63 - Ball Valves. k. Section 40_05_64 - Butterfly Valves. l. Section 40_05_65.24 - Check Valves. m. Section 40_61_00 - Common Work Results for Process Control and

Instrumentation Systems. n. Section 40_61_05 - Packaged Control System. o. Section 40_61_16 - Specific Control Strategies. p. Section 40_73_13 - Pressure/Vacuum Measurement: Gauges. q. Section 40_76_13 - Analyzers: Gas Monitors. r. Section 40_95_13 - Process Control Panels and Hardware. s. Section 46_31_52 - Ozone System: General. t. Section 46_31_58 - Cleaning for Oxygen and Ozone Service.

1.02 REFERENCES

A. American Bearing Manufacturers Association (ABMA): 1. 9, Ball Bearings, Load Ratings and Fatigue Life for 10,000 hours.


2. 11, Roller Bearings, Load Ratings and Fatigue Life for 10,000 hours.

B. American Welding Society (AWS): 1. Section D10.4-Recommended Practices for Welding Stainless Steel Piping

and Tubing.

C. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

D. Underwriters Laboratories, Inc. (UL).

1.03 DEFINITIONS

A. NEMA: 1. Type 12 enclosure in accordance with NEMA 250.


A. Each water treatment plant shall be provided with three off-gas ozone destruct units as specified herein. As a minimum, each off-gas ozone destruct unit consists of the following major equipment all mounted on a common skid: 1. Manual inlet valve. 2. Motor actuated inlet valve. 3. Temperature indicating transmitter on the inlet gas, low pressure switch on the

blower suction, temperature indicating transmitter and high temperature switch after the preheater, and differential pressure indicator across the catalyst bed.

4. Preheater. 5. Catalytic destruct media bed and vessel. 6. Off-gas blower with variable frequency drive. 7. Low ozone gas concentration analyzer. 8. Check valve on blower discharge. 9. Silencer. 10. Vendor control panel. 11. Painted carbon steel support frame of all ozone destruct unit components.

B. Performance requirements of each off-gas ozone destruct unit: 1. Provide off-gas ozone destruct units capable of destroying the ozone in the off-

gas before discharging the treated gas to the atmosphere. 2. Off-gas ozone destruct unit capacity: Each ozone destruct unit shall be

capable of treating a flow range of 40 to 320 standard cubic feet per minute of off-gas.

3. Power supply to each off-gas ozone destruct unit: a. A single 480 volts, 3-phase, 60 hertz connection. All other voltage

requirements shall be derived on the skid. 4. Maximum outlet gas ozone concentration: Less than 0.07 parts per million (by

volume). 5. Design inlet ozone concentration: 2.0 percent, by weight. 6. Design inlet gas pressure: 6 inches water column - vacuum. 7. Normal contactor headspace gas pressure: 2-inch to 4-inch water column

vacuum. 8. Off-gas temperature range: 40 to 90 degrees Fahrenheit. 9. Off-gas humidity: 100 percent.


10. Noise level at system design capacity shall not exceed 85 dBA at 3 feet for free field conditions.

C. Process piping for each off-gas ozone destruct units shall be Type 316L stainless steel pipe and shall be as specified in Section 40_05_23.01: 1. Piping and valves not specified in this Section shall be provided as specified in

Sections 40_05_63 and 40_05_64.

D. Nameplates shall be provided on each piece of equipment: 1. Each nameplate shall bear the titles of the equipment as indicated in the

performance and design requirements and as specified in the following sections.

E. Contractor will provide all anchor bolts, nuts and washers for the equipment as required.

F. Ozone System Supplier shall submit anchorage calculations for sizing of the anchor bolts for the off-gas ozone destruct units: 1. Calculations shall be signed and sealed by a professional civil or structural

engineer registered in the state of California.

1.05 SUBMITTALS.

A. General: Submit as specified in Section 01_33_00.

B. Product data: 1. Off-gas ozone destruct unit preheater characteristics and performance data. 2. Catalyst bed characteristics and performance data. 3. Off-gas ozone destruct unit blower characteristics and performance data. 4. Off-gas ozone destruct unit silencer characteristics and performance data. 5. Control panel components and materials.

C. Templates or setting plans, with tolerances, for anchor bolts.

D. Operation and maintenance data: Submit for all ozone destruct equipment, as specified in Section 01_78_23.

E. Certified test data that shows that systems meet specified performance criteria throughout the range of potential off-gas flows.

F. Design drawings with system dimensions.

G. Control panel internal and external layout drawings keyed to a bill of materials.

H. Control panel schematics and wiring diagrams.

I. Submittal information as specified in Section 40_61_00 for the instrumentation and controls portion of the ozone destruct equipment work.



A. Welding: 1. All welds shall be performed and inspected in accordance with AWS D10.4

and Section 40_05_23.01. 2. Correct deficiencies until accepted by the Engineer.


A. Factory cleaning: All items to be wetted with oxygen or ozone shall be cleaned as specified in Section 46_31_58 prior to shipping.

B. Packing, delivery and unpacking: Deliver all components in factory packaging and protect all components from environmental exposure before installation.

C. Site acceptance: All items shall be unpacked under the supervision of an OSS representative.

1.08 MAINTENANCE

A. Furnish the following spare parts for the system components for each water treatment plant: 1. Catalyst, enough for 1 replacement each in 1 off-gas ozone destruct unit

catalytic destruction vessel. 2. Catalytic destruction unit gaskets: 1 set.

PART 2 PRODUCTS

2.01 GENERAL

A. Anchor bolts supplied by Contractor: As specified in Section 05_05_24.

2.02 SYSTEM COMPONENTS

A. Vendor Control Panels: 1. The control devices for each off-gas ozone destruct unit shall be mounted in

NEMA Type 12 local control panels, respectively: a. Mount each vendor control panel on the skid of each off-gas ozone

destruct unit. b. Provide the vendor control panel as specified in Section 40_61_05 and

Section 40_95_13. c. Design each vendor control panel for the process area indoor temperature

range as specified in Section 01_81_01. Provide an air conditioning unit sized for the heat loads generated within the panel if necessary.

2. Provide dry contacts to Remote I/O RIO-200 panel for the remote indication of the following signals: a. Blower run status, remote mode status and failure. b. Preheater run status.

3. Provide the following local control devices: a. Hand/Off/Auto selector switch for preheater. b. On/Off selector switch or pushbuttons for preheater. c. Hand/Off/Auto selector switch for blower.


d. Start-Stop selector switch or pushbuttons for blower. 4. Provide the preheater solid state power controller (or contactor) and the

variable frequency drive for the off-gas blower in the local control panel: 5. The off-gas ozone destruct unit VCPs shall communicate to the Ozone

Destruct Room Remote I/O (RIO-200) as shown in the Drawings. a. Provide motor starters and contactors in accordance with Section

26_29_05. b. Provide variable frequency drives in accordance with Section 26_29_23

6. Power supply to each VCPs shall be 480-volt, 3-phase: a. Provide flange mounted disconnect in each VCP to disconnect all power

including control power. b. Minimum UL short circuit rating of 65,000 RMS symmetrical amperes.

7. The Ozone System Supplier shall provide the wire and conduit between the local control panel and all the elements provided with the ozone destruct equipment.

8. A terminal strip shall be provided in the local control panel to interface all signals to and from the ozone destruct equipment to the control system: a. The Contractor shall provide the wire and conduit to transmit these signals

to the control system and terminate the wires in the local control panel.

B. Preheaters: 1. Provide one preheater for each off-gas ozone destruct unit. 2. The minimum design gas temperature rise shall be 40 degrees Fahrenheit at

all off-gas ozone destruct unit flow rates and inlet temperatures as low as 40 degrees Fahrenheit.

3. The maximum preheater element skin temperature shall not exceed 300 degrees Fahrenheit at design gas flow conditions.

4. Maximum pressure drop across each preheater shall be 2 inches of water column at design gas flow.

5. Each preheater shall incorporate a thermocouple welded to the element sheath surface and wired to a terminal strip.

6. Each preheater shall have over-temperature protection, which shall shut down the preheater in a no-gas flow condition.

7. Any components which may come in contact with off-gas shall be passivated Type 316L stainless steel.

8. Preheater external surfaces shall be insulated with 2 inches of fiberglass material contained in a weatherproof steel jacket.

9. Inlet and outlet connections of preheaters shall be 6-inch Type 316 stainless steel Class 150 raised face flanges.

10. Power supply to preheaters shall be 480-volt, 3-phase via the local vendor control panel: a. The terminal enclosure on the preheaters shall be NEMA Type 12.

11. Preheater controls: Temperature control shall be thermocouple or RTD temperature control type for modulating temperature control: a. Switches and indicating lights shall be heavy-duty, weatherproof.

12. Preheater: a. Manufacturer: The following or equal as approved by the Engineer:

1) Watlow Industries. 2) Chromalox.

C. Catalytic destruct units: 1. Provide catalytic destruct units as specified.


2. Catalyst material shall be Carulite 200, 4 by 8 mesh extrusions: a. Manufacturer: The following or equal as approved by the Engineer:

1) Carus Chemical Company. 3. The catalytic destruction unit shell shall be AISI Type 316L stainless steel.

Provide seals and gaskets as specified in Section 46_31_52. 4. Fabricate each destruct unit so that the ends of the unit are flange-bolted to

the unit body. 5. Design the off-gas ozone destruct unit catalyst exterior housing to withstand a

maximum internal pressure of 10 pounds per square inch gauge and a vacuum of 20-inches of water. Provide a 1/8" corrosion allowance on all catalyst housings.

6. Provide a differential pressure indicator on each catalytic unit to measure pressure drop across the catalyst. Provide gauges as specified in Section 40_73_13.

D. Off-gas blowers: 1. Provide one off-gas blower for each ozone destruction unit and as specified in

this Section. 2. The rated differential pressure for the blowers shall be designed for the losses

incurred through the Ozone Destruct System at the Destruct System Capacity flow rate pulling from a 4-inch water column vacuum from the ozone contactor headspace.

3. Maximum motor speed shall be 3,600 revolutions per minute on all off-gas blowers.

4. Operating gas inlet temperature will range from 80 degrees Fahrenheit to 120 degrees Fahrenheit.

5. Blowers shall not surge at maximum inlet temperature, minimum inlet pressure and maximum discharge pressure operating conditions.

6. Blowers shall be single width, single inlet, non-overloading, centrifugal type. 7. All blower components including the housings and wheels shall be constructed

of stainless steel: a. Provide a drain connection at the low point of the scroll and a cleanout

door on each blower. 8. The fan wheel and shaft assembly shall be statically and dynamically balanced

at the factory prior to shipping. 9. The first critical speed shall not be less the 125 percent of the maximum

recommended speed. 10. Bearings shall be heavy-duty grease lubricated anti-friction type with an

ABMA rating of L-10 for 100,000 hours continuous operation. 11. Provide blowers with inlet and outlet flanged connections. 12. Install each blower and its drive motor on a structural channel base. 13. Provide vibration dampeners between each blower frame and the skid base. 14. Manufacturer: The following or equal as approved by the Engineer:

a. Cincinnati Fan, Series HP.

E. Off-gas blower equipment: 1. Motors:

a. Provide motors as specified in Section 26_05_83. b. The speed of the blower shall be controlled by the off-gas pressure in the

headspace of the ozone contactors. c. Install motors on a subbase with an adjustable motor slide base sized to

accommodate the motor frame.


d. Each motor shall be rated at 480-volts, 3-phase, 60-hertz and shall be minimum 5 horsepower, inverter duty rated in accordance with NEMA MG-1 Part 31. Contractor and Ozone System Supplier shall be responsible to coordinate and make all structural, mechanical, and electrical changes required to accommodate increased horsepower, if larger.

e. Motors shall not overload at minimum inlet temperature, maximum inlet pressure, and minimum discharge pressure operating conditions.

f. Motor enclosure: TEFC. 2. Guards: Provide guards for all exposed rotating shafts, sheaves, and

couplings as specified in Section 33_12_01. 3. Flexible connections:

a. Provide flexible vibration control joints on the off-gas blower inlet and outlet connections. Vibration control joints shall be corrugated stainless steel with stainless steel braid. Design control joints for a minimum pressure of 150 psig. End of control joints shall be ANSI Class 150 flanges. Provide Flexonics, Inc. or equal as approved by the Engineer.

b. Install flexible connections on each destruct system required. c. Flexible connections shall be compatible with gas oxygen and ozone.

4. Check valves on off-gas blower discharge: a. Provide dual plate wafer type check valve, Techno-Check by Crane, or

equal as approved by the Engineer. Provide check valves with a 316 stainless steel body, plates, springs, and trim, and TFE seats.

F. Silencers: 1. Provide a discharge silencer for each blower. 2. Provide silencers that incorporate annular adsorptive type media. 3. Silencer housings shall be of steel construction and shop painted. 4. Design the silencers such that maximum noise levels at design operating

capacity of the destruct system shall be 85 dBa at 3 feet for free field conditions.

5. Manufacturers: One of the following or equal as approved by the Engineer: a. Kittell. b. Burgess Manning.

G. Low ozone gas concentration analyzers: 1. Provide a low ozone gas concentration analyzer for each ozone destruct

system and as specified in Section 40_76_13. 2. Mount analyzer on the ozone destruct system skid. 3. Power for the analyzer shall originate from the ozone destruct system skid

control panel.

PART 3 EXECUTION


A. Contractor shall be responsible for installation of all equipment as specified in this Section, as indicated on the Drawings, and as directed by the Ozone System Supplier. The Contractor shall provide all other piping, process equipment, electrical equipment, instrumentation equipment and other items not provided by the Ozone


System Supplier to make complete and operable ozone destruct systems as indicated on the Drawings: 1. Contractor shall mount each ozone destruct system on an equipment pad as

indicated on the Drawings. 2. Contractor shall provide anchor bolts as sized by the Ozone System Supplier

to anchor the ozone destruct systems. 3. Contractor shall provide flange bolts and gaskets as required to connect piping

to the Ozone System Supplier provided equipment. Provide gaskets and bolts as specified in Section 40_05_23.01.

4. Contractor shall provide the wire and conduit necessary to connect all power and signal terminations in the local control panel of each ozone destruct systems to the destinations indicated on the Drawings: a. Contractor’s work inside the local control panels shall comply with the

electrical identification requirements as specified in Section 26_05_53.

B. Contractor shall be responsible for all coordination with the Ozone System Supplier.

C. Perform system start-up and testing on all equipment as specified in Section 01_75_17 and manufacturer’s recommendations.

END OF SECTION


SECTION 46_31_58

CLEANING FOR OXYGEN AND OZONE SERVICE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Materials, methods, and inspection procedure to be used in factory or field

cleaning of the equipment and piping used with liquid oxygen, gaseous oxygen, ozone gas, and ozone off-gas. As part of the cleaning process, all stainless steel components shall be passivated.

2. It also includes requirements for post-cleaning protection, identification, and other functions related to cleaning.

3. After cleaning, the system components must be protected from recontamination until used.

B. The Work in this Section shall be performed by a qualified provider of cleaning services. The term ‘Provider’ in this Section will refer to the cleaning services provider that performs field cleaning. This fieldwork can be performed on new equipment or piping delivered to site uncleaned or on existing equipment or piping involved with the project.


binding as if called for by all. 2. It is the CONTRACTOR’s responsibility for scheduling and coordinating the

Work or subcontractors, suppliers, and other individuals or entities performing or furnishing any of the CONTRACTOR’s Work.

3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the CONTRACTOR to see that the completed Work complies accurately with the Contract Documents: a. Section 46_31_52 - Ozone Systems: General.


A. ASTM International (ASTM) A967 - "Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts".

B. Compressed Gas Association (CGA) Publication No. G-4.1, “Cleaning Equipment for Oxygen Service.”

1.03 SUBMITTALS

A. Factory-cleaned equipment: 1. Inspection records:

a. The equipment supplier shall submit to the CONTRACTOR a copy of the manufacturer’s inspection records for all equipment cleaned for oxygen or ozone service.


b. The inspection record for each item shall include the following information: 1) A designation of the item covered. 2) Serial number. 3) Invoice number or other means of identification. 4) Cleaning specification and method employed. 5) Dates of inspection. 6) Methods of inspection. 7) Results of inspection. 8) Inspector’s signature and date signed.

B. Cleaning procedures: 1. Cleaning specifications and standards for all equipment, piping, valves, fittings,

and accessories for use during equipment installation. As a minimum, each cleaning specification shall include the following: a. Degree of cleaning in measurable terms. b. Acceptable cleaning procedures. c. Inspection procedures required and method of inspection and testing to

assure the desired level of cleaning. d. Acceptable cleaning materials. e. Acceptable lubricants, sealants, and testing equipment. f. Procedures and requirements to assure that the equipment supplier has

complied with the cleaning specifications. g. Packaging, protection, and storage of cleaned items.

C. Field cleaning plan: 1. The name of the Provider. 2. The product information on all materials used, including, but not limited to:

a. Solvents. b. Detergents. c. Lubricants. d. Drying agents. e. Leak detection solutions.

3. Field cleaning procedure including step-by-step actions. 4. Schedule of the Work including durations of required shutdowns.

D. Provider qualifications: 1. Provider experience description. 2. Provider references.

1.04 QUALITY CONTROL

A. Cleaning requirements: 1. All cleaning performed shall be performed in accordance with the requirements

of CGA Publication No. G-4.1 in addition to the specific requirements herein. 2. Stainless steel components shall be passivated in accordance with ASTM

A967.

B. Provider qualifications: 1. Experience minimum: 5 years in providing field cleaning services for

equipment in oxygen and ozone service in accordance with CGA Publication No. G-4.1.


C. The cleaning and passivation procedures shall be supervised and monitored by a person skilled and experienced in cleaning oxygen and ozone equipment cleaning: 1. This person shall be responsible for monitoring the cleaning and for

determining whether a component is cleaned properly. 2. Any components for oxygen or ozone service that were delivered to the jobsite

uncleaned shall either be returned to the manufacturer for cleaning or shall be cleaned in the field by the Provider at the option of Contractor.

3. Cleaning in the field shall be done in accordance with the Provider’s printed instructions.

4. A recalibration of the equipment components shall be done only by the manufacturer’s representative.

D. Any equipment and in-line components that have been cleaned by the manufacturer before delivery to the jobsite shall be inspected by Contractor or the Provider for adequate cleaning and packaging: 1. Components which require recleaning shall be cleaned in the field by the

Provider.

E. The pressure of the nitrogen purge on skid-mounted equipment shall be checked in the field before removing the blind flanges and connections to the piping system. 1. If pressure has been reduced to less than 2 pounds per square inch or to a

value unacceptable to the equipment supplier, the skid shall be recleaned in the field by the Provider.

PART 2 PRODUCTS

2.01 FACTORY-CLEANED EQUIPMENT

A. The equipment furnished by the Ozone System Supplier shall be factory cleaned before it is delivered to the site. The stainless steel components shall be passivated prior to delivery. Ozone system equipment provided by the Contractor will be factory cleaned before it is delivered to the site.

B. Skid-mounted equipment which has been factory cleaned, such as ozone generators and destruction units, LOX tanks, vaporizers, oxygen filters, and pressure reducing stations, shall be pressurized after cleaning at the factory with a nitrogen purge to 5 pounds per square inch: 1. A factory pressure gauge shall be mounted at the blind flange of the skid for

verification upon arrival at the project site that the nitrogen purge is still present.

C. Skid mounted equipment shall be bypassed until the connecting piping has been oxygen cleaned in the manner specified.

D. Each piece of factory cleaned equipment will be labeled "Cleaned for Oxygen Service." and sealed by the manufacturer in clear polyethylene protective wrapping to prevent recontamination during shipping, storage, and handling.


2.02 FIELD CLEANING

A. Cleaning Services Provider: One of the following or equal as approved by the Engineer: 1. Astro Pak. 2. Clean Sciences, Inc.

B. Obtain approval of field cleaning plan before commencing work.

C. Field cleaning and passivation shall be performed by the Provider.

2.03 MATERIALS

A. The following materials shall be used for field cleaning, testing, and assembly of piping and equipment components: 1. No other materials may be used without the specific approval of the Engineer. 2. Contractor shall be responsible for proper disposal of all solvents, detergents,

leak detection solutions, drying agents, and other fluids used in cleaning and testing.

3. Detergents: a. Any commercial alkaline or neutral water-soluble cleaner recommended

by the cleaning company may be used provided that it is effective and is thoroughly flushed from the equipment item or pipe after cleaning.

b. The cleaning shall be done according to the manufacturer's directions. c. Detergent shall be contained so that there is no discharge to the plant

drainage systems. 4. Utilities:

a. Contractor or Provider shall provide the compressed air or nitrogen for purging, drying, and testing the equipment after final cleaning.

b. The air or nitrogen shall be dry, with a dewpoint of -30 degrees Fahrenheit or lower, and oil-free, or shall meet the Provider’s requirements, whichever are more stringent: 1) The Contractor and the Provider shall closely monitor the operation

of the gas filtering equipment. c. Water for preparing the solutions or for flushing, rinsing, or testing the

system after final cleaning shall be deionized or shall be of equivalent or superior purity.

5. Tools and equipment used in cleaning the piping and system components: a. Store separately from other tools or thoroughly clean before each use. b. Wire brushes shall be of austenitic stainless steel or bronze to avoid

introducing iron particles in the equipment being cleaned: 1) Brushes made with natural bristles are preferred.

c. Any tanks, pumps, instruments, shunts across valves or equipment, or temporary pipe supports used during cleaning shall be furnished by the Provider.

6. Lubricants: a. General lubricant: Manufacturers: One of the following or equal as

approved by the Engineer: 1) Montedison USA, Fomblin. 2) Hooker Fluorolube, Halocarbon. 3) DuPont, Krytox. 4) 3M, Kel-F Fluorocarbon oils and greases.


5) Oxweld, No. 64 Anti-Friction Compound. b. Ozone service lubricant: Manufacturers: One of the following or equal as

approved by the Engineer: 1) Montedison USA, Fomblin. 2) DuPont, Krytox.

c. Lubricants shall be used sparingly and only to facilitate assembly or to lubricate packing.

7. Leak detection solutions: a. General leak detection: Manufacturers: One of the following or equal as

approved by the Engineer: 1) Glyco Chemicals, Sulfatate B-l (4 fluid ounces per pint of water). 2) American Gas & Chemical Company, Leak-Tec. 3) Swagelok, Snoop. 4) Ivory soap solution.

b. Leak detection chemical additives for uses at below freezing temperatures: Manufacturers: One of the following or equal as approved by the Engineer: 1) Swagelok, Real Cool Snoop. 2) Commercial grade ethylene glycol. 3) Methyl alcohol.

8. Drying agents: Isopropyl alcohol, if required.

PART 3 EXECUTION

3.01 SAFETY

A. Provider’s personnel shall be thoroughly trained in the proper cleaning techniques, shall keep their clothing and hands free of oil and grease and, if necessary, wear clean gloves.

B. Flammable solvents such as gasoline, kerosene, naphtha, mineral spirits, or acetone shall not be used for cleaning.

C. Fire extinguisher fluids shall not be used for cleaning.

D. Contractor and Provider shall have full responsibility and liability for the safety aspects of the cleaning process.

3.02 COORDINATION

A. Ozone System Supplier shall be fully and solely responsible for any damage resulting from inadequate cleaning of Supplier-furnished equipment and for any hazards associated with the cleaning process.

B. Contractor will have responsibility for ensuring that all equipment, piping, tubing, instrumentation, vessels, and any combined systems thereof that will be used with liquid oxygen, gaseous oxygen, ozone gas, and ozone off-gas, have been cleaned and recleaned, if necessary, and meet the requirements of this Section when placed into service.


3.03 PROTECTION OF PIPING SYSTEM, VESSELS, AND EQUIPMENT

A. The factory or field cleaned piping, vessels, and equipment shall be protected from contamination until they are placed in service using the methods described below.

B. Short-term protection for periods up to 1 week: 1. Pipe ends and other openings may be covered with metal or plastic caps or

plugs, or with a double layer of 6-mil polyethylene film, sealed to the pipe or nozzle with waterproof tape.

C. Medium-term protection for periods between 1 week and 1 month: 1. Welding ends: Ends shall be closed with clean Wedge Projects or equivalent

galvanized steel caps, sealed with 2 turns of Tuck No. 90 or equivalent 2-inch waterproof tape.

2. Flanged ends: Flanged ends shall be closed with 10-gage or heavier oxygen- cleaned steel flange covers over solid neoprene or “Durable” gaskets, held in place with at least 4 hex-head bolts.

D. Long-term protection for periods 1 month and longer: 1. The cleaned line shall be filled with dry nitrogen pressurized to 2 pounds per

square inch. 2. Pressurized lines shall be identified at all significant flanges and valves.

E. Protection of small parts: 1. Small parts such as valves, expansion joints, pressure gauges, etc., should be

kept in heavy polyethylene bags or wrapped and sealed in polyethylene sheeting until installation.

F. Equipment protection: 1. After cleaning, manholes, inspection ports, nozzles, and other openings shall

be covered using blind flanges, plastic protectors, hardboard covers, or polyethylene sheets securely taped in place: a. Larger pieces of equipment shall be completely covered with polyethylene

sheeting.

G. Identification: 1. Any piping, equipment, or vessels cleaned in the field as specified in this

Section shall be identified as follows: CLEANED FOR OXYGEN SERVICE.

3.04 INSPECTION AND TESTS

A. The factory or field cleaned components of the oxygen, ozone, off-gas, or supplemental nitrogen system shall be inspected using black light where possible or by any of the methods specified below as applicable: 1. If the inspection reveals contaminants, the component shall be recleaned.

B. Direct visual inspection: 1. The cleaned components shall be free of observable residual oil, grease,

lubricants, water, paint, coating, varnish, or other films; extensive adherent rust or mill scale; and loose rust, scale, abrasives, filings, loose weld spatter, chips, fluxes, dirt and any other particulate matter.

2. Marking materials, labels, and any other extraneous materials must be removed.


3. Sandblasted surfaces shall meet SSPC-The Society for Protective Coatings’ Pictorial Standard CSa2.

C. Inspection by Ultraviolet or "Black Light": 1. The cleaned surfaces shall be examined in darkness or subdued light using a

3200-3800 AU wavelength black light to reveal common hydrocarbon oils or greases that fluoresce.

2. To detect nonfluorescent such as fish oil based rust preventives, or vegetable oil-based cutting emulsion the system supplier shall review the applicable manufacturing procedures to make sure that no such products have been used.

3. If fluorescence appears as a blotch, smear, smudge, or film, the affected component shall be recleaned.

D. Wipe test: 1. The component to be tested by wiping at least 1 square foot of its surface with

clean white paper or an unbleached cloth, which shall then be examined under both normal ambient light and black light for signs of contamination.

2. If excessive discoloration or any fluorescence appears, the surface shall be recleaned.

3.05 CLEANING PROCEDURES FOR EQUIPMENT

A. All equipment requiring oxygen cleaning shall be furnished already cleaned and passivated by the equipment supplier: 1. If, for any reason, recleaning or repassivation in the field is required, it shall be

done in accordance with the equipment manufacturer's printed instructions. 2. Any equipment recalibration required shall be done by the equipment

manufacturer's representative. 3. After cleaning, the equipment shall be inspected and shall be installed

immediately or shall be packaged and tagged.

3.06 CLEANING METHODS

A. The following methods shall be used either singly or in combination to clean the oxygen, ozone, ozone off-gas, and supplemental nitrogen supply equipment: 1. The actual choice will depend on the type and size of the component to be

cleaned, the type and extent of contamination, and the facilities available.

B. The Provider shall provide temporary shunts for connecting sections of piping that are to be connected in the final installation by a factory cleaned valve or other connecting device.

C. The Provider shall also provide temporary supports for gas piping, where required, to help bear the additional weight of the water and other fluids used in cleaning the piping.

D. Mechanical cleaning: 1. Mechanical cleaning consists of physically removing contaminants from

equipment by brushing, sweeping, blowing, scraping, chaining, sandblasting, agitating, or similar methods.

2. It is generally used for a preliminary cleaning or in combination with other methods.


E. Flushing: 1. Clean the equipment or piping section with detergent solution and followed by

purging with dry, oil-free air or nitrogen. 2. The initial rinse with deionized water shall be followed by flushing with

detergent solution. 3. If detergent solution is used in a closed piping system, it shall be circulated for

at least 2 hours, followed by the final rinse which shall be continued until measurements by the Provider confirm that the system is clean: a. Measurements shall include but shall not be limited to, the pH value and

comparison between influent and effluent conductivity. 4. The system shall be dried using oilless, dry air of the quality specified, or

nitrogen or isopropyl alcohol, if required. 5. Any reference to detergent cleaning elsewhere in this Section implies both

rinsing and drying. 6. Passivation shall be done in the manner recommended by the Provider. 7. If the Provider prefers to use a different procedure than specified, it shall

submit details of such a procedure to the Engineer for review. 8. All effluent used in the cleaning process shall be contained, removed, and

disposed of off-site.

F. Immersion: 1. Cleaning by immersion involves submerging, and if possible scrubbing, the

equipment to be cleaned in a bath selected detergent solution. 2. If many components are being cleaned, 2 baths shall be used:

a. First bath: Remove most of the contaminants. b. Second bath: Remove the remainder of the contaminants.

3. When the first bath becomes heavily soiled, it shall be emptied and replaced with the second bath, and a new, clean second bath shall be provided.

4. Nonmetallic components shall be immersed briefly or wiped with a cloth as described below.

G. Wiping or mopping: 1. Large, readily accessible surfaces such as compressor parts or vessels that

can be entered, may be cleaned by wiping with a detergent solution.

3.07 CLEANING PROCEDURE FOR PIPING SYSTEMS

A. The general concept of oxygen cleaning of piping systems is to clean each pipe section, fitting, valve, or other in-line component before it is installed except where such components can be pre-assembled into spools of a size and configuration suitable for cleaning, inspecting, and handling. Inspection for cleanliness shall be the final step before installation.

B. Items that have been cleaned in the shop by their equipment supplier shall be checked for cleanliness immediately before installation, and recleaned if necessary.

C. In-place cleaning of a preassembled piping or equipment system shall be done in accordance with the procedures used by the Provider for field cleaning and as recommended by Contractor: 1. The Provider shall access and prepare any line to be cleaned in accordance

with the Owner’s procedures.


2. All valves (other than full-port ball valves) and instruments shall be removed and replaced with temporary shunts while the cleaning fluid is circulated.

3. Valves shall be cleaned separately and the system reassembled using proper techniques, acceptable to the Contractor and the Provider.

4. Cleaning of skid-mounted, factory-assembled piping systems shall be in accordance with the equipment supplier’s printed instructions, and only under the direct supervision of a representative of the equipment supplier.

D. Skid-mounted equipment which has been factory cleaned, such as ozone generators, destruction units, LOX tanks, vaporizers, oxygen filters, and skid-mounted pressure reducing stations shall be bypassed during pressure testing or startup until all piping has been cleaned.

E. Stainless steel and copper piping: 1. Small lines and fittings shall be flushed with detergent solution following cutting

to size, preparing ends for welding, and fabrication, where possible. 2. The interior surface of larger lines and fittings shall be swabbed with a rag

moistened with detergent solution. 3. After rinsing as described in this Section, the pipe shall be purged until dry and

odor-free with dry oil-free air or nitrogen. 4. After cleaning, the pipe shall be inspected and, unless it is installed

immediately, shall be protected as specified in this Section.

F. Valves: 1. All valves shall be cleaned at the factory before delivery to the project site. 2. However, if the valves require re-cleaning in the field, the cleaning shall

proceed as follows. 3. Butterfly and ball valves:

a. The valve shall be disassembled and each part cleaned by immersion or by swabbing with detergent, rinsed, as specified, and dried with dry oil-free air or nitrogen.

b. They shall be inspected and reassembled using virgin Teflon packing, new gaskets, and approved lubricant.

c. The recleaned valve shall be installed immediately or shall be packaged and tagged.

4. All other valves: a. Recleaning in the field shall be in accordance with the valve

manufacturer's printed instructions. b. If recalibration is required, it shall be done by the valve manufacturer's

representative. c. After cleaning, the valve shall be inspected and shall be installed

immediately, or shall be packaged and tagged.

G. Miscellaneous in-line components: 1. In-line components such as strainers, orifice plates, etc., shall be cleaned, if

required, by swabbing with detergent solution. 2. Expansion joints shall be cleaned by scrubbing and flushing and shall be

inspected before installation.

H. Instrumentation tubing: 1. Stainless steel tubing shall be flushed with detergent solution, rinsed as

specified in this Section, and blown dry with clean oil-free air or nitrogen.


2. Ends of tubing shall be capped until used. 3. Before use, tubing shall be tested for cleanliness.

3.08 TRAINING COURSE

A. Before beginning the assembly of piping or installation of factory cleaned items, a representative of the Provider shall visit the site and conduct a training course for Contractor’s personnel, and Owner’s personnel at the Owner’s option, in proper techniques of cleaning the equipment and piping used in oxygen and ozone service: 1. The duration of the training course shall be at least 4 hours. This training shall

be in addition to the training requirements of Section 46_31_52. 2. Scheduling of the course shall be coordinated by Contractor. 3. Notify participants at least 10 days in advance.

END OF SECTION


SECTION 46_31_59

OZONE SYSTEM TESTING

PART 1 GENERAL

1.01 SUMMARY

A. Section Includes: 1. Factory testing and ozone system performance testing requirements for the

ozone generators and their power supplies and selected ancillary equipment involved in the generation of ozone.

2. Work in this section shall be performed by the Ozone System Supplier and coordinated by the Contractor.

B. Related Sections: 1. The Contract Documents are complementary; what is called for by one is as

binding as if called for by all. 2. It is the Contractor’s responsibility for scheduling and coordinating the Work or

subcontractors, suppliers, and other individuals or entities performing or furnishing any of the Contractor’s Work.

3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents: a. Section 01_75_17 - Commissioning and Process Start-up. b. Section 46_05_94 - Mechanical Equipment Testing. c. Section 46_31_52 - Ozone Systems: General. d. Section 46_31_55 - Ozone Generating Equipment.

1.02 REFERENCES

A. Standard Methods for the Examination of Water and Wastewater, Current Edition.

B. Ozone Science and Engineering (International Ozone Association): 1. Volume 18, Guideline for Measurement of Ozone Concentration in the Process

Gas from an Ozone Generator, Rakness, et al., 1996.

1.03 DEFINITIONS

A. Average Rate of Energy Consumption (AVE-KW): The average value of the rate of energy consumption over a specific period of operation, measured in kilowatts (kW).

B. Time-Factored Specific Energy Consumption: The amount of energy consumed per pound of ozone produced (kWh/pound) at a specific production level, multiplied by the percentage which the generator would operate at the given production level.

C. Ozone Generator Specific Energy Consumption (SEC): The amount of energy consumed per pound of ozone produced (kWh/pound) during operation under a specific set of operating conditions.


1.04 PERFORMANCE TESTING GENERAL CRITERIA

A. Ozone System Performance Testing General Protocol: The Ozone System Supplier shall conduct the following performance tests on each ozone generator: 1. Energy Consumption Efficiency (ECE) Test: Designed to evaluate the energy

required to produce specific amounts of ozone by each generator at various levels of generator operation and at specified cooling water temperatures.

2. Ozone Generator Design Production Capacity (DPC) Test: Designed to evaluate the design production capacity of each ozone generator and power supply and the associated energy consumed, under specified cooling water conditions.

B. Ozone System Performance Testing Period: 1. All ozone system performance testing shall be completed within ninety days of

completion of Process Operational Period as defined in Section 01_75_17. 2. All testing, including the pretesting procedures, shall be started and completed

on weekdays, exclusive of Owner Holidays, within the hours of 7:00 am and 6:00 pm.

C. Ozone System Performance Testing Equipment and Instrumentation: Use equipment and instrumentation incorporated into the ozone system during the performance testing.

D. Ozone System Supplier Responsibility: Unless otherwise specified, the Ozone System Supplier shall be responsible for all aspects of the ozone system performance testing, modifications and retesting if required, as specified herein, including, but not limited to the following: 1. Develop performance test protocol and submit protocol to Engineer at least 30

days prior to testing period. 2. Provide independent calibration for all instrumentation associated with the

performance testing as specified herein. 3. Provide personnel to operate all elements of the ozone system as defined in

Section 46_31_52 during the performance testing, including the pretesting, and to conduct all aspects of the performance testing including the following: a. Provide personnel to make pretest adjustments to the ozone system and

to set up each performance test. b. Collect and label all samples for laboratory analysis. c. Perform all required laboratory analyses. d. Make necessary field adjustments. e. Collect and record all data necessary to document system performance. f. Prepare reports with testing results.

4. Provide, install, and maintain any temporary monitoring equipment and meters required to complete the performance testing.

5. Provide personnel to perform any system modifications and operate the ozone system during any retesting.

E. Owner Responsibility: 1. Provide electricity, liquid oxygen, and personnel to operate the plant, including

the ozone systems, during the pretest and the performance test periods. 2. At the discretion of the Owner or Engineer, provide additional services of a

consultant or an independent testing laboratory to observe test procedures, test results, and perform laboratory analyses.


1.05 SUBMITTALS

A. Qualifications Documentation: At least 30 days prior to the start of the ozone system performance testing, the Ozone System Supplier shall submit documentation specified under Article 1.06.

B. Ozone System Performance Testing Protocol: At least 30 days prior to the start of the performance testing, the Ozone System Supplier shall submit a complete description of the planned performance testing, including a minimum of the following information: 1. Approximate date of each performance test. 2. A detailed protocol for each performance test. 3. Approximate duration of pretest and performance test periods. 4. A description of any field adjustments that may be made by the Ozone System

Supplier.

C. Calibration Data: At least seven days prior to the start of the ozone system performance testing, the Ozone System Supplier shall submit documentation to show that all instrumentation associated with the performance testing has been calibrated in accordance with Paragraph 3.01.B.

D. Ozone System Performance Testing Results Report: Within 30 days of the successful completion of the performance testing, the Ozone System Supplier shall submit five copies of a report to document the performance testing. At the minimum, the report shall include the following: 1. A complete description of the performance testing procedures with emphasis

on any deviations from the proposed protocol previously submitted. 2. Complete results of the performance testing including all laboratory analysis

data. 3. A description of any failures, the required adjustments and the results of the

retesting. 4. A certification section verifying the authenticity of the report with the signature

of the representative of the Ozone System Supplier.


A. Ozone System Supplier Representative Qualifications: In accordance with the RFQ.

B. Third Party Agents or Consultants: Any outside agency or consultant participating in the performance testing, including the testing laboratory and the calibration consultant, shall be approved to practice and meet minimum industry standards.

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION


A. Perform factory functional testing on the following ozone system components as described herein: 1. Ozone generators coupled with their dedicated power supplies.


2. Closed-loop cooling water pumps. 3. Nitrogen generator. 4. Off-gas destruct units.

B. Factory test the ozone generators as follows: 1. Hydrostatically test both the gas and water sides of the ozone generator shell.

Test at a minimum pressure of 1.5 times the maximum allowable operating pressure of the shell for a minimum of one hour. Repair any leaks and retest the generator shell.

2. The equipment shall be given the manufacturers’ standard quality control inspections and tests to ensure the quality of materials used in the manufacture of the equipment and workmanship conform to the specified requirements. Factory-certified one-hundred-percent testing (not sample testing) of all components shall be conducted.

3. Factory test each PSU and its controls for proper functional performance, operation, and wiring. Tests may be performed with a simulated ozone generator load. Verify proper operation of all controls, instrumentation, and protective functions. Operate the controller through its specified range at the rated power supply load for at least four hours. In addition, make a heat run, operating the equipment at full load to verify that it is operating within the component limits. Provide certified copies of each factory test report.

4. Each ozone generator and PSU shall be factory tested to determine power consumption and ozone production characteristics. The Owner and/or Engineer may, at the option of the Owner, witness the factory tests at the Owner’s expense. The OSS shall notify the Owner at least 30 days before each test is to occur. The ozone system equipment shall be factory tested in accordance with the following procedures: a. A proposed factory test report, including a test data sheet and ozone

production computations, shall be submitted to the Engineer for approval at least 30 days prior to factory testing of the equipment.

b. Test each ozone generator and associated PSU under actual operating conditions, to determine that their operation is satisfactory and the power consumption and ozone production characteristics are completely developed. Two types of tests shall be conducted. Three consecutive readings at each power loading or production level shall be taken and recorded at 15-minute intervals after steady-state ozone production conditions have been attained. 1) Test each generator and associated PSU at minimum and maximum

oxygen flow rates at power loadings of 20, 60, and 100 percent of the rated power setting or at maximum power loading without exceeding the design maximum ozone product gas concentration.

2) Test each generator and associated PSU while maintaining 10 percent constant concentration by varying oxygen flow as required to produce ozone at 20, 60, and 100 percent of the rated power setting.

c. For each generator, the minimum test data recorded shall include the time, oxygen flow rate, inlet oxygen pressure and temperature, ozone-in-oxygen concentration, ozone production, power consumption, power factor, cooling water flow rate, and cooling water inlet and outlet high temperatures. The ozone concentration shall be monitored using the installed high concentration ozone-in-oxygen analyzers. Analyzer accuracy shall be confirmed using the “Iodometric Method for the


Determination of Ozone in a Process Gas,” as developed and approved by the International Ozone Association.

d. Additionally, each ozone generator and associated PSU shall be operated at its rated power setting at an ozone-in-oxygen concentration of 12 percent continuously for 4 hours. Readings of the test data listed above shall be taken every hour for the duration of the 4-hour period.

e. The failure of any ozone generator and associated PSU to produce the minimum and maximum ozone production rates or to meet the power and cooling water efficiency requirements, as specified, will be grounds for failing the factory test. If a failed factory test occurs, the OSS may reschedule another identical factory test within a reasonable time, but no longer than 8 weeks after the first/previous factory test, unless extended by the Owner and/or Engineer, after the first/previous failed factory test. The OSS shall be responsible for all labor and expense costs associated with the Engineer’s travel to, during and from any subsequent factory test(s) after the first. Costs will be invoiced by the Engineer directly to the OSS. Labor costs will be invoiced at the normal billing rates of the Engineer. Expenses will be invoiced at the Per Diem rates listed in the Federal Travel Regulation (FTR).

f. If the ozone system equipment does not satisfy the specified performance criteria based on factory testing results, the OSS shall modify or replace the tested equipment with units that meet the specified criteria at no additional cost to the Owner.

C. Factory test the nitrogen generator skid and off-gas destruct units as follows: 1. Test in accordance with Level 2 General Equipment Performance Test as

specified in Section 46_05_94:

D. Factory testing of the closed loop cooling water pumps is acceptable at the point of manufacture.

E. Power Quality Testing 1. Monitor the power supply power quality over the course of the ozone

production testing with a power quality data logger and analyzer. 2. Submit a power quality harmonic distortion report summarizing the voltage and

current distortion and power quality throughout the testing procedure. 3. Submit a separate report for each PSU. 4. Report shall compare factory test operating data with the harmonic distortion

values provided for each PSU during the submittal process specified under Section 46_31_55. Report shall compare operating and submitted data highlighting any discrepancies between the two and providing an explanation for any such deviations.

F. Factory testing protocol: 1. Factory tests may be witnessed by Owner and Owner’s Representative. 2. Schedule the factory tests for all ozone system equipment to occur over a

maximum period of five consecutive days. 3. Notify the Engineer a minimum of 30 days prior to date of factory testing or

retesting. 4. Provide a certified factory test report for each tested ozone system component

with all collected data attached.


5. Upon conclusion of factory testing, seal the ozone generators and off-gas destruct units and prepare for shipping with a nitrogen purge as specified in Section 46_31_58.

6. Prepare and submit certified results of all testing.

3.02 GENERAL OZONE SYSTEM PERFORMANCE TESTING REQUIREMENTS

A. Ozone System Performance Tests: Conduct the following performance tests, as specified herein, on each ozone generator and power supply at the plant site: 1. Energy Consumption Efficiency Test. 2. Ozone Generator Design Production Capacity Test. 3. Harmonic Testing. 4. Power Factor Testing.

B. Calibration of Testing Equipment: 1. Approximately 30 days prior to the initiation of any performance test, the

Ozone System Supplier shall commission an independent contractor to calibrate all instrumentation associated with the performance testing with the exception of the high concentration ozone analyzers.

2. Adjust the high concentration ozone analyzer to reflect actual sample cell temperature and pressure if required. Verify the accuracy of each high concentration ozone analyzer by the procedure given as Method B - Instrument (UV) Method Verified by Wet-Chemistry as described by Rakness, et al.

3. If retesting of any generator or an entire ozone system is required, the Ozone System Supplier shall have the independent contractor recalibrate all instruments associated with the retest if they have not been calibrated within the previous 30 days and submit that information to the Engineer prior to retesting.

C. Cooling Systems: 1. The ozone generators shall only be cooled with the designed cooling system

with ultimate rejection of heat to nonpotable water from the plant finished water system, with a range of quality as specified in Section 46_31_52.

2. Power supplies shall only be cooled with systems provided and installed as permanent components of the ozone system.

D. Energy Consumption Measurement: 1. Measure rate of energy consumption, in kilowatts (kW), for each generator at

the generator power meter located in the ozone system motor control center. Average the rate of energy consumption over each specific testing period to determine the AVE-KW used in the calculations.

E. Ozone Production Measurement: Base the ozone production calculation on the mass gas flow rate and gas phase ozone concentration in accordance with the following: 1. Measure gas flow at the orifice plate flow meters located on the GOX piping

immediately upstream of each ozone generator. Adjust for actual pressure and temperature conditions.

2. Measure gas phase ozone concentration by the procedure given as Method B-Instrument (UV) Method Verified by Wet-Chemistry as described by Rakness, et al.


F. Product Gas Concentration: The ozone product gas concentration shall be within the range of 10.0 percent to 10.5 percent during the ECE test. The ozone product gas concentration shall be within the range of the design value to +0.5 percent of the design value during each DPC test for each ozone production requirement defined in Section 46_31_55.

G. Flow Rate Deviation: The calculated ozone mass flow rate for a specific energy consumption test shall be within two percent of the desired production level.

H. Data Collection: 1. Direct readings from the instruments shall be used in the calculations to

determine conformance with the Specifications. 2. Readings shall be obtained from digital trends from the ozone system control

system or by manually recording the values directly from the instrument. 3. Record (and round if necessary) to the level of accuracy of the instrument

before any calculations. 4. Collect manual instrument readings at 30-minute intervals during the

performance tests. Average the data collected during each test before the calculations.

5. There shall be no adjustment to readings or calculations due to random or systematic instrumentation error or accuracy limitations.

I. Equipment Operation During Ozone System Performance Testing: 1. Operate all ozone equipment, as defined in Section 46_31_52, as it was

designed to operate in the automatic mode. 2. Operate ozone injection system under normal hydraulic conditions. Operate all

injectors and ozone contactors under normal hydraulic conditions.

J. Equipment Modifications: The Ozone System Supplier shall be responsible for all ozone system modifications in accordance with the following: 1. If any aspect of the performance testing is not satisfied, modify equipment as

required so that the entire ozone system conforms with the Specifications at the expense of the Ozone System Supplier.

2. All modifications shall be reviewed and accepted by the Engineer and shall conform with the Drawings and Specifications.

3. Design all modifications to be permanently installed for continuous service. 4. Maintain, as much as practical, ozone system operation prior to and during the

modifications. Provide temporary facilities and make temporary modifications as necessary to keep the ozone system in operation prior to and during the modifications.

5. The Ozone System Supplier shall document all modifications and amend the operations and maintenance manuals and record drawings to reflect the modifications.

K. Retesting: The Ozone System Supplier shall be responsible for all retesting in accordance with the following: 1. Reconduct the performance testing in the event of any system fails to meet the

testing protocol or the performance criteria specified herein, in accordance with the following: a. If a generator fails the ECE test and has not yet passed the DPC test,

modify the generator as required and reconduct the ECE test on that generator.


b. If a generator fails the ECE test and has already passed the DPC test, modify the generator as required and reconduct the ECE test on that generator and the DPC on that system with that generator in service.

c. If an ozone system fails the DPC test, modify the system as required and reconduct all performance tests specified herein.

d. If a process parameter (i.e., cooling water temperature or flow rate or ozone mass flow rate) varies from the range specified herein, immediately reconduct only the specific performance testing unless significant modifications, as judged by the Engineer, are required.

2. Complete all retesting within six months after completion of the start of the performance testing.

3. Recalibrate all instrumentation associated with the retest in accordance with specified requirements for testing equipment if the instrumentation had not be calibrated within the 30 days immediately prior to the retest.

4. Reimburse the Owner for all Owner’s labor costs associated with the retesting, including engineering fees and administration costs.

3.03 ENERGY CONSUMPTION EFFICIENCY TESTS

A. Conduct the ECE tests on each ozone generator and power supply.

B. Cooling Water Temperature: Conduct the ECE tests when the raw water supply temperature is 80 degrees Fahrenheit plus or minus two degrees Fahrenheit or adjust the AVE-KW values in accordance with the efficiency versus cooling water temperature curves for the new ozone generators as submitted by the Ozone System Supplier.

C. Test Production Capacities: Test each new generator at the following generator operating capacities at the product gas concentration specified in Paragraph 3.02,F, herein: 1. 1700 pounds ozone per day. 2. 730 pounds ozone per day. 3. 200 pounds ozone per day.

3.04 OZONE GENERATOR DESIGN PRODUCTION CAPACITY TESTS

A. Conduct the DPC tests on each ozone generator and power supply.

B. Operate each ozone generator at the Ozone Generator Design Production Capacity corresponding to an ozone product gas concentration as specified in Section 46_31_55, during the DPC test.

3.05 ENERGY CONSUMPTION EFFICIENCY TESTING PROCEDURE

A. Conduct the following ECE testing procedure on each new ozone generator at 10 percent ozone concentration: 1. Immediately prior to the ECE testing, operate the generator at an operating

level greater than 1700 pounds ozone per day for a minimum of two hours. 2. Reduce the operating level of the generator to a stable production level of

1700 pounds ozone per day. 3. Operate the generator at the 1700 pound ozone per day operating level for two

hours. Record the rate of energy consumption, in kW, during the test as specified herein.


4. Reduce the operating level of the generator to a stable operating level of 730 pounds per day.

5. Operate the generator at the 730 pound ozone per day operating level for two hours. Record the rate of energy consumption, in kW, during the test as specified herein.

6. Reduce the operating level of the generator to a stable operating level of 200 pounds per day.

7. Operate the generators at the 200 pound ozone per day operating level for two hours. Record the rate of energy consumption, in kW, during the test as specified herein.

B. Calculations: Calculate the ozone generator actual SEC (kW-h/pound ozone) for these operating conditions by summing the time-factored specific energy consumption at each of the operating levels according the following equation:

(AVE-KW1700 ppd kW/(1700 x 0.0417) x 0.10 + (AVE-KW730 ppd kW/(730 x 0.0417) x 0.60 + (AVE-KW200 ppd kW/(200 x 0.0417) x 0.30 = _______________________________________

Actual specific energy consumption, SECACT for these operating conditions.

Average the SECACT obtained for each ozone generator of each plant and utilize in the calculations for each plant of Section 46_31_52.

3.06 OZONE GENERATOR DESIGN PRODUCTION CAPACITY TESTING PROTOCOL

A. Conduct the following DPC testing protocol on each ozone generator: 1. Immediately prior to each DPC test, operate the ozone generator to be tested

at the Ozone Generator Design Production Capacity and its corresponding ozone product gas concentration and under design operating conditions, as specified in Sections 46_31_52 and 46_31_55, for a minimum of six hours.

2. Following the pretest period, operate the ozone generator being tested at the Ozone Generator Design Production Capacity and corresponding ozone product gas concentration and under design operating conditions, as specified in Sections 46_31_52 and 46_31_55, for a minimum of two hours. Record mass flow rate of ozone being produced, in lb/day, and the rate of energy consumption, in kW, during the test as specified herein.

3. Calculate the actual specific energy consumption, SECACT, under design production conditions by the following equation:

SECACT = kW x 24 Ozone Generator Design Production Capacity

3.07 HARMONIC FIELD TESTS

A. Perform field harmonic monitoring over the course of the production testing to verify the simulation power quality study scenarios submitted under Section 46_31_55. Harmonic testing shall be performed at each pounds per day and concentration scenarios specified.


B. Monitoring shall occur throughout the test period at: 1. Each PSU. 2. 480V secondary of both serving substations. 3. 12 kV primary switchgear serving both substation.

C. Furnish suitable temporary power monitoring data loggers with all necessary CTs, PTs, and other ancillary devices necessary for voltage and current distortion monitoring. Record voltage and current power quality data throughout the production testing period. 1. PT's shall configured as 3-phase, 4-wire. 2. The Nexus power meters installed on each PSU, may be used for voltage and

current distortion monitoring provided the instrument transformers meet the specified accuracy requirements.

D. Submit a power quality harmonic distortion report summarizing the voltage and current distortion and power quality throughout the testing procedure. 1. Submit a separate report for:

a. Each PSU (harmonic spectrum data). b. 480V secondary of both serving substations. c. 12 kV primary switchgear feeder serving both substation.

2. Submit instantaneous harmonic snapshots up to the 50th harmonic. 3. Submit current and voltage maximum and average distortion values for each

harmonic order up the 50th over the study period. Include date and time of the maximum distortion event(s).

4. Submit with voltage total harmonic distortion and current total demand distortion, maximum and average over the study period. Include date and time of the maximum distortion event(s).

5. Submit power factor results at each location over the course of the testing. 6. Report shall compare factory test operating data with the harmonic distortion

values provided for each PSU during the submittal process specified under Section 46_31_55. Report shall compare operating and submitted data highlighting any discrepancies between the two and providing an explanation for any such deviations.

E. Review test results and submit written reports describing the nature of the tests, operating conditions, single line diagrams showing installed location of the meter, and summary test results for maximum and average, individual and total harmonic distortion. All results shall be submitted for both current and voltage and indicate conformance or non-conformance with the specified harmonic distortion limits.

F. Submit raw field data in electronic format as both XLS or CSV open format file and the native instrument data files i.e. Fluke data recorder, Nexus 1272 files, for review by the Engineer.

G. Test reports shall be signed by the electrician or technician performing the test.

H. Should the results indicate that the measured harmonics exceed the specified maximum distortion values submit complete design solution for harmonic mitigation to be applied at each location by the System Supplier.

END OF SECTION

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