SECTION 01324 PROGRESS SCHEDULES AND REPORTS PART …

150141 – 2017 Upgrades and Rehabilitation 01324-1 Progress Schedules and Reports James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 01324

PROGRESS SCHEDULES AND REPORTS

PART 1–GENERAL

1.01 SUMMARY

A. Section includes: Preparation, submittal, and maintenance of computerized progress schedule and reports, Contract Time adjustments, and payment requests, including the following: 1. Preliminary Schedule. 2. Baseline Schedule. 3. Monthly Schedule Updates. 4. Weekly Summary Schedule. 5. Schedule of Submittals. 6. Manpower Schedule. 7. Equipment Schedule. 8. Commissioning and Process Start-up Schedule. 9. As-built Schedule.

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

called for by all. 2. It is the Contractor’s responsibility for scheduling and coordinating the Work of

subcontractors, suppliers, and other individuals or entities performing or furnishing any of Contractor’s Work.

3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the Contractor to see that the completed Work complies accurately with the Contract Documents. a. Division 00 - General Conditions. b. Division 00 – Supplementary Conditions c. Section 01010 – Summary of Work d. Section 01200 - Price and Payment Procedures. e. Section 01292 - Schedule of Values. f. Section 01300 - Submittals. g. Section 01660 – Equipment and System Functional and Performance Testing. h. Section 01664 – Training.

1.02 SCHEDULER

A. Designate, in writing and within 5 calendar days after Notice of Award, person responsible for preparation, maintenance, updating, and revision of all schedules.

B. Qualifications of scheduler: 1. Authority to act on behalf of Contractor.


2. 8 years verifiable experience in preparation of complex construction schedules for projects of similar value, size, and complexity.

3. Knowledge of critical path method (CPM) scheduling utilizing Primavera P6 Professional software.

C. References: Submit written reference of 3 project Owners who have personal experience with this scheduler on previous projects. Identify name, address, telephone number, project name, and cost.

D. Owner reserves the right to disapprove scheduler when submitted by Contractor if not qualified. Owner reserves the right to remove scheduler from the project if found to be incompetent.

1.03 SCHEDULING FORMAT AND SOFTWARE

A. Schedule format: Utilize CPM format.

B. Prepare computerized schedule utilizing Primavera P6 Professional, or ASTA Powerproject, most current version.

1.04 PRECONSTRUCTION SCHEDULING MEETING

A. Engineer will conduct Preconstruction Scheduling Meeting with Contractor’s Project Manager, General Superintendent, and scheduler within 7 calendar days after Notice to Proceed. This meeting is separate from the Preconstruction Conference Meeting and is intended to cover schedule issues exclusively.

B. At the meeting, review scheduling requirements. These include schedule preparation, reporting requirements, Work Breakdown Structure (WBS), cost loading (Schedule of Values), labor and equipment loading, updates, revisions, and schedule delay analysis. Present schedule methodology, planned sequence of operations, cost loading (Schedule of Values), resource loading methodology, and proposed activity coding structure.

C. Coding structure: 1. Submit proposed coding structure, identifying the code fields and the associated code

values it intends to use in the project schedule. 2. A minimum, include code fields for Project Segment or Phase, Area of Work, Type of

Work, Submittal/Procurement/Construction and Responsibility/Subcontractor. Refer to NETWORK DETAILS AND GRAPHICAL OUTPUT for listing of activity categories to be included in the schedule.

D. Naming convention: Name schedule files with the year, month, and day of the data date, revision identifier, and a description of the schedule. 1. Example 1: 2017_07_30 rev 1 draft baseline schedule.xer. 2. Example 2: 2017_09_30 rev 2 sep final update.xer.

1.05 SCHEDULE PREPARATION

A. Preparation and submittal of Progress Schedule represents Contractor's intention to execute the Work within specified time and constraints. Failure to conform to requirement may result


in termination for cause as defined in Section 00700, under Article 15, Suspension of Work and Termination.

B. Contractor's bid covers all costs associated with the execution of the Work in accordance with the Progress Schedule.

C. During preparation of the preliminary Progress Schedule, Engineer will facilitate Contractor's efforts by being available to answer questions regarding sequencing issues, scheduling constraints, interface points, and dependency relationships.

D. Prepare schedule utilizing Precedence Diagramming Method (PDM).

E. Prepare schedule utilizing activity durations in terms of working days. Do not exceed 15 working day duration on activities except concrete curing, submittal review, and equipment fabrication and deliveries. Where duration of continuous work exceeds 15 working days, subdivide activities by location, stationing, or other sub-element of the Work. Coordinate holidays to be observed with the Owner and incorporate them into the schedule as non-working days.

F. Failure to include an activity required for execution of the Work does not excuse Contractor from completing the Work and portions thereof within specified times and at price specified in Contract. Contract requirements are not waived by failure of Contractor to include required schedule constraints, sequences, or milestones in schedule. Contract requirements are not waived by Owner’s acceptance of the schedule. In event of conflict between accepted schedule and Contract requirements, terms of Contract govern at all times, unless requirements are waived in writing by the Owner.

G. Reference schedule to working days with Notice to Proceed as Day "1".

H. Baseline Schedule and Project Completion: Should Contractor submit a Baseline Schedule showing project completion more than 20 working days prior to Contract completion date, Owner may issue Change Order, at no cost to Owner, revising time of performance of Work and Contract completion date to match Contractor’s schedule completion date. Adjust accordingly any Contract milestone dates.

I. Contract float is for the mutual benefit of both Owner and Contractor. Changes to the project that can be accomplished within this available period of float may be made by Owner without extending the Contract Time, by utilizing float. Time extensions will not be granted nor delay damages owed until Work extends beyond currently accepted Contract completion date. Likewise, Contractor may utilize float to offset delays other than delays caused by Owner. Mutual use of float can continue until all available float shown by schedule has been utilized by either Owner or Contractor, or both. At that time, extensions of the Contract Time will be granted by Owner for valid Owner-caused or third party-caused delays which affect the planned completion date and which have been properly documented and demonstrated by Contractor.

J. Resource loading and leveling: Input labor and equipment data on each schedule activity. Manpower data consist of the man-hours estimated to perform each task, categorized by trade. Equipment data consist of equipment hours estimated to perform each task, categorized by piece of equipment. Optimize and level manpower and equipment requirements. Resource leveling reflects a reasonable plan for accomplishing Work. Individual activities may be


sequenced within limits of available float. Keep to a minimum critical or near critical paths resulting from use of labor or equipment restraints. Near critical path identified as path with 15 or less working days of float.

K. Schedule logic: Assembled to show order in which Contractor proposes to carry out Work, indicate restrictions of access, availability of Work areas, and availability and use of manpower, materials, and equipment. Form basis for assembly of schedule logic on the following criteria: 1. Which activities must be completed before subsequent activities can be started? 2. Which activities can be performed concurrently? 3. Which activities must be started immediately following completed activities? 4. What major facility, equipment, or manpower restrictions are required for sequencing

these activities?

L. Non-sequestering of float: Pursuant to float sharing requirements of Contract, schedule submittals can be rejected for, use of float suppression techniques such as preferential sequencing or logic, special lead or lag logic restraints, extended activity durations or imposed dates.

M. Major subcontractor, parallel prime contractor sign off: Provide written confirmation of concurrence from all major subcontractors and independent prime contractors on site with all schedule submittals. Term “major subcontractor” as used in this Section means any subcontractor, at any tier, with a subcontract worth 5 percent or more of the total cost of the Work.

N. Imposed dates, hidden logic prohibited: Do not use imposed dates or hidden logic in preparation of schedule.

O. Interim milestone dates, operational constraints: In event there are interim milestone dates and/or operational constraints set forth in Contract, show them on schedule. Do not use Zero Total Float constraint or Mandatory Finish Date on such Contract requirements.

P. Schedule windows for Owner-furnished, Contractor-installed equipment or materials: Immediately after Award of Contract, obtain from Engineer anticipated delivery dates of Owner furnished equipment or materials. Show these dates in the schedule in same manner indicated by Engineer.

Q. Cost loading: All schedules: 1. Only on-site construction activities. 2. The sum total of all cost loaded activities equal to the current value of the Contract,

including change orders, at all times. 3. Owner acceptance of the Baseline Schedule creates the Schedule of Values required as

specified in Section 01292. 4. Provide updated Schedule of Values as the monthly Payment Application as specified in

Section 01200. 5. Payments will not be made until updated Schedule of Values is accepted.


1.06 NETWORK DETAILS AND GRAPHICAL OUTPUT

A. Submit preliminary and baseline schedule in accordance with the Conditions of the Contract as modified by this Section 01324.

B. Submit, on a monthly basis, updated schedules as specified with each Application for Payment. Submit final schedule update as specified.

C. Submit revised schedules and time impact analyses as specified.

D. Distribute copies of reviewed schedules to Project site file, subcontractors, suppliers, and other concerned parties.

E. Instruct recipients to promptly report, in writing, problems anticipated by projections indicated in schedules.

F. Produce a clear, legible, and accurate calendar based, time scaled, graphical, network diagram. Group activities related to the same physical areas of the Work. Produce the network diagram based upon the early start of all activities.

G. Include for each activity, the description, activity number, estimated duration in working days, total float, and all activity relationship lines.

H. Illustrate order and interdependence of activities and sequence in which Work is planned to be accomplished. Incorporate the basic concept of the precedence diagram network method to show how the start of 1 activity is dependent upon the start or completion of preceding activities and its completion restricts the start of following activities.

I. Indicate the critical path for the project.

J. Delineate the specified contract duration and identify the planned completion of the Work as a milestone. Show the time period between the planned and Contract completion dates, if any, as an activity identified as project float unless a Change Order is issued to officially change the Contract completion date.

K. Identify system shutdown dates, system tie-in dates, specified interim completion or milestone dates and contract completion date as milestones.

L. Include, in addition to construction activities: 1. Any activity by the Owner or the Engineer that may affect progress or required

completion dates. 2. Equipment and long-lead material deliveries over 8 weeks. 3. Approvals required by regulatory agencies or other third parties.

M. Produce network diagram on 22-inch by 34-inch sheets with grid coordinate system on the border of all sheets utilizing alpha and numeric designations.

N. Identify the execution of the following: 1. Mobilization.


2. All required submittals and submittal review times showing 30 calendar day duration for such activities and equal amount of time for re-submittal reviews.

3. Equipment and materials procurement/fabrication/delivery. 4. Excavation. 5. Backfill and compaction. 6. Dewatering. 7. Grading, subbase, base, paving, and curb and gutters. 8. Fencing and landscaping. 9. Concrete, including installation of forms and reinforcement, placement of concrete,

curing, stripping, finishing, and patching. 10. Tests for leakage of concrete structures intended to hold water. 11. Masonry. 12. Metal fastenings, framing, structures, and fabrications. 13. Wood structures, finish carpentry, architectural woodwork, and plastic fabrications. 14. Waterproofing and dampproofing, insulation, roofing and flashing, and sealants. 15. Doors and windows, including hardware and glazing. 16. Finishes including coating and painting, flooring, ceiling, and wall covering. 17. Building specialties including furnishings, laboratory equipment, and toilet and bath

accessories. 18. Process equipment, including identification of ordering lead-time, factory testing, and

installation. 19. Pumps and drives, including identification of ordering lead time, factory testing, and

installation. 20. Conveying equipment including hoists and cranes, conveyor systems, and materials

handling equipment, including identification of ordering lead-time and installation. 21. Other mechanical equipment including fans and heating, ventilating, and air conditioning

equipment. 22. Trenching, pipe laying, and trench backfill and compaction. 23. Piping, fittings and appurtenances, including identification of ordering and fabrication

lead time, layout, installation and testing. 24. Valves, gates, and operators, including identification of order lead-time, installation, and

testing. 25. Plumbing specialties. 26. Electric transmission, service, and distribution equipment, including identification of

ordering lead-time, and factory testing. 27. Other electrical work including lighting, heating and cooling, and special systems,

including identification of ordering lead-time. 28. Instrumentation and controls, including identification of ordering lead-time. 29. Preliminary testing of equipment, instrumentation, and controls. 30. Commissioning Phase:

a. Source Testing. b. Owner Training. c. Installation Testing.


d. Functional Testing. e. Clean Water Facility Testing.

31. Process Start-up Phase: a. Process Start-up. b. Process Operational Period. c. Instrumentation and Controls Performance Testing.

32. Substantial completion. 33. Punch list work. 34. Demobilization.

1.07 SUBMITTAL OF PROGRESS SCHEDULES

A. Submit preliminary and baseline schedule.

B. Submit, on a monthly basis, updated schedules as specified.

C. Submit final schedule update as specified.

D. Submit revised schedules and time impact analyses as specified.

E. Submit schedules in the media and number of copies as follows: 1. Submit electronic schedule file in native format and in PDF format.

1.08 PRELIMINARY SCHEDULE

A. Submit Preliminary Schedule within 14 calendar days after Notice to Proceed. Include a detailed plan of operations for first 90 calendar days of Work after receipt of Notice to Proceed.

B. Meet with Engineer within 7 calendar days after receipt of Preliminary Schedule to review and make necessary adjustments. Submit revised preliminary schedule within 5 calendar days after meeting.

C. Submit schedule of manpower and costs for all activities with revised Preliminary Schedule. Provide realistic and level manpower and costs so as not to have unusual manpower requirements.

D. Schedule of costs: 1. Schedule of Values as specified in Section 01292 for first 90 calendar days of Work. 2. Submittal and acceptance of Preliminary Schedule is condition precedent to making of

progress payments as specified in Section 01200 and payments for mobilization costs otherwise provided for in the Contract.

3. Proceed with pay item Work after Preliminary Schedule and schedule of costs have been accepted by Owner.

E. Incorporate unchanged, the accepted Preliminary Schedule as first 90 calendar days of activity in Contractor’s Baseline Schedule.


F. Update Preliminary Schedule monthly during first 90 calendar days after Notice to Proceed. Use Preliminary Schedule as the payment application as specified in Section 01200.

1.09 BASELINE SCHEDULE

A. No more than 45 calendar days after Notice to Proceed, submit the Baseline Schedule for all Work of the project. Show sequence and interdependence of all activities required for complete performance of all Work, beginning with date of Notice to Proceed and concluding with date of final completion of Contract.

B. Acceptance of the Baseline Schedule by the Owner is a condition precedent to making payments as specified in Section 01200 after the first 90 calendar days after Notice to Proceed.

1.10 REVIEW AND ACCEPTANCE OF SCHEDULES

A. Engineer will review Baseline Schedule, Schedule Updates, Schedule Revisions and Time Impact Analyses to ascertain compliance with specified project constraints, compliance with milestone dates, reasonableness of durations and sequence, accurate inter-relationships, and completeness.

B. Engineer and Owner will issue written comments following completion of review of Baseline Schedule within 21 calendar days after receipt.

C. Written comments on review of Schedule Updates and Schedule Revisions and Time Impact Analyses will be returned to Contractor within 14 calendar days after receipt by Engineer.

D. Revise and resubmit schedule in accordance with Engineer’s comments within 7 calendar days after receipt of such comments, or request joint meeting to resolve objections.

E. If Engineer requests a meeting, the Contractor and all major subcontractors must participate in the meeting with Engineer. 1. Revise and resubmit schedule within 7 calendar days after meeting.

F. Use accepted schedule for planning, organizing, and directing the work and for reporting progress.

G. Engineer’s submittal review response: 1. When schedule reflects Owner's and Contractor's agreement of project approach and

sequence, schedule will be accepted by Owner. 2. Engineer’s submittal review response for schedule submittal will be “Receipt

Acknowledged – Filed for Record” including applicable comments. 3. Acceptance of the schedules by the Owner is for general conformance with the Contract

Documents and for Owner’s planning information, and does not relieve the Contractor of sole responsibility for planning, coordinating, and executing the Work within the contract completion dates. Omissions and errors in the accepted schedules shall not excuse performance less than that required by the Contract Documents. Acceptance by the Owner in no way constitutes an evaluation or validation of the Contractor’s plan, sequence or means, methods, and techniques of construction.


1.11 SCHEDULE UPDATES

A. Any update: 1. Prepare update using most recent accepted version of schedule including:

a. Actual start dates of activities that have been started. b. Actual finish dates of activities that have been completed. c. Percentage of completion of activities that have been started but not finished. d. Actual dates on which milestones were achieved. e. Update activities by inputting percent complete figures with actual dates. f. Use retained logic in preparing Schedule Updates. g. When necessary, input remaining durations for activities whose finish dates cannot

be calculated accurately with a percent complete figure only. h. Revisions to the schedule may be included that have been previously approved as

specified in this Section under Revisions to Schedule.

B. Monthly updates: 1. Submit written narrative report in conjunction with each Schedule Update including

descriptions of the following: a. Activities added to or deleted from the schedule are to adhere to cost and other

resource loading requirements. 1) Identify added activities in manner distinctly different from original activity

designations. b. Changes in sequence or estimated duration of activities. c. Current or anticipated problems and delays affecting progress, impact of these

problems and delays and measures taken to mitigate impact. d. Assumptions made and activities affected by incorporating change order work into

the schedule. 2. Submit updated schedule and materials specified under Submittal of Progress Schedules,

5 calendar days before the monthly schedule update meeting. 3. Since Monthly Schedule Update is the application for progress payment required as

specified in Section 01200, submittal and acceptance of the monthly Schedule Update is a condition precedent to the making of any progress payments.

C. Weekly progress meeting: 1. Update the schedule prior to weekly progress meeting.

a. Identify overall progress of each Major Item of Work in the Summary Schedule. b. If there are significant changes to the schedule, submit a written report at the weekly

progress meeting. 2. Should monthly Schedule Update show project completion earlier than current Contract

completion date, show early completion time as schedule activity, identified as “Project Float”.

3. Should monthly Schedule Update show project completion later than current Contract completion date, prepare and submit a Schedule Revision in accordance with the Revisions to Schedule.


1.12 REVISIONS TO SCHEDULE

A. Submit Revised Schedule within 5 days: 1. When delay in completion of any activity or group of activities indicates an overrun of

the Contract Time or milestone dates by 20 working days or 5 percent of the remaining duration, whichever is less.

2. When delays in submittals, deliveries, or work stoppages are encountered making necessary the replanning or rescheduling of activities.

3. When the schedule does not represent the actual progress of activities. 4. When any change to the sequence of activities, the completion date for major portions of

the work, or when changes occur which affect the critical path. 5. When Contract modification necessitates schedule revision, submit schedule analysis of

change order work with cost proposal.

B. Create a separate submittal for Schedule Revisions. 1. Comply with schedule updates as specified in this Section. 2. Do not submit with Schedule Updates.

C. Schedule Revisions will not be reflected in the schedule until after the revision is accepted by the Owner. 1. This includes Schedule Revisions submitted for the purpose of mitigating a Contractor-

caused project delay (Recovery Schedule).

1.13 PAYMENT REQUESTS AND CASH FLOW

A. After Baseline Schedule has been submitted and accepted by the Owner, submit on a monthly basis a tabular and graphic report showing anticipated earnings each month of the Contract period. This tabulation will be based on the summation of the cost-loaded activities each month. Submit an updated payment schedule each month showing actual earned amounts and anticipated remaining earnings.

B. Utilize cost loaded monthly Progress Schedule Updates as the applications for payment specified in Section 01200. List payment application in Excel format of all schedule activities showing cost and percentage completion during the current month for which payment is sought. Progress payments will not be made until monthly Progress Schedule Update is provided.

1.14 WEEKLY SCHEDULE

A. Submit to Engineer, at every weekly progress meeting, a 6-Week Schedule showing the activities completed during the previous week and the Contractor’s schedule of activities for following 5 weeks.

B. Use the logic and conform to the status of the current progress schedule when producing a Weekly Schedule in CPM schedule or a bar chart format. 1. In the event that the Weekly Schedule no longer conforms to the current schedule,

Contractor may be required to revise the schedule as specified in this Section.


C. The activity designations used in the Weekly Schedule must be consistent with those used in the Baseline Schedule and the monthly Schedule Updates.

D. Contractor and Engineer must agree on the format of the Weekly Schedule.

1.15 SCHEDULE OF VALUES

A. Requirements for Schedule of Values are specified in Section 01292.

B. Submit, in conjunction with the Progress Schedule, a Schedule of Values identifying costs of all on-site construction activities as generated by the cost loaded schedule. Equate the aggregate of these costs to the Lump Sum Contract Price.

1.16 ADJUSTMENT OF CONTRACT TIMES

A. Contract Time will be adjusted only for causes specified in Contract Documents. 1. Non-excusable delay: Non-excusable delays include actions or inactions of the

Contractor, or events for which the Contractor has assumed contractual responsibility (including actions or inactions of subcontractors, suppliers, or material manufacturers at any tier) that would independently delay the completion of the Work beyond the current Contract completion date). No time extensions will be granted for non-excusable delays.

2. Excusable delay: Events which are unforeseeable, outside the control of, and without the fault or negligence of either the Owner or the Contractor (or any party for whom either is responsible), which would independently delay the completion of the Work beyond the current Contract completion date. The Contractor is entitled to a time extension only. No other damages will be approved. a. (Addendum#1) Should additional project schedule be required due to the

adequately demonstrated fault of the centrifuge Manufacturer, the project schedule will be amended accordingly and without penalty to the Contractor in terms of liquidated damages. Any additional cost to the Contractor for such delay shall be borne by the Contractor/Manufacturer.

3. Compensable delay: Actions or inactions of the Owner, or events for which the Owner has assumed contractual responsibility, which would independently delay the completion of the Work beyond the current Contract completion date. The Contractor is entitled to a time extension and delay damages.

4. Concurrent delay: Concurrent delay is any combination of the above 3 types of delay occurring on the same calendar date. a. Exception to concurrent delay: Cases where the combination consists of 2 or more

instances of the same type of delay occurring on the same calendar date. When one cause of delay is Owner-caused or caused by an event which is beyond the control and without the fault or negligence of either the Owner or the Contractor and the other Contractor-caused, the Contractor is entitled only to a time extension and no delay damages.

B. If the Contractor believes that the Owner has impacted its work, such that the project completion date will be delayed, the Contractor must submit proof demonstrating the delay to the critical path. This proof, in the form of a Time Impact Analysis, may entitle the Contractor to an adjustment of Contract Time.

C. Time Impact Analysis:


1. Use the accepted schedule update that is current relative to the time frame of the delay event (change order, third party delay, or other Owner-caused delay). Represent the delay event in the schedule by: a. Inserting new activities associated with the delay event into the schedule. b. Revising activity logic. c. Revising activity durations.

2. If the project schedule’s critical path and completion date are impacted as a result of adding this delay event to the schedule, a time extension equal to the magnitude of the impact may be warranted.

3. The Time Impact Analysis submittal must include the following information: a. A fragment of the portion of the schedule affected by the delay event. b. A narrative explanation of the delay issue and how it impacted the schedule. c. A CD containing the schedule file used to perform the Time Impact Analysis.

D. When a delay to the project as a whole can be avoided by revising preferential sequencing or logic, and the Contractor chooses not to implement the revisions, the Contractor will be entitled to a time extension and no compensation for delay damages.

E. Indicate clearly that the Contractor has used, in full, all project float available for the work involved in the request, including any float that may exist between the Contractor's planned completion date and the Contract completion date. Utilize the latest version of the Schedule Update accepted at the time of the alleged delay, and all other relevant information, to determine the adjustment of the Contract Time.

F. Adjustment of the Contract Times will be granted only when the Contract Float has been fully utilized and only when the revised date of completion of the Work has been pushed beyond the Contract completion date. Adjustment of the Contract Times will be made only for the number of days that the planned completion of the work has been extended.

G. Actual delays in activities which do not affect the critical path work or which do not move the Contractor's planned completion date beyond the Contract completion date will not be the basis for an adjustment to the Contract Time.

H. If completion of the project occurs within the specified Contract Time, the Contractor is not entitled to job-site or home office overhead beyond the Contractor's originally planned occupancy of the site.

I. Notify Engineer of a request for Contract Time adjustment. Submit request as specified with Contract Documents. In cases where the Contractor does not submit a request for Contract Time adjustment for a specific change order, delay, or Contractor request within the specified period of time, then it is mutually agreed that the particular change order, delay, or Contractor request has no time impact on the Contract completion date and no time extension is required.

J. The Engineer will, within 30 calendar days after receipt of a Contract Time adjustment, request any supporting evidence, review the facts, and advise the Contractor in writing. 1. Include the new Progress Schedule data, if accepted by the Owner, in the next monthly

Schedule Update. 2. When the Owner has not yet made a final determination as to the adjustment of the

Contract Time, and the parties are unable to agree as to the amount of the adjustment to


be reflected in the Progress Schedule, reflect that amount of time adjustment in the Progress Schedule as the Engineer may accept as appropriate for such interim purpose. It is understood and agreed that any such interim acceptance by the Engineer shall not be binding and shall be made only for the purpose of continuing to schedule the Work, until such time as a final determination as to any adjustment of the Contract Time acceptable to the Engineer has been made. Revise the Progress Schedule prepared thereafter in accordance with the final decision.

1.17 SUMMARY SCHEDULE

A. Provide Summary Schedule, which consolidates groups of activities associated with Major Items of Work shown on Baseline Schedule. Summary Schedule is intended to give an overall indication of the project schedule without a large amount of detail.

B. Submit updated Summary Schedule at weekly progress meetings and after each Schedule Update or Schedule Revision.

1.18 SCHEDULE OF SUBMITTALS

A. Schedule of Submittals shall include submittals required in the Contract Documents but not limited to Commissioning and Process Start-up Plans, Training Plans, test procedures, operation and maintenance manuals, shop drawings, samples, record documents, and specifically required certificates, warranties, and service agreements.

B. Preliminary Schedule of Submittals: 1. Due date: After Preliminary Schedule has been submitted and accepted by Owner. 2. Format:

a. Include submittals anticipated in the first 90 calendar days after Notice to Proceed using early start dates.

b. Indicate week and month anticipated for each submittal. c. Indicate “Priority” submittals where review time can impact Contractor’s schedule.

1) “Priority” indication will not alter review times specified in Section 01330. 2) Engineer will endeavor to provide early review of “Priority” submittals where

possible. 3. Submittal of Preliminary Schedule of Submittals shall be a condition precedent to Owner

making progress payments during the first 90 calendar days after Notice to Proceed.

C. Final Schedule of Submittals: 1. Due date: After Baseline Schedule has been submitted and accepted by Owner. 2. Format:

a. Include submittals using early start dates. b. Include all submittals, including those required in the Preliminary Schedule of

Submittals. c. Indicate week and month anticipated for each submittal. d. Indicate “Priority” submittals where review time can impact Contractor’s schedule.

1) “Priority” indication will not alter review times specified in Section 01330.


2) Engineer will endeavor to provide early review of “Priority” submittals where possible.

3. Submittal of Final Schedule of Submittals shall be a condition precedent to Owner making progress payments after the first 90 calendar days after Notice to Proceed.

D. Provide updated Schedule of Submittals with updated schedules if schedule revisions change listing and timing of submittals.

1.19 MANPOWER SCHEDULES

A. Due date: After Baseline Schedule has been submitted and accepted by Owner.

B. Format: 1. Schedule histogram depicting total craft manpower and craft manpower for Contractor’s

own labor forces and those of each subcontractor. 2. Submit electronically on a computer disk in Excel format, with 1 paper copy.

C. Progress payments after the first 90 calendar days after Notice to Proceed will not be made until manpower schedule is provided.

1.20 EQUIPMENT SCHEDULE

A. Due date: After Baseline Schedule has been submitted and accepted by Owner.

B. Format: 1. Tabular report listing each major piece of construction equipment to be used in

performing the Work. 2. Include major equipment for Contractor and each subcontractor. 3. Submit electronically on a computer disk in Excel format with 1 paper copy.

C. Progress payments after the first 90 calendar days after Notice to Proceed will not be made until equipment schedule is provided.

1.21 COMMISSIONING AND PROCESS START-UP SCHEDULE SUBMITTAL

A. Proposed Commissioning and Process Start-up Schedule: 1. Submit and receive approval of a startup plan within the schedule constraints as specified

in Section 01660. 2. Engineer response due within 20 calendar days of receipt. 3. Contractor responsible for updating schedule and resubmitting within 10 calendar days of

receipt of Engineer and Owner comments.

B. The Commissioning and Process Start-up Schedule may not be combined with the Detailed Schedule until Engineer acceptance of the Proposed Commissioning and Process Start-up Schedule.

C. Commissioning and Process Start-up Schedule monthly update requirements: 1. Highlight percentages of completion, actual start and finish dates, and remaining

durations, as applicable.


2. Include activities not previously included in the previously accepted detail work plan Commissioning and Process Start-up Schedule.

3. Change Order required for any change to contractual dates. 4. Reviews of these submittals by Engineer will not be construed to constitute acceptance

within the time frames, durations, or sequence of work for each added activity.

1.22 FINAL SCHEDULE SUBMITTAL

A. The final Schedule Update becomes the As-Built Schedule. 1. The As-Built Schedule reflects the exact manner in which the project was constructed by

reflecting actual start and completion dates for all activities accomplished on the project. 2. Contractor’s Project Manager and scheduler sign and certify the As-Built Schedule as

being an accurate record of the way the project was actually constructed.

B. Retainage will not be released until final Schedule Update is provided.

PART 2–PRODUCTS (NOT USED)

PART 3–EXECUTION (NOT USED)

**END OF SECTION**


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150141 – 2017 Upgrades and Rehabilitation 07540-1 Fluid Applied Elastomeric Roof Coatings Over Polyurethane Foam

James R. DiIorio Water Reclamation Facility Construction Bid Set

(ADDENDUM#1) SECTION 07540

FLUID-APPLIED ELASTOMERIC ROOF

COATINGS OVER POLYURETHANE FOAM (PUF)

PART 1–GENERAL

1.01 DESCRIPTION

A. This section specifies a fluid-applied elastomeric roof coating which is applied over polyurethane foam (PUF) roof insulation.

1.02 QUALITY ASSURANCE

A. REFERENCES: 1. This section contains references to the following documents. They are a part of this

section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail.

2. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, whether or not the document has been superseded by a version with a later date, discontinued or replaced.

Reference Title

ASTM D56 Flash Point by Tag Closed Tester

ASTM D93 Flash Point by Pensky-Martens Closed Tester

ASTM D412 Rubber Properties in Tension

ASTM D471 Rubber Property-Effect on Liquids

ASTM D570 (1988) Water Absorption of Plastics

ASTM D624 Rubber Property-Tear Resistance

ASTM D822 Operating Light- and Water-Exposure Apparatus (Carbon-Arc Type) for Testing Paint and Related Coatings and Materi-als

ASTM D2240 Rubber Property-Durometer Hardness

ASTM D2369 Volatile Content of Coatings

ASTM D2697 Volume Nonvolatile Matter in Clear or Pigmented Coatings



Reference Title

ASTM E 96 Water Vapor Transmission of Materials

ASTM G26 Operating Light-Exposure Apparatus (Xenon-Arc Type) With and Without Water for Exposure of Nonmetallic Materials

ASTM G53 Operating Light- and Water-Exposure Apparatus (Fluorescent UV-Condensation Type) for Exposure of Nonmetallic Materials

SPI PFCD-GSI-4 Polyurethane Foam Contractors Division Guidelines for Spray Polyurethane Foam Systems for New and Remedial Roofing

UL 790 Tests for Fire Resistance of Roof Covering Materials

UL BMD Building Materials Directory

B. QUALIFICATIONS OF APPLICATOR: 1. The applicator shall be qualified and certified by the roof coating manufacturer.

C. MATERIAL CERTIFICATIONS: 1. Certificates shall be provided from the manufacturer certifying that materials

provided conform to all requirements specified herein, and are chemically and physically compatible with each other and are suitable for inclusion within the total roof system specified herein.

D. WARRANTY: 1. The Contractor shall furnish the manufacturers' standard warranties for the

roofing system. The warranty shall provide, but not be limited to the following: a. The warranty shall be issued directly to the Owner. b. The warranty period shall be not less than 10 years from the date of acceptance

of the work. c. The warranty shall cover workmanship and materials including both the roof

coating and the polyurethane foam insulation which is specified in Section 07545.

1.03 SUBMITTALS

A. The following information shall be provided in accordance with Section 01300. 1. Evidence of coating manufacturer's approval of the applicator as specified in

paragraph 07540-1.02 B. 2. UFCA foam surface texture visual standards. 3. Mineral granule manufacturer's standard colors. 4. Operating and Maintenance Data: Operation and Maintenance manuals

conforming to Section 01730. Standard operations and maintenance instructions



typically provided by equipment manufacturers will not be accepted as fulfilling this requirement.

1.04 DELIVERY AND STORAGE

A. Materials shall be delivered and stored in their original, tightly sealed containers or unopened packages. Storage area shall be weatherproof. Containers and packages shall be clearly labeled with the manufacturer's name, product identification, date of manufacture, shelf-life expiration date, UL labels, and lot number where appropriate. Where materials are covered by a referenced specification, the labels shall bear the specification number, type, and class, as applicable.

PART 2–PRODUCTS

2.01 ROOF COATING

A. The roof coating shall be Type CB with Type CT top coat. 1. Type CB Coating: Aromatic urethane elastomer (two component). The uncured

urethane shall have the following values when tested for the listed properties in accordance with the listed test method:

Property Value Test method

Solids content: percent by volume (minimum). 73 ASTM D2697

Solids content: percent by weight (minimum). 81 ASTM D2369

Flash point: degrees F (minimum). 82 ASTM D56 or ASTM D93

2. The cured aromatic urethane elastomer shall have the following values when tested

for the listed properties in accordance with the listed test method:


Elongation: percent, at 75 degrees F and 50 percent relative humidity (minimum).

400 (base coat) 150 (topcoat)

ASTM D412

Tensile strength: psi, at 75 degrees F and 50 percent relative humidity (minimum).

1600 ASTM D 412

Permanent set: at break, percent 25 ASTM D412

Tear resistance: pounds per linear inch (minimum). 150 ASTM D624 die C

Ultraviolet exposure: 6000 hr in atlas xenon or carbon arc weatherometer, or QUV.

No cracking, checking, loss of flexibility, or significant discoloration

ASTM D822 ASTM G26 ASTM G53

Water absorption: 168 hr, 75 degrees F, weight percent (maximum).

2.0 ASTM D471



Durometer hardness: Shore A (minimum) 60 ASTM D2240

Permeability: U.S. perm (maximum) 1.0 ASTM E96 Procedure B"

3. Type CT Coating: Aliphatic urethane elastomer (two component). The uncured

urethane shall have the following values when tested for the listed properties in accordance with the listed test method:


Solids content: percent by volume (minimum) 55 ASTM D2697

Solids content: percent by weight (minimum) 69 ASTM D2369

Flash point: degrees F (minimum). 71 ASTM D56 or ASTM D 93

4. The cured aliphatic urethane elastomer shall have the following values when tested

for the listed properties in accordance with the listed test method:


Elongation: percent, at 75 degrees F and 50 percent relative humidity (minimum).

150 ASTM D412

Tensile strength: psi, at 75 degrees F and 50 percent relative humidity (minimum).

1600 ASTM D412

Permanent set: at break, percent 15 ASTM D412

Tear resistance: pounds per linear inch (minimum). 195 ASTM D624 die C

Ultraviolet exposure: 6000 hr in atlas xenon or carbon arc weatherometer, or QUV.

No cracking, checking, loss of flexibility, or significant discoloration

ASTM D822 ASTM G26 ASTM G53

Water absorption: 168 hr, 75 degrees F, weight percent (maximum)

2.8 ASTM D471

Durometer hardness: Shore A (minimum) 80 ASTM D2240

Permeability: U.S. perm (maximum) 1.0 ASTM E96 Procedure B"

5. Coating shall be applied in a Class I Division I classified area. Coating shall not

generate static. Silicone coating shall not be allowed.

2.02 PRIMER

A. The primer shall be as recommended by the coating and foam manufacturers.



2.03 SEALANT

A. The sealant shall be as recommended by the coating manufacturer.

2.04 MINERAL GRANULES

A. Granules for the aggregate surfacing shall be siliceous mineral granules, 98 percent passing the No. 10 sieve and 98 percent retained on the No. 35 sieve. Granules shall be free of fines and dust. A one-color granule surfacing shall be used and the granule color shall be compatible with the color of the topcoat. The color of the granules shall be as selected by the Engineer from the manufacturer's samples and descriptive literature.

2.05 STANDARD COLOR

A. The color for the coating shall be as selected by the Engineer for Type CT. Color range shall be beige to gray.

2.06 FIRE SAFETY

A. The complete roof covering assembly shall have a UL 790, Class A classification, be listed in UL BMD, and have the UL Follow-on Labeling Service.

2.07 PRODUCT DATA

A. The following information shall be provided in accordance with Section 01300. 1. Certificates of Compliance specified in paragraph 07540-1.02 C. 2. Warranty as specified in paragraph 07540-1.02 D.

2.08 WALKING MATS

A. 100 linear feet of Sika Sarnafil Crossgrip walkway mats shall be installed on the digester cover in foot trafficked areas.

PART 3–EXECUTION

3.01 PREPARATION OF SURFACES

A. GENERAL: 1. Surfaces to which roof coating is applied shall be free of water, grease, oils, dirt,

debris, and other foreign materials, and shall be cured completely. Where foam insulation has been left uncoated overnight, foam shall be removed and new foam applied.

B. URETHANE FOAM ROOF INSULATION: 1. The foam shall be of the specified density. Surface of the foam shall be free of

ridges, bumps, excessive pinholes, and depressions and shall not exceed visual standards for "orange peel" as defined in SPI PFCD-GSI-4 and by approved samples. Damaged top skin of the insulation shall be repaired with extra brush-coats of coating or sealant. Surfaces of the insulation which become damaged, overexposed to weather, or contaminated such that they cannot be



cleaned and repaired to the satisfaction of the coating applicator shall be removed and new insulation provided.

C. METAL, CONCRETE, AND MASONRY SURFACES: 1. Rust and scale shall be cleaned from metal surfaces which are to receive roof

coatings by abrasive cleaning or wire brushing, followed with a solvent wipe using an industrial solvent such as naphtha or mineral spirits. Concrete and masonry surfaces which are to receive roof coatings shall be wire-brushed and resulting dust removed.

3.02 APPLICATION

A. GENERAL: 1. Roof coatings shall not be applied during inclement weather or when wind speed

exceeds 15 mph, unless windscreen devices which ensure application of coatings having the required surface texture and thickness are used. Roof coatings shall not be applied when there is ice, frost, surface moisture, or visible dampness present on the surface to be coated.

2. Prior to applying coating, polyurethane foam shall be checked with a moisture resistance meter to assure that the foam is dry. Roof coating shall be applied between the temperature ranges of 40 and 100 degrees F.

3. Roof coating on urethane foam insulation shall be applied not less than 2 hours after but on the same day as installation of the insulation. Foam shall not be left uncoated overnight. Coating shall be applied on insulation, and continued up walls and roof penetrations to a point where concealed behind counter flashings and up and over the top of parapet walls where specified. Terminal edges of the foam at roof penetrations and roof edges shall be given an extra base coat back 3 inches from the edge. Dry film thickness for each coat shall not be less than specified in paragraph 07540-3.02 F. Coatings shall be smooth, free of runs, dry spray, or overspray, and provide a uniform film over the foam.

B. BASE COAT APPLICATION: 1. Type CB coating shall be applied as the base coat. Application shall be in

accordance with the manufacturer's printed installation instructions. The coating shall be applied uniformly and in one direction. The completed surface shall be inspected for blowholes, pinholes, cracks, breaks, voids, blisters, and other imperfections, and repaired with base coat material. Areas of the base coat which become dirty shall be cleaned with a clean wet cloth, prior to application of the intermediate coat.

C. INTERMEDIATE COAT APPLICATION: 1. Type CB coating shall be applied in the same manner as the base coat except it shall

be applied in a direction perpendicular to the direction in which the base coat was applied.

D. TOPCOAT APPLICATION: 1. Type CT coating shall be applied as the topcoat in accordance with the

manufacturer's printed installation instructions. Coating shall be applied at the



specified rate, and in the same manner as the base and intermediate coats except in a direction perpendicular to the direction in which the intermediate coat is applied.

E. OVERSPRAY MASKING: 1. Masking protection shall be provided as required to protect surfaces and property

not to be sprayed.

F. DRY FILM THICKNESS: 1. Minimum Dry Film Thickness (DFT) in mils shall be as follows:

Type Base coat Intermediate coat Topcoat Total

CB-Urethane 15 15 -- 30

CT-Urethane -- -- 15 15

45

G. AGGREGATE SURFACING: 1. Where specified, mineral granules shall be spray-applied to the topcoat within 2 to

5 minutes after application of the topcoating, depending on temperature and humidity, as required by the roof coating manufacturer's printed installation instructions. The spray applicator equipment shall be a sand blaster with output pressure reduced to 10 to 20 psi. The granules shall be applied to the surface evenly at a rate of 50 pounds per 100 square feet. Traffic shall not be allowed on finished areas for 24 hours after granule application is completed.

H. SURFACING: 1. The entire surface of the digester covers shall be surfaced to be suitable for foot

traffic.

3.03 FIELD TESTING 1. Prior to application of base coat, one 4-inch-square, flat metal test plate shall be

placed on the surface of foam insulation for every 100 square feet for the purpose of measuring wet film thickness of coating during application. During application of intermediate and topcoats, plates shall be placed on surface of previously applied coat in the same manner.

3.04 CLEANUP

A. Roof coating materials shall be cleaned from all surfaces which are not designated to receive such materials. Overspray masking materials and coverings shall be removed upon completion of the spray work. Debris, scraps, waste materials, calibration materials, rubbish and trash from the immediate work area shall be removed at the end of each work day and placed in the location designated by the Contractor

**END OF SECTION**




150141 – 2017 Upgrades and Rehabilitation 07545-1 Sprayed Polyurethane Foam (PUF) for Roofing Systems



SPRAYED POLYURETHANE FOAM (PUF) FOR ROOFING SYSTEMS

PART 1–GENERAL

1.01 DESCRIPTION

A. SCOPE: 1. This section specifies material and application requirements for sprayed

polyurethane foam (PUF) roofing over which a fluid-applied elastomeric protective coating is to be provided. Elastomeric coating is specified in Section 07540.

B. DEFINITION: 1. The term "roofing system" means an insulating substrate of sprayed polyurethane

foam with a top coating of fluid-applied, elastomeric protective coating as specified in Section 07540.


A. QUALIFICATIONS OF APPLICATOR: 1. The PUF applicator shall be approved by the roof coating manufacturer.

B. REFERENCES: 1. This section contains references to the following documents. They are a part of this

section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail.

2. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced.

Reference Title

ANSI Z87.1 Practice for Occupational and Educational Eye and Face Protection

ASTM C177 Steady-State Thermal Transmission Properties by Means of the Guarded Hot Plate

ASTM C273 Shear Test in Flatwise Plane of Flat Sandwich Construction of Sandwich Cores



Reference Title

ASTM C518 Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Heat Flow Meter

ASTM D1621 Compressive Properties of Rigid Cellular Plastics

ASTM D1622 Apparent Density of Rigid Cellular Plastics

ASTM D1623 Tensile Properties and Tensile Adhesion of Rigid Cellular Plastics

ASTM D2126 Response of Rigid Cellular Plastics to Thermal and Humid Aging

ASTM D2842 Water Absorption of Rigid Cellular Plastics

ASTM D2856 Open Cell Content of Rigid Cellular Plastics by the Air Pycnometer

ASTM E96 Water Vapor Transmission of Materials

OSHA 29 CFR Occupational Safety and Health Standards 1910.134

SPI PFCD-GS1-4 Polyurethane Foam Contractors Division Guidelines for Spray Polyurethane Foam Systems for New and Remedial Roofing

UL 790 Fire Tests of Roof Coverings UL BMD Building Materials Directory

SSPC SP6-85 Commercial Blast Cleaning

C. TEST AREA: 1. The PUF roofing system shall be applied in a designated test area of not less than 50

square feet. The Contractor shall be notified a minimum of 48 hours prior to the test application. The applied test system shall conform with applicable roofing details; meet requirements of foam adhesion, and adhesion of the roof coating to the foam. Equipment used in the construction shall be used in the application of the test roof system.

D. WARRANTY: 1. The roofing system, including the polyurethane foam insulation and roof coating,

shall be covered by the roof coating manufacturers' standard warranty, in accordance with Section 07540.

1.03 SUBMITTALS

A. The following information shall be provided in accordance with Section 01300: 1. Manufacturer's literature including material description, physical properties,

recommended storage conditions, shelf life expiration date, application details and instructions, warnings or precautions on flammability and toxicity. Include manufacturers' written recommendations for primers and for surface preparation of galvanized iron or other metal, concrete, or other surfaces.

2. PUF sample installation consisting of one piece, 2 inches thick, 2 feet square, spray applied on plywood. Not less than, "orange peal" surface texture as described in SPI PFCD-GSI-4.

3. Certificate for Qualifications certifying that applicator meets requirements specified under paragraph 07545-1.02 A.



1.04 DELIVERY AND STORAGE

A. Materials shall be delivered to the job site in manufacturer's standard commercial containers unopened, undamaged, and bearing the following legible information: 1. Name of manufacturer. 2. Name of contents/product code. 3. Net weight of contents. 4. Lot or batch number. 5. Storage temperature limits. 6. Shelf life expiration date. 7. Mixing instructions/proportions of components. 8. Safety information and instructions.

B. Where materials are specified by an applicable document, labeling shall include the referenced specification numbers, and material designation, such as type and class of the contents. Materials shall be delivered in sufficient quantity to allow work to continue without interruption and shall be stored and protected from damage and weather in accordance with manufacturer's instructions, except as amended in this paragraph. Stored material containers shall be supported on pallets and covered with tarpaulin, not polyethylene, with all sides of tarp tied to the bottom of pallets. PUF component containers shall be kept tightly sealed and stored at temperatures between 50 and 80 degrees F and not be exposed to direct sunlight for periods of time sufficient to cause contents to exceed 80 degrees F. Materials which have been exposed to moisture or that exceed shelf life limits shall not be used.

PART 2–PRODUCTS

2.01 MATERIALS

A. PUF: 1. PHYSICAL CHARACTERISTICS: The PUF is a two-part component system

made by combining an isocyanate (A) component with a polyol (B) component. The cured, sprayed-in-place PUF shall possess the following physical characteristics:

Properties ASTM test Value Units

Density (sprayed-in-place) D1622 2.50-3.50 lb/ft3 K-Factor (aged) C177 or

C518 0.16 (max.) degree F per in

Btu per ft2/hr;

Compressive strength parallel to foam rise

D1621 40 (min.) lb/in2

Shear strength C273 35 (min.) lb/in2 Tensile strength parallel to foam rise

D1623 60 (min.) lb/in2



Dimensional stability (humid aging) 28 days, 160 deg. F, 100 percent relative humidity

D2126 15 (max.) Procedure F

Percent net volume change

Water vapor permeability E 96 3.0 (max.) Perm/in Percentage closed/open cells D2856 90 (min.)

10 (max.) Percent by volume

Water absorption D2842 0.10 (max.) lb/ft2

2. SHELF LIFE: PUF material components shall have a minimum shelf life of 6 months. A written statement or other certification shall be submitted showing shelf life expiration date.

B. PUF PRIMER: 1. Primer used shall be as required and recommended by the manufacturer of the

spray foam materials specified except that no cut-back asphalt primers shall be permitted.

C. ELASTOMERIC PROTECTIVE COATING: 1. The elastomeric roof coating shall be as specified in Section 07540.

2.02 FIRE SAFETY PROPERTIES

A. When tested as a composite system, the sprayed PUF and elastomeric protective coating shall meet the following requirements: roof-covering material shall be rated for exterior fire exposure; UL 790, Class A rating. Composite roof system shall be included in the UL BMD for use as a roof covering material.

2.03 PRODUCT DATA

A. The following information shall be provided in accordance with Section 01300: 1. Manufacturer's certification that materials are physically and chemically

compatible, that materials comply with requirements of this specification, and that each material suits the intended purpose. Materials not listed on the certificate will not be permitted in the work area.

2. Certification of minimum shelf life of PUF material components as specified in paragraph 07545-2.01 A.2.

PART 3–EXECUTION

3.01 SPECIAL PRECAUTIONS AND INSTRUCTIONS

A. SAFE WORKING LOAD LIMITS: 1. Materials or equipment shall not be placed on the roof deck exceeding the indicated

live load limits.

B. PRIMERS:



1. Primers or other materials shall not be diluted unless required and recommended by manufacturer. Cleaning solvents shall not be used for thinning primers or other materials.

C. MATERIAL HANDLING: 1. Materials and containers shall be handled safely and in accordance with

recommendations of the manufacturer. Liquids shall be stored in airtight containers and containers kept closed except when removing materials. Equipment or containers containing remains of dissimilar materials or products shall not be used.

D. SHOES: 1. Clean, soft-soled shoes without heels shall be worn while walking on roofing

surfaces during installation.

E. FIRE AND EXPLOSION HAZARDS: 1. Open flames, sparks, welding and smoking shall be prohibited in the application

area.

F. WARNING SIGNS: 1. Warning signs shall be posted a minimum of 150 feet from the application area

stating the area is off-limits to unauthorized persons and warning of the presence of flammable materials, irritating fumes, and potential of overspray damage.

3.02 ROOF AREA PREPARATION

A. PRE-APPLICATION OF THE PUF SYSTEM: 1. Contractor shall ensure that drains, curbs, cants, expansion joints, roof

penetrations, and equipment supports are in place prior to the application of the primer and PUF. Air intake vents shall be sealed off during PUF application. Surfaces shall be examined and all defects corrected that will adversely affect the roofing system application or performance. Masking protection shall be provided as needed to protect surfaces and property which are not to be primed or sprayed with foam.

B. SURFACE PREPARATION: 1. Surfaces that are to be primed or receive spray foam application shall be dry;

completely cured; free of grease, oils, dirt, or other foreign matter; and prepared in accordance with the following: a. Iron and steel surfaces which are not primed, shop painted, or otherwise

protected shall be sandblasted in accordance with SSPC SP-6. Loose rust and unsound primer shall be removed from shop-primed iron and steel surfaces by scraping or wire brushing. All iron and steel surfaces shall then be coated to EA-1 in accordance with Section 09900 prior to receiving the polyurethane foam system.



3.03 WORK SEQUENCE

A. Work shall be scheduled in order to prevent the use of newly constructed roofing for storage, walking surface, material, or equipment movement. If access is necessary, new roofing surfaces, flashings, and mechanical equipment shall be protected.

3.04 APPLICATION AND EQUIPMENT

A. GENERAL: 1. The application of PUF and equipment requirements shall be in accordance with

printed recommendations of the manufacturer of the PUF system material or as specified herein. In case of conflict, the manufacturer's instructions shall prevail.

B. PUF APPLICATION: 1. Primer shall not be applied during inclement weather or when wind speed over an

unprotected roof work area exceeds 15 mph. Primer manufacturer's application requirements shall be followed except that no primer shall be applied when ambient temperature is below 40 degrees F or when ambient temperature is expected to fall below 35 degrees F during drying-curing period.

2. PUF shall not be sprayed on roof surfaces when wind speed in the work area exceeds 12 mph unless windscreen protection is used. When wind speed exceeds 25 mph, spraying shall be suspended. PUF shall not be sprayed if the roof surface temperature is less than 50 degrees F, higher than 120 degrees F, or is less than 5 degrees F above the dew point. The dew point shall be determined at the job site prior to and upon completion of each day's work unless variable weather conditions require more frequent monitoring.

3. Foam shall be applied to provide a minimum finished thickness of 2 inches in at least two spray passes. Each spray pass shall be applied at right angles to the previous pass to the extent practicable. Each pass, except for filleting or tapering as required at terminations, shall be between 0.5 and 1 inch in thickness.

4. Unless otherwise specified, work shall conform with manufacturer's standard details, for foam thickness around penetrations, curbs, and other terminations. Transitions between horizontal and vertical surfaces shall be smooth and sprayed at a nominal angle of 45 degrees.

5. Foam thickness shall not exceed the minimum thickness of the foam by more than 0.25 inch. Foam shall be applied of a sufficient overall surface uniformity to prevent water ponding in excess of 0.25 inch depth. Such individual pools shall not exceed 10 square feet in area nor affect major roof drainage.

6. The finished surface of applied foam shall be "orange peel" or smoother in conformance with sample submitted under paragraph 07545-1.03 and shall be free of pinholes.

7. If the sprayed foam skin is removed to correct surface texture or to remove excess foam thickness, the cut surface shall be resprayed to provide a protective foam skin prior to application of specified elastomeric protective coating. Spray-applied foam that is not bonded, of poor cell structure, wet, or otherwise does not meet the material quality specifications specified herein shall be removed.

8. Spray foam application shall not be started on an area larger than can be brought to the full foam thickness specified on the same day. Foam shall not be applied if it cannot be coated with a roof coating on the same day. No applied PUF, except for



leading edges, shall stand uncoated overnight. The applied PUF shall be cured for a minimum of 2 hours prior to application of the elastomeric protective coating. Protective shields or barriers shall be used when spraying foam along open roof edges to prevent uncontrolled overspray.

C. FOAM SPRAY EQUIPMENT: 1. The Contractor shall use an airless foam spray gun of the mechanical, self-cleaning

type, that does not require a flushing solvent during the spray operation. The foam metering equipment shall be fully calibrated to monitor each liquid component to within 2 percent of the foam material manufacturer's required metering ratio. Foam metering equipment shall be capable of developing and maintaining the foam manufacturer's required liquid component pressures and temperatures. Foam metering equipment shall have gauges for visual monitoring.

2. The surfaces of component supply containers or tanks used to feed the foam metering/ proportioning equipment shall be protected from moisture by blanketing with dry nitrogen. Compressed air, in contact with foam components during mixing or atomization, shall be supplied through moisture traps that are continuously bled.

3. The Contractor shall not deposit, on the roof surfaces to be sprayed, materials used for cleaning of equipment or materials dispensed for calibration purposes and establishment of spray gun pattern. Such materials shall be disposed of in compliance with safety requirements and job site regulations.

D. CLEANUP: 1. Debris, scraps, waste materials, rubbish and trash shall be removed from the

immediate work area and disposed of in a designated location at the end of each workday. Overspray masking materials and coverings shall be removed upon completion of the spray foam application and prior to the application of elastomeric protective coating. The masking over the air intake vents shall not be removed until two hours after the application of the roofing system.

3.05 SPECIAL SAFETY PROVISIONS

A. During application, the following shall be required unless in conflict with a manufacturer's recommendations or other requirements of a recognized legal authority, in which case, those requirements take precedence: 1. Canister-type or fresh air supply masks shall be worn when applying the foam or

when handling hazardous liquid materials. Respiratory protective devices shall be as recommended by OSHA 29 CFR and approved by the Mining Enforcement and Safety Administration or be acceptable to the U.S. Department of Labor for the specific contaminant to which a person is exposed. Personnel required to use respiratory protective devices shall be instructed in their use. Such equipment shall be maintained and inspected regularly.

2. Eye and face protection shall be used during PUF application. Face protective equipment shall meet the requirements of ANSI Z87.1.

3. Protective clothing and gloves shall be worn during PUF application. Skin areas not covered by clothing shall be protected by suitable protective creams.

4. When opening the "B" (polyol) foam component material drum, begin by partially unscrewing the bung cap to gradually vent the drum. Pressure develops when "B" component drums are at temperatures above 72 degrees F.



5. When opening the "A" (isocyanate) foam component material drum, do not inhale vapors. The empty nonreturnable "A" component drums shall be decontaminated by filling with water and allowing to stand for 48 hours with bung cap removed. Under no circumstances shall the drums be sealed or closed.

**END OF SECTION**

150141 – 2017 Upgrades and Rehabilitation 07900-1 Joint Sealants James R. DiIorio Water Reclamation Facility Construction Bid Set


JOINT SEALANTS

PART 1 - GENERAL

1.01 DESCRIPTION

A. This section specifies sealants for interior and exterior joints in construction systems not filled by another material, and that are not required to be open for operation .


A. References: 1. This section contains references to the following documents. They are a part of this



Reference Title FEDSPEC TT-S-00230C Sealing Compound: Elastomeric Type, Single Component FEDSPEC TT-S-00227E Sealing Compound: Elastomeric Type, Multi-Component

PART 2 - PRODUCTS

2.01 SILICONE SEALANT

A. Acceptable Manufacturers: 1. Acceptable manufacturers shall be Sika Corporation, Dow Corning Corporation,

Tremco Incorporated or Pecora Corporation.

B. Product: 1. Silicone sealants shall conform to FEDSPEC TT-S-0230C.

a. Single-Component, Nonsag, Neutral-Curing Silicone Joint Sealant conforming to ASTM C 920, Type S, Grade NS, Class 100/50, for Use NT.

C. Primer: 1. Primer shall be as recommended by the sealant manufacturer.

150141 – 2017 Upgrades and Rehabilitation 07900-2 Joint Sealants James R. DiIorio Water Reclamation Facility Construction Bid Set

D. Backer Rod or Backer Tape: 1. Backer rod shall be open cell polyethylene or polyurethane foam. Rod shall be

cylindrical unless otherwise specified. Backer tape shall be polyethylene or polyurethane with adhesive on one side.

2.02 PRODUCT DATA

A. The following information shall be provided in accordance with Section 01300: 1. Manufacturer's product data showing conformance to the specified products. 2. Manufacturer's recommendations for storage, handling and application of sealants

and primers.

PART 3 - EXECUTION

3.01 GENERAL

A. Sealants and primers shall be applied according to the sealant manufacturer's recommendations. Silicone sealants shall be used as shown and on all construction joints.

B. Joints and spaces to be sealed shall be clean, dry and free of dust, loose mortar, concrete and plaster. Additional preparation of joints and spaces shall be provided in accordance with manufacturer's recommendations. Primer shall be applied only to the surfaces that will be covered by the sealant.

3.02 SILICONE SEALANTS

A. General: 1. Nonsag silicone sealants shall be used on vertical joints.

B. Joint Dimensions: 1. Unless otherwise specified, joints and spaces to be filled shall be constructed to the

following criteria. Joints and spaces shall have a minimum width of 1/4 inch and a maximum width of 1 inch. The depth of the sealant shall be one-half the width of the joint, but in no case less than 1/4 inch deep. Sealant depth shall be measured at the point of smallest cross section. When joints exceed the depth requirements, backing rod shall be inserted to provide the joint depth specified. If the joint sealant depth is within the specified tolerances, backer tape shall be placed in the bottom of the joint.

**END OF SECTION**

150141 – 2017 Upgrades and Rehabilitation 07905-1 Performed Joint Fillers James R. DiIorio Water Reclamation Facility Construction Bid Set


PREFORMED JOINT FILLERS

PART 1 GENERAL

1.01 DESCRIPTION

A. This section specifies preformed joint fillers for interior and exterior joints in construction systems.


A. References: 1. This section contains references to the following documents. They are a part of this



Reference Title ASTM D994 Preformed Expansion Joint Filler for Concrete (Bituminous Type) ASTM D1752 Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving

and Structural Construction

PART 2 PRODUCTS

2.01 PREFORMED ASPHALT FIBERBOARD

A. Preformed asphalt fiberboard joint filler shall be in accordance with ASTM D994 and shall be 1/2 inch thick unless otherwise specified.

2.02 PREFORMED RESIN-BONDED CORK

A. Preformed resin-bonded cork joint filler shall be in accordance with ASTM D1752, Type II. Cork joint filler thickness shall match the specified joint width.

2.03 PRODUCT DATA

A. The following information shall be provided in accordance with Section 01300:

150141 – 2017 Upgrades and Rehabilitation 07905-2 Performed Joint Fillers James R. DiIorio Water Reclamation Facility Construction Bid Set

1. Manufacturer's recommendations for handling and installation of the material.

PART 3 EXECUTION

3.01 GENERAL

A. Preformed joint fillers shall be placed into position before the concrete is poured. Where it is necessary for the filler to be fixed to existing concrete or other building materials, a suitable adhesive recommended by the filler manufacturer shall be used. Filler surfaces shall be clean and dry prior to the placement of the concrete.

3.02 PREFORMED ASPHALT FIBERBOARD

A. Preformed asphalt fiberboard joint fillers shall be used for expansion joints in concrete sidewalks, curbs, and roadways.

3.03 PREFORMED RESIN-BONDED CORK

A. Preformed resin-bonded cork joint filler shall be used for expansion joints in concrete structures. The expansion joint shall be sealed with backer rod and sealant as specified in Section 07900.

**END OF SECTION**

150141 – 2017 Upgrades and Rehabilitation 10441-1 Warning Signs James R. DiIorio Water Reclamation Facility Construction Bid Set


WARNING SIGNS

PART 1–GENERAL

1.01 DESCRIPTION

A. This section specifies informational and accident prevention signs.

1.02 OPERATING AND DESIGN REQUIREMENTS

A. GENERAL: 1. Accident prevention signs shall conform as to design with OSHA Section 1910.145 of

Subpart J, Part 1910, Chapter XVII, Title 29 of the Code of Federal Regulations. Exit signs shall conform with Section 1910.37(g) of the OSHA Safety and Health Standard for General Industry, Article 10, Section 10.113 of the Uniform Fire Code, and where applicable with local fire regulations.

2. In addition to the signs identified on the schedule in Part 3 of this section, the following shall be provided: a. Exit signs shall be provided in accordance with the luminaire schedule. b. "Caution Automatic Equipment May Start at Any Time" signs shall be

provided in accordance with paragraph 11000-2.07. c. Chemical storage tank safety signs shall be provided in accordance with

paragraph 15230.2.10. d. Construction warning signs in all buildings where Work is being performed

such as "hard hat area", "overhead danger". e. Other construction related barricades or ribbon. f. Warning signs for Contractors non-potable water sources. g. Construction related site barricades, lights, etc. at roadway and other site

excavations. h. Warning signs at all electrical areas warning of electrical shock hazards in

accordance with OSHA regulations. i. Construction information signs at plant entries stating that all visitors must

register and check-in with the Contractor and/or Engineer. j. Electrical arc-flash hazard signs in accordance with Section 16431.

B. DESIGN REQUIREMENTS: 1. SIZE: Sign size shall be as follows:

a. 14 inch x 20 inch b. 10 inch x 14 inch c. 7 inch x 10 inch

2. TYPE: The sign type shall be as follows:

Type

Message


Type

Message

I CAUTION--AUTOMATIC EQUIPMENT MAY START AT ANY TIME

II DANGER--480 VOLTS III CAUTION - POLYMER IV NOTICE--NON-POTABLE WATER--DO NOT DRINK VI DANGER--HIGH VOLTAGE VII DANGER--CONFINED SPACE--HAZARDOUS ATMOSPHERE VIII

EAR PROTECTION REQUIRED BEYOND THIS POINT

X CAUTION – DANGEROUS CHEMICAL EYE PROTECTION REQUIRED

PART 2–PRODUCTS

2.01 GENERAL

A. Sign lettering shall be single stroke and shall contrast in color with the background. For those messages for which there are international symbols, the international symbols shall be used. Chain mounted signs shall have lettering on both sides.

2.02 MATERIALS

A. Signs shall be 0.100-inch thick fiberglass with embedded fadeproof legends.

PART 3–EXECUTION

A. Signs shall be distributed as follows:

Location Number

Size Message Mount

All 480 volt junction boxes and panels -- B II Panel All exterior electrical equipment rated 480 volts or above

-- C VI As required

All Utility Stations -- B IV Wall All motorized equipment -- B I Wall or

Equipment Polymer Room 3 B III Door Polymer Room 2 C X Wall Polymer Room 3 C III Wall


Polymer Room 3 C XII Wall Centrifuge Room 2 C XIII Wall Miscellaneous 5 C To be

determined Wall

**END OF SECTION**



150141 – 2017 Upgrades and Rehabilitation 11069-1 Adjustable Frequency Drives James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 11069

ADJUSTABLE FREQUENCY DRIVES

PART 1–GENERAL

1.01 DESCRIPTION

A. SCOPE: 1. This section specifies 480 Vac rated adjustable frequency drive motor controller systems

using insulated gate bipolar transistors (IGBT) for pulse width modulation technology (PWM).

2. (Addendum#1) The AFDs specified in this section shall be the product of a single vendor and mounted in the specified cabinet enclosure or as part of a Vendor Control Panel (VCP).

3. The terms AFD (adjustable frequency drive), ASD (adjustable speed drive), VFD (variable frequency drive), and VSD (variable speed drive) are interchangeable for the purposes of this specification.

4. Refer to the drawings for control and monitoring requirements including special interlocking requirements.

B. SYSTEM REQUIREMENTS: 1. The AFD system shall convert 460 volt, 60-Hertz nominal input to a suitable voltage and

frequency to cause a premium efficient, inverter duty, squirrel-cage induction motor to run at a speed proportional to an external input analog 4 to 20 ma dc or digital input command as specified for the required AFD speed range.

2. The AFD system shall include rectifier units, inverter units, control circuitry, protective equipment, input line reactors and output load reactors and other filters and accessories as necessary to provide the specified functions to meet voltage and current harmonics at the specified point of common connection and to mitigate the motor reflected voltage wave. Unless otherwise specified, the point of common connection for AFDs shall be the 480-distribution bus (motor control center, distribution panel, etc.) immediately upstream of the AFD.

3. The AFD system torque requirement shall match the pump torque requirement. Verify the pump type and select variable torque (VT) or constant torque (CT) as specified. Select 6-Pulse units for small pump motors and 18-Pulse units for large pump motors (100 HP or greater).

C. ENVIRONMENTAL CONDITIONS: 1. (Addendum#1) Ambient conditions are specified in Section 01800. Note the project is

located in Pueblo, Colorado thus the VFDs will have to be de-rated for this elevation.

D. SEISMIC: 1. Freestanding AFDs shall be braced per Section 01900.


A. REFERENCES:


1. This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail.


Reference Title

IEEE 519 IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power System

NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 2 Industrial Control and Systems: Controllers, Contactors, and Overload Relays Rated 600 Volts

NEMA ICS 6 Industrial Control and Systems: Enclosures

NEMA ICS 7 Industrial Control and Systems: Adjustable-Speed Drives

NEMA ICS 7.1 Safety Standards for Construction and Guide for Selection, Installation, and Operation of Adjustable-Speed Drive Systems

NFPA 70 National Electrical Code (NEC)

UL Standard 508 Industrial Control Equipment

B. INDUSTRY STANDARDS: 1. The AFD shall be UL 508 listed and shall conform to the requirements specified in

NEMA ICS 2, 6, 7 and 7.1.

C. UNIT RESPONSIBILITY: 1. The Contractor shall assign unit responsibility for the adjustable frequency drives in this

section as specified in paragraph 11000-1.02 C. The Contractor shall submit letters of certification with the shop drawings from the AFD manufacturer, the motor manufacturer, and the driven equipment manufacturer stating that they have reviewed each application and that the combination will satisfy the application duties required, for the actual motor sizes required, regardless of deviations from the scheduled "nominal horsepower."

1.03 PRODUCT HANDLING

A. AFD units shall be shipped in air-cushion vans to ensure against shipping damage and packed in suitable protective containers. The units shall be inspected upon receipt for damage.


1.04 SUBMITTALS

A. The following information shall be provided in accordance with Section 01300: 1. 1.A copy of this specification section, with addendum updates included, and all

referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. a. Check marks shall denote full compliance with a paragraph as a whole. If deviations

from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation.

b. The Construction Manager shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications.

c. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.

2. A copy of the contract document control diagrams and process and instrumentation diagrams relating to the submitted equipment, with addendum updates that apply to the equipment in this section, marked to show specific changes necessary for the equipment proposed in the submittal. a. If no changes are required, the drawing or drawings shall be marked "no changes

required". Failure to include copies of the relevant drawings with the submittal shall be cause for rejection of the entire submittal with no further review.

3. Certificate of Unit Responsibility attesting that the Contractor has assigned, and that the manufacturer accepts, unit responsibility in accordance with the requirements of this Section and paragraph 11000-1.02 C. No other submittal material will be reviewed until the certificate has been received and found to be in conformance with these requirements.

4. Catalog and technical data including outline dimensions, shipping section dimensions, weight, and foundation requirements for all assemblies.

5. Schematic diagrams and wiring connection diagram showing functions and identification of terminals.

6. Voltage and current Total Harmonic Distortion (THD) calculations with line reactors or filter design to mitigate harmonics to meet IEEE-519, if applicable.

PART 2–PRODUCTS

2.01 MANUFACTURERS

A. The Owner and Construction Manager believe the following candidate manufacturers are capable of producing equipment and/or products that will satisfy the requirements of this Section. This statement, however, shall not be construed as an endorsement of a particular manufacturer’s products, nor shall it be construed that named manufacturers’ standard equipment or products will comply with the requirements of this Section. AFDs shall be installed in the custom enclosures as specified and Candidate manufacturers include:


1. ABB ACS-550 2. (Addendum#1) Or approved equal

2.02 ENCLOSURES

A. Provide AFD in NEMA enclosures with fan cooling and conformal coating protection on circuit boards for corrosive atmosphere protection.

B. GENERAL: 1. Provide enclosures with AFDs and custom control as required for the project and as

indicated on the drawings. Each drive shall be designed for stand-alone operation and multiple drives shall not utilize shared components. Review the project site location, elevation, temperature, humidity, plant atmosphere, and load current-torque requirements to size the AFD and its associated enclosure with requirements specified herein and the control and monitoring devices and interlocks as indicated.

2. Enclosures shall be designed for indoor service when located in the electrical rooms; each AFD system shall be mounted in a NEMA 12 ventilated and filtered with internally force ventilation with UL approved Class 1 filters on ventilation openings. VFD’s located on the process floor shall be mounted in a NEMA 4X, 316 SST enclosure. Enclosures shall be fabricated from 12-gage minimum thickness sheet steel with an interior frame or formed to provide a rigid structure.

3. Provide enclosure size to allow entry of power source and motor load cables as indicated on the drawings. Submit drawing of the source and load power cable location within the enclosure and indicated barriers from control and instrument wiring.

4. Door width shall not exceed 30 inches and shall be hung on removable-pin hinges, with three-point latch hardware, and handle latch for 3/8-inch-shackle padlock.

C. FINISH AND COATINGS: 1. AFD systems enclosures shall be finished with corrosion protection coatings inside and

outside for hydrogen sulfide atmospheres. The electrical and electronic assemblies shall have conformal coatings.

2.03 AFD ASSEMBLIES

A. GENERAL: 1. AFDs shall include the following assemblies:

a. Power disconnect using a thermal magnetic circuit breaker with flanged handle sized for the specific application by the manufacturer.

b. Line input harmonic filter for harmonic mitigation. MTE or approved equal. c. A dV/dT output filter or motor terminator units for addressing dv/dt effects at the

motor. d. Rectifier, direct current bus filter, and inverter. e. Control circuitry interface with Operator Interface Unit f. Output protection including phase overload

B. AFD FEATURES: 1. Provided with the following features:


a. Fused control circuit transformer and microprocessor for system logic sequencing functions. Provide fuses with blown fuse indicator lamps.

b. Accept 4 to 20 mAdc and or Ethernet IP speed reference signal. c. A 4 to 20 mAdc and or Ethernet IP speed feedback output signal proportional to inverter

output frequency for the speed range specified. d. Adjustable minimum/maximum frequency limits:

1) Minimum frequency shall be adjustable from 6 to 40 Hertz. 2) Maximum frequency shall be adjustable from 48 to 90 Hertz.

e. Adjustable and independent timed linear acceleration and deceleration functions, adjustable from 6 to 20 seconds.

f. Current limiting. g. Automatic restart. h. Control Wiring:

1) 600 volt stranded copper 2) 90 degrees C color-coded insulation 3) No. 16 AWG

2. Wiring Identification and Termination: Crimp type wire lugs with sleeve type markers at each termination point and numbered terminal blocks for external connections.

3. Electrically isolated discrete output contacts and or Ethernet IP for ready, running, remote mode status and trouble alarm.

4. Conformal coated terminal blocks for control and signal wires entering and leaving the controller.

5. Control Power: Provide a 120 Vac, triple fused, control power transformer for cooling fans and external control circuits when required. Control circuits shall be isolated from power circuits by distance and by insulated barriers.

6. Provide 120 Vac or 24 Vdc as required for Operator Interface Unit.

C. FUNCTIONAL REQUIREMENTS: 1. SUPPLY POWER: Operate continuously with supply power of 480 volts plus or minus

10 percent, 60 Hertz plus or minus 3 percent and remain on line and operate without damage to the AFD or connected load during a supply power under-voltage variation to the drive up to 85% of its nominal value for 30 milliseconds at full load.

D. ENVIRONMENTAL CONDITIONS: 1. (Addendum#1) Ambient temperature: 0 to + 40 50 degrees C / 104 122 degrees F 2. Atmosphere: Hydrogen Sulfide

3. LOAD: Capable of driving the specified maximum motor load continuously and under

the following conditions: a. Deliver 110 percent of the specified load for up to 60 seconds in variable torque

applications. b. Deliver 150 percent of the specified load for up to 60 seconds in constant torque

applications.


4. EFFICIENCY: Not less than 95 percent at 60 Hertz output driving the specified maximum load at rated torque and speed at 40 degrees C ambient based on measured input power versus output power with all specified components in the system.

5. FREQUENCY AND VOLTAGE REGULATION: Output frequency regulated to within 0.6 Hertz of the signal/output frequency relationship. Output voltage regulated to within 1.0 percent to produce minimum motor heating at any operating frequency within the specified range.

6. FREQUENCY RANGE: AFD shall be capable of continuous operation with the specified load at any frequency between 6 and 60 Hertz unless noted otherwise.

7. SPACE AND AFD ACCESS: a. Enclosure size shall not exceed the size allotments specified on the drawings nor

shall any portion of the AFD system exceed a height of 90 inches. b. Front accessible only and shall not require rear access. c. Mount against the wall without any clearance for ventilation or other purposes. d. Submit AFD in the enclosure drawing with the detail of front door and the internal

arrangement, including the feeder and motor cables, and the control cables, and the instrument cable location and terminations.

8. AMBIENT NOISE: Free field noise generated shall not exceed 85 dBA at 3 feet out from any point on the AFD enclosure under any normal operating condition.

9. MOTOR COORDINATION: AFDs shall be configured as required to maintain output voltage peaks at the connected motor windings from reaching levels damaging to the motor insulation. Provide protection integral to the AFD or as protective hardware to be installed at the motors. a. Where motor terminator units are provided, they shall be rated for the environment in

which they are located. Motor terminator units shall be: b. Allen Bradley 1204 Motor Terminator for AFD with the maximum carrier frequency

of 6 kilohertz, c. Cutler Hammer Reflected Wave Trap (RWT) with the maximum carrier frequency of

12 kilohertz, d. Or Equal product

E. PROTECTION AND ANNUNCIATION: 1. OVERCURRENT PROTECTION: Electronic current limit at 150 percent of motor

nameplate current and provide motor running overcurrent protection in compliance with NFPA 70.

2. SHORT CIRCUIT PROTECTION: Protected against load faults: bolted faults, phase to phase or phase to ground shall not damage the unit. Fault protection based on a power source short circuit capacity of 42,000 amperes RMS symmetrical at the AFD power input terminals with impedance or current limiting device provided.

3. LINE VOLTAGE: Protected against high and low line voltage on one or more phases. 4. INTERNAL FAULTS: Internal fault monitoring system to detect malfunctions to protect

from transient and sustained faults and to limit damage that may be caused. 5. MOTOR OVER TEMPERATURE: Interface to motor over temperature device 2-ampere

output contact to shut down and alarm if the motor becomes overheated. 6. FAULT ALARM: Indicates the cause of any shutdown visible on the AFD keypad/display

without opening the AFD enclosure. As a minimum, the following faults shall be alarmed:


a. Motor over-temperature b. Motor overcurrent c. Incoming power line over/under/unbalanced-voltage d. AFD over-temperature e. AFD over-voltage f. AFD control failure

7. SAFETY FEATURES: The AFD shall include: a. Padlock main disconnect handle in the “OFF” position. b. Mechanical interlock to prevent opening enclosure door with disconnect in the “ON”

position while the unit door is open. c. Auxiliary contact on main disconnect to isolate 120Vac control power when fed from

external source. d. Barriers and warning signs on terminals that are energized with the power disconnect

“OFF”. e. Separation and insulated barriers between the power and control and instrument

products. f. External emergency stop input

8. REVERSE DIRECTION PROTECTION: Provide protection from inadvertent operation in reverse where reverse rotation can damage the driven equipment. CRITICAL SPEED BYPASS: Provide capability to program speed bypass for minimum two critical speed points.

9. TRANSIENT VOLTAGE PROTECTION: Provide solid state transient voltage protection to meet or exceed ANSI C37.90.

2.04 CONTROL AND MONITORING DEVICES

A. Front door mounted on the AFD enclosure between 36 inches and 72 inches above the floor for each unit: 1. Digital Operator keypad/display located on the enclosure door. 2. Local-Off-Remote door mounted selector switch. (NOT REQUIRED FOR THE

CENTRIFUGE VFD’s) 3. Manual speed control: Potentiometer function. (NOT REQUIRED FOR THE

CENTRIFUGE VFD’s) 4. Internal terminal strips for remote monitoring:

a. Run status b. Trouble / Fail alarm c. Auto Mode status d. Additional devices as indicated on the drawings.

B. OPERATOR INTERFACE UNIT: 1. Digital keypad/display for monitoring and controlling the drive and to input drive

parameter settings with a backlit LCD or equally visible display with a minimum of 16 characters per line.


2. Digital keypad for numerical settings in English engineering units and a guide to parameter settings. Setup operations and adjustments stored in non-volatile EEPROM memory transferable to new and spare boards. Settings shall be protected from unauthorized tampering, revision, or adjustment by a

3. The digital keypad to provide programming of the drive and include: a. Up and Down arrow keys: Increase or decrease output frequency or data values. b. Monitor key: Selection of control mode. c. Run and Stop keys: Starting and stopping in the manual mode. d. Fault clear / Enter keys: Reset fault conditions and enter chang e. Program key: Enter the program mode and adjust parameters. f. Remote / Local Location keys: Operation location and local speed control. g. Auto / Manual Mode keys: Program mode. h. Number keys: 0 through 9 keys to access specific parameters. i. Keypad digital illustrations: English and display the last 5 faults. j. Frequency / Motor Speed Indication: Calibrated in Hertz and RPM. k. Run Status Indication. l. Ready Status Indication. m. Fault Alarm Indication.

C. CONTROL AND MONITORING COMMUNICATION 1. EtherNet IP Communication Card, device level ring type.

2.05 KEYPAD FUNCTIONS AND OPERATION

A. Adjustment of the following parameters through the OIU digital keypad: 1. Current limit and torque boost. 2. Maximum voltage level. 3. Minimum/Maximum speed, Volts/Hertz, Upper and Lower limit. 4. Adjustable acceleration rate and deceleration rate. 5. Electronic thermal overload setting. 6. Coast, controlled ramp or DC injection selectable modes of stopping. 7. PID setpoint and time-function selection. 8. Critical frequency avoidance: Three set points selectable from 0 to 9. maximum frequency with set points adjustable from 0-30 Hertz.

2.06 SPARE PARTS

A. The following spare parts shall be supplied with each type or frame size AFD: 1. Three sets of all replaceable fuses for each type unit.

2.07 PRODUCT DATA

A. The following information shall be provided in accordance with Section 01300: 1. Operation and maintenance information as specified in Section 01730, including:

a. Final reviewed submittal.


b. As-built drive configuration settings. 2. Installation certification Form 11000-A as specified in paragraph 11069-3.01. 3. Training certification Form 11000-B as specified in paragraph 11069-3.03.

PART 3–EXECUTION

3.01 FIELD INSTALLATION

A. Each adjustable speed controller shall be installed and tested by the Contractor with the assistance of factory-trained pump manufacturer engineer/technician and AFD engineer/technician in accordance with the manufacturer's specifications and Section 11069, and witnessed by the Construction Manager.

B. Manufacturers’ factory representatives shall provide field testing for devices including the setup of the Operator Interface Unit and the setup of the data communication devices, where used. Upon satisfactory completion of the testing, the Contractor shall submit two certified copies of the test report to the Construction Manager.

C. Component failure during testing will require repeating any test associated with the failure or modified components to demonstrate proper operation.

D. The installation shall be certified on Form 11000-A specified in Section 01999. 1. Adjust drive and perform “start-up” tests as recommended by manufacturer. Set

parameters and carrier frequency for existing motors to avoid insulation damage. 2. Establish proper direction of rotation for the motor controlled by the drive. Verify that

the AFD is precluded from operating in a direction that can damage the driven equipment. Change motor or AFD power lead connection and not the AFD direction, where rotation is incorrect.

3. Verify that the drive will operate properly both in the “manual speed control mode” and in the “remote or automatic mode” from a remote speed signal input.

4. Set the maximum “locked rotor” current drawn during start-up recommended by the manufacturer and approved by the Construction Manager.

5. Set the minimum and maximum speeds and the acceleration and deceleration “ramps” recommended by the Construction Manager.

6. Verify the motor high temperature switch contacts are wired into the AFD 120 Vac control circuit and will trip on high winding temperature. Test or simulated the alarm and trip feature at the motor for high temperature and for high vibration, where used.

7. Operate the drive at 100 percent speed for one hour and monitor output current. The output current shall remain below the full load current listed on the motor nameplate.

8. Check for excessive heating of the drive and motor. Report any discrepancies to the Construction Manager.

3.02 HARMONIC TESTING

A. The Testing Firm specified in Section 16030 shall perform a harmonics acceptant test with all AFD motor controllers operating to verify compliance with IEEE-519 of less than 5 percent voltage THD and 12 percent current THD at the defined point of common connection when running from Power Utility power source with a BMI-Dranetz or equal harmonic test set that provides a hard-copy record of the test results.


B. The test shall also be run with power sourced from the standby generator where such a power source is being used at the project site. THD shall be limited to a maximum level of 8 percent voltage THD on standby generator operation.

C. Submit the test performance to the Construction Manager per latest version NETA ATS Acceptance Testing Specifications. Refer to the electrical testing specification Section 16030.

3.03 TRAINING

A. Two hours of onsite AFD operation and maintenance training shall be provided for the Owner’s Operation and Maintenance Staff.

B. Manufacturers’ factory representative shall conduct the training, upon acceptance of a resume submitted by the trainer.

C. Training shall be certified on Form 11000-B specified in Section 01999.

**END OF SECTION**

150141 – 2017 Upgrades and Rehabilitation 11347-1 Submersible Wastewater Pumps James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 11347

SUBMERSIBLE WASTEWATER PUMPS - VARIABLE SPEED

PART 1–GENERAL

1.01 SUMMARY

A. Scope: 1. This section specifies submersible pumps suitable for pumping fluids containing screened

wastewater solids at infinitely variable speed. Pumps furnished under this specification shall have discharge nozzles greater than 3 inches in diameter and shall have motors 7.5 horsepower and larger.

2. Each pump will be driven by a single variable speed drive provided under Section 11069. The pump vendor shall submit a letter of confirmation on the suitability for use of the Contractor’s proposed drive selection.

3. Pumps will be installed in a wet-pit configuration. 4. Pump units shall be complete with motor, inlet nozzle, discharge fitting, guide bar and

brackets, chain and cable hooks and other accessories as specified. 5. Manufacturers proposing to furnish equipment specified under this section shall hold

current certification under ISO 9001-2001. Application for certification under ISO 9001 shall not be deemed as an acceptable substitute for current certification. Documentation attesting to current certification shall be signed by an officer of the manufacturer’s corporation and shall be notarized.

6. Equipment shall additionally conform to the requirements of Section 11050 with the exception that provisions of Section 11050-1.05 and Section 11050-1.07 do not apply unless specifically called out in this project specification.

B. Type: 1. Pumps shall be of the heavy-duty, submersible, vertical shaft, centrifugal nonclog type,

suitable for pumping fluids containing screened wastewater solids. The pumps shall be designed for continuous or cyclic operation under submerged, partially submerged, or totally dry condition without damage to the pump and motor. Special attention shall be devoted to the shaft design to limit deflection under all operating conditions, as specified in this section.

C. Equipment List:

Item Equipment Number

Raw Sewage Pump 1A P-6301A Raw Sewage Pump 1A VFD VFD-6301A Raw Sewage Pump 1B P-6301B Raw Sewage Pump 1B VFD VFD-6301B Raw Sewage Pump 1A 1B Control Panel VCP-6301 Hydroyclones Feed Pump 1 P-8211 Hydroyclones Feed Pump 1 VFD VFD-8211 Hydrocyclones Feed Pump 2 P-8212 Hydrocyclones Feed Pump 2 VFD VFD-8212


1.02 RELATED SECTIONS

A. This section contains specific references to the following related sections. Additional related sections may apply that are not specifically listed below. 1. Section 11069 Adjustable Frequency Drives 2. Section 11050 General Requirements for Centrifugal and Axial Flow Pumping 3. Section 11000 General Requirements for Equipment 4. Section 11002 Rigid Equipment Mounts 5. Section 11060 Electric Motors 6. Division 16 Electrical 7. Division 17 Instrumentation and Controls

1.03 REFERENCES

A. This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail.

B. References shall be as listed in Section 11050.

1.04 DEFINITIONS

A. Terminology used in this section conforms to the following definitions:

B. Equipment Pad: concrete foundation (block or slab) supporting and elevating equipment mounts above the supporting structural floor slab or local grade

C. Mounting Pads: thickened or raised areas of baseplates and soleplates where the feet or mounting surfaces of mounted equipment and drivers rest on the baseplate or soleplate

1.05 ADMINISTRATIVE REQUIREMENTS

A. Coordination: 1. Coordinate pump and motor operational and starting characteristics with adjustable-

frequency drive settings used for control of this equipment. A system curve is available upon request from the Construction Manager. Include the following:

2. Motor minimum operational speed 3. Motor maximum operational speed 4. Motor ramp-up and ramp-down speed, voltage, and hertz requirements 5. Other operating limits that are imposed by the driven equipment for operation and

warranty

B. Unit Responsibility: 1. Assign unit responsibility, as specified in Section 11000, to the manufacturer of the

vertical, nonclog submersible pumps provided for all equipment and accessories under this section. Have all mechanical equipment components, at least, of this entire


equipment assembly furnished by the pump’s manufacturer. Provide a completed, signed, and notarized Certificate of Unit Responsibility (Form 11000-C, Section 01999). The manufacturer shall submit a letter indicating whether the proposed units are satisfactory or not for use with the pumps in this section.

1.06 SUBMITTALS

A. Action Submittals: 1. Procedures: Section 01300. 2. Submittals shall conform to the requirements of Section 11050. A copy of this Section,

addendum updates included, along with the sections listed below shall be submitted with each paragraph check-marked to indicate compliance or marked to indicate requested deviations.

3. This Section (11347) 4. Section 11000 – General Requirements for Equipment 5. Section 11002 – Rigid Equipment Mounts 6. Section 11060 – Electric Motors 7. Section 11050 – General Requirements for Centrifugal and Axial Flow Pumping

Equipment 8. The specification copies shall be complete with addendum updates included, with each

paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check-marks () shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated and, therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. The submittal shall be accompanied by a detailed, written justification for each deviation. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.

9. A copy of the contract document control diagrams and process and instrumentation diagrams relating to the submitted equipment, with addendum updates that apply to the equipment in this section, marked to show specific changes necessary for the equipment proposed in the submittal. If no changes are required, the drawing or drawings shall be marked "no changes required". Failure to include copies of the relevant drawings with the submittal shall be cause for rejection of the entire submittal with no further review.

10. Unit Responsibility Certification form (Form 11000-C) attesting that unit responsibility has been assigned in accordance with the requirements of this Section and Section 11000. No other submittal material will be reviewed until the certificate has been found in conformance with this requirement.

11. Predicted pump performance curves for each condition point specified showing head, power, efficiency, and NPSH on the ordinate plotted against capacity on the abscissa. Curves shall be provided to demonstrate operation at all speeds required to achieve the specified reduced speed operating conditions. All curves shall clearly display the specified operating conditions, POR and the manufacturer’s limits for the AOR.


12. Drawings showing general dimensions and confirming the size of pumps, motors, drives and specified appurtenances; piping connections; construction details of equipment (including bearings and bearing isolators); wiring diagrams; and weight of equipment.

13. Control panel drawings and schematics including the following: a. Fabrication details and placement of operator interface devices and associated

elements. b. Scale drawings showing dimensions and location of panel-mounted devices, doors,

louvers, and subpanels, internal and external. c. Construction details showing panel NEMA rating, enclosure dimensions, panel

configuration (e.g., type of mounting), panel material, internal backplane dimensions, detailed cable configuration and protocol configuration, and other construction details.

d. Schematic diagrams using NEMA standards. e. Instrumentation and control components schedule including item number, tag

designations, nameplate inscriptions, instrument scale, and any other special information and remarks required for clarity.

f. Bill of materials indicating item identifier, tag number, description, model number, and quantity.

g. Construction notes including panel wire color schemes, wire and terminal block numbering, and labeling scheme.

h. PLC-related items, if used, such as input/output (I/O) type and address, PLC rack number, PLC slot number, PLC point number, PLC number, and PLC equipment manufacturer and part numbers. The PLC I/O shall be developed based on the City’s Design Criteria Standards.

i. Shop painting systems, including descriptive technical catalog literature and specifications.

14. Control sequence descriptions for equipment control and external interface requirements which would be provided if controls were provided by Manufacturer as a package system (either hardwired or PLC-based) which meets specified requirements herein and shown on Drawings. Include recommendations for operation and safety interlocks if required. The control sequence descriptions shall be provided in non-technical terms using clear sentence structure that includes sequence of events, interlocks, action on fault conditions, set points for alarms, and process ranges.

15. Manufacturer's data including materials of construction and equipment weight. 16. Motor Data Form 11060-A. 17. Proof of service of previously installed units of similar size and configuration in wet

wells of the type specified in this Section. 18. Written factory tests report, as specified in paragraph 1.19. 19. Shaft deflection calculations. 20. Anchorage calculations and required documentation. 21. Cooling system calculations. 22. Manufacturer’s operation and maintenance information in accordance with Section

01730. 23. Installation Forms in accordance with Section 11000. 24. 5-Year warranty in accordance with paragraph 1.09. 25. Testing Forms in accordance with Section 01660.


26. Field vibration test protocol as specified in ANSI/HI 11.6. 27. Field discharge connection leakage test video files in accordance with paragraph 3.03.

B. Informational Submittals: 1. Procedures: Section 01300. 2. Submittals shall conform to the requirements of Section 11050. 3. Letter of confirmation of suitability of variable frequency drives being provided by the

pump manufacturer for this equipment in accordance with Section 11069. 4. Coordination items required for proper setup of the variable frequency driver as specified

in paragraph 1.05.A. Coordination.

C. Closeout Submittals: 1. Operating and maintenance submittals.

D. Procedures: Section 01730.

E. Spare parts: 1. Procedures: Section 11000. Provide the following spare parts for each model and size of

pump furnished for this Section: 2. One complete set of all gaskets and seals 3. Two complete sets of all bearings 4. Two complete sets of mechanical seals 5. Two complete sets of discharge connection sealing devices 6. One removable cable seal chamber cap with cable length as required in this Section. 7. If oil-filled motor is furnished, provide spare oil in sufficient quantity to allow for one-

time flushing and replacement of coolant for all installed pumps. 8. One complete spare pump 9. Two sets of each type fuse 10. Two of each type relay


A. Qualifications: 1. Independent testing agent hired by the Contractor for field vibration testing: Section

11050. 2. Critical Speeds: Critical Speeds shall be in accordance with Section 11050-1.04 except

when the title of the detailed section includes “Custom Engineered” in which case Section 11050-1.05 applies.

3. Vibration Limits: Vibration limits for submersible pumps shall be in accordance with ANSI/HI 11.6. Field testing shall be in accordance with paragraph 3.03 of this section.

1.08 DELIVERY, STORAGE, AND HANDLING

A. Procedures: Section 01605

B. Block shaft and prevent damage to bearings during shipment


1.09 SPECIAL WARRANTY

A. Provide a Special 5-Year Warranty. The manufacturer shall warrantee the pumps provided under this section against defects in materials and workmanship for 5 years.

PART 2–PRODUCTS

2.01 MANUFACTURERS

A. Raw Sewage Pumps 1. (Add#1) The Owner and Engineer believe the following manufacturers are capable

of producing equipment and products which will satisfy the requirements of this Section. This statement, however, shall not be construed as an endorsement of a particular manufacturer's product, nor shall it be construed that a named manufacturer's standard product will comply with the requirements of this Section. The following candidate manufacturers are capable of producing equipment and/or products that will satisfy the requirements of this Section. The manufacturer’s standard product may require modification to conform to specified requirements: a. Xylem – Flygt b. Sulzer c. (Add#1) Ebara d. Engineer approved equal

B. Hydrocyclones Feed Pumps 1. The following candidate manufacturers are capable of producing equipment and/or

products that will satisfy the requirements of this Section. The manufacturer’s standard product may require modification to conform to specified requirements: a. Sulzer b. Engineer approved equal

2.02 TYPE

A. Heavy-duty, submersible, vertical shaft, centrifugal nonclog type, suitable for pumping fluids containing unscreened wastewater solids.

2.03 PERFORMANCE/DESIGN CRITERIA

A. Service Conditions:

Description

Equipment number P-6301A P-6301B

P-8211 P-8212

Area exposure Per Section 16000, Class I, Division 1 Not classified

Fluid type

Screened wastewater containing up 300 mg per liter of suspended solids consisting of organic and inorganic materials, rocks, grit, petroleum products, and grease The pumped material will have a tendency to form long fibrous strings due to the rotation of water through the piping passageways.

Screened wastewater containing up 300 mg per liter of suspended solids consisting of organic and inorganic materials, rocks, grit, petroleum products, and grease The pumped material will have a tendency to form long fibrous strings due to the rotation of water through the piping passageways.

Fluid temperature 40 to 75 degrees F 40 to 75 degrees F


B. Operating Conditions: 1. The performance requirements presented in tabular form below are intended to describe

the results of hydraulic calculations developed using a mathematical modeling program specifically developed for the purpose. The model was intentionally used to develop the limits of expected extremes in variation of static head, coefficients for pipeline resistance, and turbulence losses through fittings and valves.

2. Equipment furnished under this section shall be fully suitable for continuous operation at any specified condition or any condition lying between the extremes of the operating conditions specified in the following table. The total head in the information below is the total system head at the operating capacity, essentially a summation of the head of the two pumps at that capacity. The notes presented at the end of the table are intended to be complementary to the information presented in the table.

C. Table of Operating Conditions:

Operating Condition Value Value Equipment number P-6301A

P-6301B P-8211 P-8212

Full-speed operation, Condition A 1,5 Capacity, gpm 3820 176 Total head, feet 37 95 NPSHA, feet 24.6 26.4 Full-speed operation, Condition B 2,5 Capacity, gpm Per H/C curve Per H/C curve Total head, feet 33.5 82 NPSHA, feet 26.3 28.6 Reduced-speed operation, Condition C 3,5 Capacity, gpm 2462 88 Total head, feet 35 81 NPSHA, feet 24.6 26.4 Reduced-speed operation, Condition D 4,5 Capacity, gpm 0 0 Total head, feet 34 93.5 NPSHA, feet 24.6 26.4

1. Condition A shall be taken as the rated operating condition. Performance at the rated condition shall be guaranteed in accordance with Section 11050. Condition A has been selected to obtain the rated pumping capacity for the installation. It is not intended that the pumps be selected for maximum efficiency at Condition A. Pumps furnished under this section shall be selected to achieve Condition A performance, and also shall operate continuously without objectionable vibration or cavitation at the head specified under Condition B. Condition A shall be located in the Preferred Operating Region as established by the pump manufacturer in accordance with ANSI/HI 9.6.3 and published in the manufacturer’s published application data for the specific model proposed for this application.

2. Condition B head is presented to indicate operating conditions when the pump is operating at maximum speed against minimum anticipated system head, assuming a hypothetical head-capacity curve. Condition B shall be used for pump selection. Condition B shall be located within the Preferred Operating Region as established by the pump manufacturer in accordance with ANSI/HI 9.6.3 and listed in the manufacturer’s published application data for the specific model proposed for this application. Condition B shall be located to the right of BEPQ. Pumps with head-capacity curves steeper than that assumed will produce somewhat less flow at somewhat lower head. The reverse will occur with pumps having a shallower head-capacity curve. Proposed pump selections meeting this discharge head requirement by operating the equipment at less


than full speed will be rejected. NPSHA, as listed for Condition B is calculated on a pumped flow of 4,200 gpm for the Raw Sewage Pumps and 220 gpm for the Hydrocyclones Feed Pumps.

3. Condition C is the anticipated continuous duty minimum speed condition. Pumps furnished under this specification shall be capable of sustained (24 hours per day) operation at this condition within the requirements set forth in Section 11050. Condition C shall be located within the Preferred Operating Region as established by the pump manufacturer in accordance with ANSI/HI 9.6.3 and listed in the manufacturer’s published application data for the specific model proposed for this application.

4. Condition D represents the expected momentary (startup/shutdown) condition. Pumps furnished under this specification will operate for no more than 30 seconds at this condition when initiating or terminating a service cycle. The maximum anticipated number of service cycles is 12 per day.

5. Total head in the above tabulation is the algebraic difference between the discharge head and suction head as defined in ANSI/HI 1.1 – 1.6. Net positive suction head available (NPSHA) in the above tabulation is referred to the pump inlet piping at centerline elevation as shown and is calculated in accordance with ANSI/HI 1.3 for average barometric pressure and maximum temperature conditions. NPSHA at the pump impeller eye can be determined by adjusting the given value by proposed pump dimensions and the indicated requirements for pump installation details. An allowance of five feet has been included for the presence of volatile constituents in the pumped fluid. Required NPSHA margin shall be as specified in Section 11050.

6. Maximum expected surge pressure is 1.5 feet.

D. Design Requirements:

Item Value Value Equipment number P-6301A

P-6301B P-8211 P-8212

Rigid sphere, inches diameter (min.), capable of passing through the pump from inlet to discharge (Impeller Alternate 1/Alternate 2)

4 2.6

Minimum efficiency at best efficiency point (BEP) at maximum speed, percent 1

80 35

Piping connection size, inches, minimum Pump inlet 12 3 Pump discharge 12 3 Inlet bell outer diameter, minimum2 4 Operating speed, rpm, maximum 1200 3520 Operating speed, constant or variable Variable Variable Approximate pump suction centerline elevation, feet 4617.4 4639.7 Maximum expected surge pressure, feet 1.5 times discharge pressure 1.5 times discharge pressure Motor

Maximum Horsepower 60 25 Type Submersible, explosion

proof Submersible

Inverter duty Yes Yes Over temperature protection Yes Yes Moisture sensors Yes Yes Operating speed, rpm, maximum 1200 3520 Voltage/Phase 460 VAC, 3 Phase 460 VAC, 3 Phase

1. The minimum acceptable efficiency at best efficiency point (BEP) at the speed required to achieve the performance specified under Condition Points A and B. The minimum acceptable efficiency is not necessarily required to be associated with any operating condition specified in paragraph 1.13 Operating Conditions.

2. The inlet velocity shall not exceed 4 feet per second at Condition Point B as specified in this Section. A suction nozzle, fitted with a flared inlet, will be required to reduce the suction velocity to 4.0 feet per second or less, and the nozzle length must exceed the difference between the inlet and outlet diameter of the nozzle. It is preferred that the suction nozzle be a standard US or metric ductile iron flange-to-flare fitting.


E. (Addendum#1) Raw Sewage Pumps 1A and 1B (P-6301A and P-6301B) shall be able to connect to and be compatible with the base elbows of the existing Raw Sewage Pumps manufactured by Flygt.

2.04 SYSTEM OPERATION

A. Equipment numbers P-6301A and P-6301B 1. The pumps will be installed in an outdoor reinforced concrete structure downstream of the

headworks facility. The pumps will obtain the pumped fluid from a common influent channel. In this application, the pumps will be operated at variable speed, responding to a control system that will cycle and vary the speed of the pumps in accordance with the specified program. Under normal operation, there will be no cascade into the wet well and the wet well level will vary between the levels indicated.

2. The pumps will be operated by a control system configured to control wet well liquid surface elevation. This objective will be achieved by adjusting pump speed to match the pumping rate to the rate of inflow into the wet well. The pump drives will be adjusted to establish minimum speed when the wet well is at preset low elevation. Pump speed control increments and sequenced starts of additional pumps will be initiated based on rising wet well level. Pumps will be at maximum speed when the liquid level is at the preset maximum level.

B. Equipment numbers P-8211 and P-8212 1. See Section 17900 for system operation.

2.05 MATERIALS

A. Materials specified are considered the minimum acceptable for the purposes of durability, strength, and resistance to erosion and corrosion. The Contractor may propose alternative materials for the purpose of providing greater strength or to meet required stress limitations. However, alternative materials must provide at least the same qualities as those specified for the purpose.

B. Provide materials of construction in accordance with the following table:

Component Material Pump and motor casing Rated head < 100 feet Rated head > 100 feet

Cast iron, ASTM A48, Class 30 or 35 Cast ductile iron, ASTM A 536, Class 65-45-12

Discharge elbow Cast iron, ASTM A48, Class 30 or 35 Impeller Cast duplex stainless steel, ASTM A744 or European standard

1.4474, or Cast duplex stainless steel, ASTM A890 Grade 1B, or Hard Chrome Iron ASTM A532-IIIA

Motor and pump shaft Stainless steel, ASTM A276 Type 329, 403, 416, 420 or ASTM A479 Type 403, 431

Wearing rings Stainless steel, ASTM A276 Series 440B or Cast duplex stainless steel, ASTM A890 Grade 1B or 5A

External bolts and nuts Stainless steel, ASTM A276 Type 316 Guide bar brackets Stainless steel, ASTM A276 Type 316 Anchor bolts Stainless steel, ASTM A276 Type 316 Guide rails, lifting assemblies Stainless steel, ASTM A276 Type 316


2.06 COMPONENTS

A. General: 1. The motor and rotating parts shall be removable from the motor end of the pump. All

motor mating surfaces where watertight sealing is required shall be machined and fitted with nitrile O-rings. The pump shall be fitted with a dynamically balanced nonclog impeller designed to pass coarse solids and stringy materials. The pump shall be listed by Factory Mutual or Underwriters Laboratory as conforming in all respects to the requirements in UL 1207.

B. Casing: 1. The volute casing shall be a one-piece casting with a tangential or center discharge

nozzle. The volute shall be designed for efficient conversion of kinetic to potential energy and shall have clear passageways designed to pass the solid sphere specified in this Section. The solids passing capability of the furnished equipment will be subjected to a field test in accordance with this Section. The solids passing capability of the furnished equipment will be subjected to a field test in accordance with paragraph 2.03.

2. The cutwater shall be specifically designed for use in fluids with stringy solids and rags. The volute casting shall be specifically designed to bear the loads associated with removal and placement of the pump when submerged or exposed and to withstand the loads imposed by the operations specified in this Section. The discharge nozzle shall be not less than the diameter specified in this Section and shall be reinforced for the loads imposed by the specified conditions of service. The nozzle flange face shall be designed to mate with the discharge fitting specified in this Section. The volute casing shall be drilled and tapped or otherwise fitted with an inlet nozzle conforming to the requirements specified in this Section.

C. Shaft: 1. The pump shaft shall be turned, ground and polished, of proportions suitable for use in

the specified application. The shaft shall be of sufficient section to limit deflection at the shaft seal to not more than 4.0 mils when the pump is operating at any continuous-duty point defined by the envelope of conditions specified in this Section. The method for calculating shaft deflection shall be as established in Section 11050. Additionally, under no circumstances shall the distance from the lower bearing and the hub of the impeller exceed two times the diameter of the shaft. The documentation required under Section 11050 shall be included as a submittal.

D. BEARINGS: 1. Bearings shall be heavy-duty, oil lubricated or permanently greased lubricated anti-

friction type double shielded and factory sealed. Bearings shall be designed for an L-10 rating life of at least 50,000 hours at any operating condition specified in this Section. Loads for radial bearing calculations shall be calculated in accordance with this Section. Bearings isolators in accordance with 11050 are not required for submersible pumps.

E. Impeller: 1. The impeller shall be dynamically balanced with a non-clogging design capable of

passing solids, fibrous materials, heavy sludge, and other matter found in normal sewage applications through to the discharge nozzle. Impellers for pumps with discharge nozzles


4 inches in diameter and greater shall be not less than two-vane design. Fit between the impeller and the shaft shall be a sliding fit with a taper-lock bushing pressed by a screw that is threaded into the end of the shaft, or a slip fit onto the shaft and drive key and fastened to the shaft by an impeller nut having cover for protection from pumped fluid. A wearing ring system designed for abrasion resistance shall provide efficient sealing between the volute and impeller.

F. Mechanical Seals: 1. The pump shall be provided with a tandem double mechanical seal running in an oil

reservoir, composed of two separate lapped face seals. The lower seal unit, between the pump and oil chamber, shall consist of one stationary and one positively driven, rotating tungsten-carbide or silicon-carbide ring, with each pair of rings held in contact by a separate spring. The upper seal unit, between the oil sump and the motor housing, shall consist of one stationary tungsten-carbide or silicon-carbide ring and one positively driven tungsten carbide, or silicon-carbide ring. Ceramic seals will not be acceptable. The seals shall require neither maintenance nor adjustment and shall be easily replaceable. Conventional double mechanical seals with a single or a double spring between the rotating faces, or that require constant differential pressure to effect sealing and are subject to opening and penetration by pumping forces, will not be acceptable. The pump shall be capable of continuous submergence without loss of watertight integrity to a depth of 65 feet. The mechanical seal shall accommodate the manufacturer’s shaft deflection at the seal face and shaft angularity with a safety factor of 3.

2. Each pump shall be provided with a seal lubricant chamber for the shaft sealing system. The seal lubricant chamber shall be designed to assure that an air pocket is provided in the seal lubricant chamber, to absorb the expansion of the seal lubricant due to temperature variations. The drain and inspection plug with positive anti-leak seal shall be easily accessible from the outside.

G. MOTOR: 1. The pump motor shall be a squirrel-cage induction, shell type design, housed in an air-

filled or an oil-filled, watertight chamber, NEMA B type Inverter Duty with a service factor of 1.15 based upon nameplate rating. Motor shall be rated for operation with VFD. The manufacturer shall furnish an unqualified warranty guaranteeing (full replacement at no cost to the City) the performance of the motors furnished under this project for a period of five years when operating under the specified conditions.

2. The stator winding and stator leads shall be insulated with moisture resistant Class H insulation, which shall be rated at a temperature of 180 degrees C. Motor shall be provided with thermal sensors to protect the motor from excessive heating. Thermal sensors shall be as specified in this Section. The temperature rise of the motor shall not be in excess of that specified in NEMA MG-1 for class B insulating materials when operating continuously under load.

3. Motors shall be Factory Mutual or UL listed in accordance with UL 674 and 1207 for Class I, Group D hazardous atmospheres.

4. The motor shall be designed for continuous duty in air and in 95 degree Fahrenheit water, capable of sustaining a minimum of 20 starts per hour when operated with variable frequency motor controllers.

5. The junction chamber, containing the terminal board, shall be hermetically sealed from the motor. Connection between the cable conductors and stator leads shall be made with threaded compressed type binding post permanently affixed to a terminal board.


H. COOLING SYSTEM: 1. The cooling system may rely on radiation of excess heat energy to the fluid in the wet

well or, alternatively, shall be provided a closed circuit circulating system utilizing glycol or heat transfer oil, which shall in turn circulate to a heat exchanger incorporated into the cavity behind the pump impeller. It is specifically required that the cooling system be compatible with the contemplated control schedule, which may require that the motor case to be exposed continuously or intermittently.

2. The cooling jacket shall encircle the stator housing to provide cooling for the motor under all conditions (i.e., submerged or non- submerged).

3. The cooling system shall not employ the pumped fluid to directly cool the motor through wastewater passageways incorporated into the motor shell.

4. The system shall be designed to prevent clogging by virtue of dimensions and configuration and shall be specifically configured to maintain motor temperatures within conservative limits.

I. Temperature Sensors: 1. The stator shall be equipped with three thermal sensors, embedded in the end coils of the

stator winding (one sensor in each stator phase). These shall be wired to the specified motor protection relay for motor protection.

J. Moisture Detection: 1. Provide motors with a moisture detection system.

a. A primary moisture detector shall be provided in the stator housing leakage chamber. b. A second moisture detector shall be located in the motor junction box or inspection

chamber. 2. All moisture detectors shall be wired to the motor junction box for connection to the

specified motor protection relay. 3. Moisture detectors shall be either mechanical float switch or capacitance probe type as

recommended by the manufacturer.

K. Motor Protection Relay: 1. Provide motor protection relay to protect motor from high temperature and moisture. 2. During normal pump operation, the temperature switch shall be closed and the leakage

switch shall be normally open. Sensor circuit shall operate on 12 or 24 VDC feed from the main relay body. The relay shall be provided with LEDs to indicate status of relay on face for leakage, temperature, and supply voltage.

3. Latch detection of open temperature switch. An external reset shall be required to clear alarm.

4. Moisture detection shall auto reset. 5. Power supply shall be 120 VAC. 6. Provide one SPDT contact for remote over-temperature alarming. Provide one SPDT

contact for remote moisture detection alarming. 7. Relay shall be UL or UR approved, suited for panel installation. 8. Relay shall be mounted inside the associated pump’s motor controller panel. Mounting

shall be DIN rail mount or back panel mount. Coordinate to provide relay for installation at the shop where the associated motor controller is being fabricated. Coordinate size, wiring, and mounting of the relay into the motor controller.


9. During power failures and restoration of power, the protective relays shall come to the ready state. If an alarm occurs the fault shall latch and require a manual reset.

10. Relay manufacturer shall be Xylem-Flygt, ATC Diversified Electronics, Dwyer, or approved substitute.

L. Variable Frequency Drives: 1. The variable frequency drive will be provided per Section 11069 and will conform to the

requirements of Section 11069, the Contract electrical one-line diagrams, and the Contract wiring diagrams.

2. P-6301A and P-6301B: The variable frequency drives shall be integral to Vendor Control Panel VCP-6301. Pump manufacturer shall be responsible for the variable frequency drives and the Control Panel, inclusive of level control and motor protection systems.

3. (Addendum#1) P-8211 and P-8212: The variable frequency drives shall be integral to Local Control Panel LCP-8211 8200. Contractor shall be responsible for the variable frequency drives and the Control Panel, inclusive of level control and motor protection systems.

M. Cables: 1. Cable:

a. The pump shall have two cables. One cable shall be for power, and one cable shall be for control (the motor thermal sensors and moisture detector). The cable design shall be suitable for installation in a municipal wastewater pumping station. The cable length shall not exceed the product manufacturer’s recommended length. The Contractor shall be responsible for determining the length of cable required to wire the motors and sensors from the wet well to the terminal boxes. The Contractor shall provide additional cable length for slack to allow the pumps to be removed from the wet well. The length of cable for slack shall be based on the pump manufacturer’s recommendation.

2. Cable Seal: a. The cable entry water seal design shall preclude specific torque requirements to

insure a watertight and submersible seal. The cable entry shall be comprised of individual cylindrical elastomer clamps having a close tolerance fit against the cable conductor insulation and the entry inside diameter and compressed by the entry body containing a strain relief function, separate from the function of sealing the cable. The cable entry junction chamber and motor shall be separated by a stator lead sealing gland, potting chamber or terminal board, which shall isolate the motor interior from foreign material gaining access through the pump top. If a potting chamber is used, the potting procedure shall employ an epoxy-potting compound combined with a procedure that insures penetration of the compound into the individual cable conductor strands to prevent development of wicking pathways for entrance of water into the motor.

3. Cable Disconnection: a. The pump shall be designed such that power/ control cable can be removed from the

pump motor without breaking the cable seal. The power/ control cable shall be sealed to a removable motor chamber cap that shall be universal to the same manufacturer’s pump series. The pump shall be able to be removed from the wet well and disconnected from the cable by removing the motor chamber cap.


N. TERMINAL BOXES: A NEMA 4X, 316SST, terminal box shall be provided for each submersible pump. Cords from the pumps shall be connected to the terminal boxes with plugs. The contractor shall terminate submersible cables at the terminal boxes per this section. 1. Boxes:

a. Unclassified. b. Water tight. c. See the drawings for information about boxes, conduits, and cords. d. Terminals per specification Section 16110.

2. Pump terminal box: a. Contain a ground stud bonded to the enclosure and support four #8 AWG crimped

one hole standard barrel terminal lugs.

O. Inlet Nozzle: 1. The wet well design for the hydrocyclones feed pumps (P-8211 and P-8212) has been

developed on the basis of limiting velocity at the pump inlet to 4 feet per second and a confined inlet designed for cleaning by operating the pump until it breaks suction. Inlet nozzles are required for all hydrocyclones feed pumps with entrance velocities exceeding this limitation. If a nozzle is required, the pump casing shall be drilled and tapped to receive an inlet nozzle and bell fitting to extend the pump inlet connection into the confines of the wet well or sump to achieve the floor separation required by the Hydraulic Institute Intake Standard (ANSI/HI 9.8). The inlet nozzle may be of commercially available forged steel fittings or cast iron and shall have a smooth, flared transition from a bell fitting at the entrance to the nozzle and a smooth, direct entry to the connection at the impeller inlet. The final configuration of the inlet bell and nozzle shall be selected to efficiently convey the pumped fluid into the impeller eye. Dimensions shall be as specified in this Section.

P. Pump Discharge Connection Seal: 1. The connection between the pump discharge connection shall be fitted with a means of

sealing. The seal may be either a replaceable dynamic seal or a metal-to-metal seal to effect a complete closure between the pump discharge flange and the mating connection on the anchor fitting described in this Section. Leakage through the seal shall not exceed 1.5 percent of the flow specified for Condition Point A when operating at pump shutoff head and not more than 1 percent of total pump flow at Condition Point B. The seal shall be subject to field test for acceptance in accordance with the requirements of this Section.

2. The dynamic type of seal shall affect a seal meeting the requirements of this paragraph using the head developed by the pump when in operation to expand the sealing device, which may be of metallic or elastomeric construction, against the inner contours of the discharge fitting. The design of the seal shall incorporate features to protect the integrity of the seal during the pump removal/setting process.

Q. Pump Anchorage, Guide System and Access Cover: 1. The pump shall be provided with a guide system to allow easy removal of the pump

without entering the wet well. The guide rail system may be of either the single or dual rail type. The discharge connection shall be bolted to the structure as indicated and shall serve as a lower attachment for the guide rails. The discharge connection shall be either horizontal or elbow discharge type, as indicated. The anchorage system shall be designed


to transmit the forces specified in this Section safely to the structure. Calculations and supporting documentation justifying the support design shall be provided with the submittals required under Section 11050.

2. The pump and guide rail system shall be designed to automatically connect the pump to the discharge piping when lowered into place on the discharge connection. The design shall be non-sparking and shall conform to UL requirements for installation in a location classified in accordance with NFPA 70, Article 500 for Class 1, Group D, Division 1 locations. The pump shall be easily removable for inspection or service, requiring no bolts, nuts, or other fastenings to be removed for this purpose, and no need for personnel to enter the pump wet well or sump. Sealing of the pumping unit to the discharge connection shall be accomplished by a simple linear downward motion of the pump with the entire weight of the pumping unit guided to and pressing tightly against the discharge connections. No portion of the pump shall bear directly on the floor of the sump and no rotary motion of the pump shall be required for sealing. Guide bars provided for directing the pump into position or for removing the pump for maintenance shall steer the pump into proper contact with the discharge elbow. Once the pump has been positioned on its support fitting at the discharge fitting, the guide bar system shall not be required for pump support.

3. Hardware and miscellaneous attachments shall all be constructed out of ASTM A276, Type 316 stainless steel. Dielectric isolation shall be provided for dissimilar metals.

R. Accessories 1. Pumps shall be provided with lifting chains, guide bars, upper guide bar brackets,

intermediate guide bar brackets, cable holder assemblies, safety chain hook assemblies, discharge elbow connections, metric to english pipe increaser, anchor bolts, and all other accessories necessary to complete the installation as specified. All connecting hardware and miscellaneous attachments shall be constructed out of ASTM A276, Type 316 stainless steel. Dielectric isolation shall be provided for dissimilar metals.

2.07 ELECTRICAL COMPONENTS AND ACCESSORIES

A. Provide all necessary electrical components and wiring for a complete, functional system. Electrical components and wiring shall be provided and installed in accordance with the National Electric Code (NEC) and additional requirements by the State of Colorado as necessary.

B. Variable speed drives shall be as required by Section 11069 and installed in the control panels supplied under this Section.

2.08 INSTRUMENTATION AND CONTROLS

A. GENERAL: 1. Provide the Control Panel as specified in this Section and as shown on the Contract

Drawings. Each control panel shall be NEMA 4X with 3 point latching handle, 316 stainless steel, manufacturer powder coated white and shall be UL-508A approved. The control panel shall be supplied with one 480 Vac, 60 Hz, 3-phase power as shown; power supply shall be provided under Division 16. The control panel shall be provided with a control power transformer to power the controls at 120 VAC. Control panels shall be constructed in accordance with Divisions 16 and 17. The local control panel shall contain operator control devices, control relays, indicating lights and other panel devices


as specified in Division 17, and as shown on the contract drawings. The control system shall be configured where upon loss of power and return of power the system shall return to the ready state. Provide a main circuit breaker, flange type, 480 V, 60 Hz, three phase, with minimum 42K AIC. VFD’s, shall be supplied as part of the manufacturers/contractors control panel. 480 VAC power equipment shall be separated, using a painted metal barrier, from the 120 VAC equipment.

2. Control panels shall include provisions for cooling as required.

B. As required by Division 17, the following is a MINIMUM: 1. The control system shall be hardwired relay logic or PLC based using Allen Bradley

CompactLogix model. a. Ethernet switch as manufactured by MOXA, if used. b. The OIT shall be an Allen Bradley PanelView Plus 10”, color with touchscreen or

equal; if used. 2. Coordinate with the Systems Integrator to integrate the monitoring and control features

with the plant SCADA System as specified. 3. Pilot devices shall be NEMA 4 rated, 30mm type. 4. Control relays shall be rated at 10amps and include an indicator. 5. Analog signals shall include surge protection at the field and control panel terminations. 6. HOA for each motor. 7. Pump 1/Pump 2/Alternate selector switch, as specified. 8. Run light for each motor. 9. Off light for each motor. 10. Fault light for each motor. 11. Pump High Moisture for each motor. 12. Pump High Temperature for each motor. 13. Reset pushbutton for each pump. 14. Status contacts (dry) for each pump of the following:

a. HOA in Auto status b. Motor Run status c. Motor Fault status d. Pump Overtemp Alarm e. Pump Moisture Alarm

C. REFERENCE CONTROL DRAWINGS 1. Provide controls as shown on the contract drawing and as specified in this Section.

a. I-63-01 Raw Sewage Pumps b. I-82-01 Hydrocyclones Feed Pumps

2.09 SPARE PARTS 1. Electrical and Controls:

a. One set of each type fuse used. b. Two of each type relay used.


c. Five (5) of each type pilot light bulb used.

2.10 FINISHES

A. Procedures: Section 09900

B. Prime Coat: Shop applied, coating material per 09900

C. Finish Coat: Field applied, coating material per 09900

2.11 SOURCE QUALITY CONTROL

A. Provide non-witnessed factory testing at a location in the Continental United States and in accordance with Section 11050-1.06

B. Submit factory testing results report in accordance with Section 11050

C. Hydrostatic tests: 1. Factory-test all pressure-sustaining parts in accordance with Section 11050

D. Performance and NPSH tests: 1. Subject each pump to performance and NPSH testing in accordance with Section 11050

to verify the full range of operating condition

E. Motor tests: 1. First check impeller, motor rating, and electrical connections for compliance with the

specifications 2. Subject all motor circuits to electrical resistance tests to confirm functionality

PART 3–EXECUTION

3.01 EQUIPMENT MOUNTING

A. Procedure: Section 11002

B. Position equipment pad and equipment anchors for final placement of equipment

C. Use a bolting template to position equipment anchors

D. Level mounting plates

E. Pour grout bed supporting each mounting plate

F. Eliminate grout voids below mounting plate

G. Tension equipment anchors

H. Provide a completed Form 11000-A, Section 01999, for each equipment installation


3.02 COATINGS

A. Finish Coating: see paragraph 2.08.

3.03 FIELD QUALITY CONTROL

A. Field Testing 1. Procedures: Section 01660 and Section 01662.

B. Static Solid Pass Test: 1. Upon arrival and before installation in the project, each pump shall be given a solids pass

test. The test shall consist of inserting a rigid ball of the diameter specified in paragraph 2.03 in the pump discharge opening. The Contractor shall demonstrate that the ball will pass clear though the pump to the inlet bell with no force other than the weight of the ball used to demonstrate compliance with the requirements of this Section.

C. Vibration Test: 1. Vibration levels shall be determined by affixing suitable sensors to the top of the motor

housing in both the x-x (parallel to the nozzle) and y-y (perpendicular to the nozzle) directions. The Contractor or his designated testing agent shall provide all sensors and monitoring equipment.

2. As a condition precedent to final acceptance of the equipment, the pumps shall be individually operated at all specified operating conditions. The Contractor shall provide the means to recirculate pumped fluid or alternatively throttle the pumps to achieve the specified head at specified flow.

3. Vibration levels shall not exceed that specified in paragraph 1.07 when the pump is operating within the manufacturer’s listed POR as determined in accordance with Section 43 23 03. When operating at conditions outside the POR, vibration levels shall be no more than 125 percent of that specified in paragraph 1.07.

D. Leakage Test: 1. Leakage testing for each wet-pit pumps shall include five sets of tests, each set consisting

of two tests, one with the pump operating against a closed discharge valve and one with the pump operating at Condition B, as specified in paragraph 2.03. Testing shall be scheduled with and witnessed by the Construction Manager. For each test the wet well shall be drawn down such that the pump discharge elbow is clearly visible prior to the test. Additional lighting shall be provided if necessary to clearly see leakage discharge, if any, from the discharge elbow connection. Each test shall be not less than 30 seconds in duration. Between each test set, the pump shall be lifted clear of its support bracket and re-lowered to connect again. The tests results shall be video recorded. The apparent average rate of leakage shall not exceed that specified in paragraph 2.06 Pump Discharge Connection Seal. If the discharge connection leakage rate at either against a closed valve or at Condition Point B exceeds the specified allowance, the Contractor shall cause the pump manufacturer to correct the defect and the pump shall be tested again as described in this paragraph. If the pump should fail the second test, the pump shall be removed from the site and the Contractor shall furnish a replacement which in turn shall be tested for acceptance in accordance with this paragraph. Video files shall be submitted.


E. Manufacturer Services: 1. On-Site Inspections and Training: Provide a factory-trained manufacturer’s representative

at the Site for the following activities. Specified durations do not include travel time to or from the Site. a. Installation Inspections: Assist, supervise, and inspect the Contractor’s activities

during installation. Provide a completed Form 11000-A, Section 01999. b. Component Test Phase Inspections: Assist, supervise, and inspect the Contractor’s

activities during the system test phase specified in Section 01660 and this Section. c. System Test Phase Inspections: Assist, supervise, and inspect the Contractor’s

activities during the system test phase specified in Section 01660. d. Operational Test Phase Inspections: Assist, supervise, and inspect the Contractor’s

activities during the operational test phase specified in Section 01660. e. Training Sessions: Procedures Section 01664. Provide a minimum of 8 hours

classroom training for each training session. Conduct two training sessions, one training session per week on two consecutive weeks to accommodate the shift schedules of operation and maintenance staff. Certify completion of training on Form 43 05 11-B, Section 01999.

3.04 SYSTEMS START UP

A. Procedures: Section 01660.

B. Preoperational (factory) testing; See paragraph 2.09.

C. Component testing: Perform the following tests. 1. Complete field testing in accordance with paragraph 3.03.

3.05 SYSTEM TESTING: PERFORM THE FOLLOWING TESTS:

A. Submit a draft vibration testing plan that will measure vibration for station pumping rates between station minimum and maximum design capacities in 10 increments starting with 10 percent above minimum and rising. Incorporate client review comments into final plan. 1. If vibration testing reveal that operation is impaired by poor operation of ancillary

equipment (improperly torqued flanges, etc.), repair ancillaries and retest pumps if directed by the owner.

2. After owner/engineer review of the vibration design professional’s draft and final reports for lateral vibration, participate with the owner and engineer in making any required adjustments to the pumping control strategy that may be required to avoid damaging vibrations, to protect the pumps and meet performance requirements.

**END OF SECTION**



150141 – 2017 Upgrades and Rehab 11365-1 Dewatering Centrifuges James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 11365

DEWATERING CENTRIFUGES

PART 1–GENERAL

1.01 SCOPE

A. Work described in this section includes furnishing equipment, materials, tools, incidentals and services required for a complete and operable installation and performance testing of two dewatering centrifuges. Each dewatering centrifuge shall be provided with dedicated vendor control panel, instrumentation, main/bowl and scroll variable frequency drives, and related appurtenances. All dewatering centrifuges shall be identical.

B. The dewatering centrifuges manufacturer has been evaluated and pre-selected by the Owner.

C. The centrifuges shall be of the high-speed, dry solids, solid bowl horizontal, continuous feed, scroll conveyor type specifically configured for dewatering-only applications and intended to maximize solids content in the dewatered sludge. No disc type or nozzle bowl type or basket type centrifuges will be allowed.

D. Equipment Tagging: 1. The supplier shall tag all components of the system in strict accordance with the Owner’s

tagging standards. All components that could be replaced must be tagged. These components include, but are not limited to, valves, pumps, switches, lights, indicators, instruments and panels. Reference the P&IDs for the numbering sequences and tag numbers.

E. All equipment shall be installed, adjusted, performance tested, and placed in operation in accordance with these Specifications, the manufacturer’s recommendations, and as shown on the Drawings.

F. Unit Responsibility: The Contractor shall assign unit responsibility as specified in Section 11000 to the centrifuge manufacturer for supplying the centrifuges, complete with all accessories and appurtenances (including, but not necessarily limited to, equipment identified in this specification) and for the design, assembly, delivery, installation supervision, startup, and testing of the centrifuge. This manufacturer is the Unit Responsibility Manufacturer and has unit responsibility, as described in Section 11000, for the equipment assembly specified in this Section, for the electric motors specified in Section 11060, for the associated control panels specified in Division 17, for the PLCs and OITs specified in Division 17, for the VFDs specified in Section 11069, and including all related and ancillary equipment specified to be supplied by the Unit Responsibility Manufacturer under all referenced Specification sections. A completed, signed and notarized Certificate of Unit Responsibility shall be provided using Form 11000-C specified in Section 11000.

G. The centrifuge manufacturer shall furnish all components and accessories of the system to enhance compatibility, ease of operation and maintenance, and as necessary to place the equipment in operation in conformance with the specified performance, features, and functions. The centrifuges shall be produced and assembled by the manufacturer at a facility owned and operated by the manufacturer and under the direct supervision and control of the manufacturer.


H. Equipment to be provided for each centrifuge shall include, but not be limited to: 1. Solid bowl centrifuge. 2. Electric bowl motor drive. 3. Electric scroll motor drive. 4. Lubrication system for rotating assembly’s main bearings 5. Variable frequency drives for both bowl and scroll drives with harmonic mitigation. 6. Centrifuge control panel with I/O components and PLC. 7. Centrifuge OIT panels in centrifuge operating room. 8. All necessary sensors and monitoring equipment. 9. All necessary vibration isolators. 10. Centrate and dewatered sludge chutes, including provisions for dewatered sludge

sampling. 11. Belt guards. 12. Flexible connections for all piping, all wiring connections, the dewatered sludge

discharge chute and the centrate discharge chute. 13. All necessary sole plates, bolts, anchor bolts, and hardware for centrifuge unit, panels,

and chutes, and ancillary devices. 14. Centrifuge stand. 15. All electrical connections and terminal cabinets for field connection to power,

instrumentation and control devices. 16. Special tools.

I. All equipment shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the Drawings and Specifications, engineering data, and instructions provided herein. The dewatering centrifuge systems shall be specifically designed for the intended conditions of service and materials shall be suitable for service conditions described herein. All equipment shall be new and shall be designed, fabricated, and assembled in accordance with the best engineering and shop practices.

J. The installation of all materials and equipment supplied herein shall be completed by the Contractor. The manufacturer shall be responsible for: 1. Design and fabrication of the centrifuge equipment and integrated control system. 2. Conduct all shop, field, and performance tests of equipment and integrated control

system. The Contractor will assist with all field and performance tests. 3. On-site advisory assistance during installation of all centrifuge related equipment. 4. Partial disassembly and on-site reassembly of centrifuge unit to facilitate moving the

centrifuges into the room through the access hatch. 5. Start-up and training services for all equipment supplied under this Section. 6. Submittal of all shop drawings, certifications, Equipment Service Manuals, warranties,

etc. as required in these Specifications. Equipment naming and tagging shall be in accordance with that shown on the contract P&ID Drawings.

7. Manufacturer shall provide as-built P&IDs, and control strategies. Centrifuge manufacturer shall provide equipment-specific P&ID Drawings to the Owner in PDF format showing manufacturer-specific information accurately.


1.02 RELATED SECTIONS

A. The requirements of the following sections and divisions apply to the Work of this Section. Other sections and divisions of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this Work. 1. Section 01071, Standard References 2. Section 01300, Submittal Requirements 3. Section 01605, Product Storage and Handling Requirements 4. Section 01660, Equipment and System Performance and Operational Testing 5. Section 01664, Demonstration and Training 6. Section 01730, Operation and Maintenance Data 7. Section 01800, Environmental Conditions 8. Section 01900, Design Requirements for Non-Structural Components and Non-Building

Structures 9. Section 05100, Structrual Metal Framing 10. Section 05502, Anchors to Concrete 11. Section 05560, Metal Fabrications 12. Section 09900, Coating Systems 13. Section 11000, General Requirements for Equipment 14. Section 11060, Electric Motors 15. Section 11069, Adjustable Frequency Drives 16. Section 17110 Instrument and Control Panels 17. Section 17310 Programmable Logic Controllers

1.03 DESIGN CONDITIONS AND PERFORMANCE REQUIREMENTS

A. All equipment and appurtenances including the centrifuge control panels shall be suitable for exposure to splash and spill conditions, and operation in continuous 95 percent relative humidity conditions and in ambient air temperatures from 40 to 104 degrees F.

B. The variable frequency drives will be located in an electrical room. The electrical room temperature range is expected to be 70 to 85 degrees F, with relative humidity between 40 and 60 percent.

C. The units shall be capable of continuous operation for 24 hours per day, seven days per week.

D. The centrifuges shall be capable of dewatering sludge having the following characteristics: 1. Sludge Type: Municipal Wastewater Treatment Plant Anaerobically Digested 2. Description of James R. DiIorio Water Reclamation Facility (JRDWRF): The JRDWRF

is designed to treat up to 19 million gallons per day (mgd) of raw sewage from mostly residential and commercial development in the greater Pueblo area. Liquid stream treatment processes at the JRDWRF consist of the following: a. Raw wastewater screening b. Grit removal c. Primary clarification d. Secondary activated sludge process


e. Secondary clarification f. UV disinfection

3. Solids treatment processes consists of the following: a. Screenings and grit are collected and washed prior to disposal. b. Primary clarifier sludge is degritted and thickened in a gravity thickener. c. Dissolved air floatation thickeners are used to thicken primary and secondary scum

and sludge. d. Thickened sludge is anaerobically digested. e. Digested sludge is dewatered by centrifuges. Dewatered solids are hauled to the

landfill for disposal. 4. Centrifuge dewatering feed characteristics are as described in Table 1.

TABLE 1. DEWATERING FEED CHARACTERISTICS

PARAMETER VALUE Nominal Sludge Composition, Total Dry Solids Weight Basis

Anaerobically digested blend of 40-60% primary sludge and 40-60% waste activated sludge.

Note: Inorganic tertiary solids from phosphorus precipitation is tentatively expected for the year 2030. Tertiary solids are expected to

make up approximately 10% of the total solids after start up. Solids Concentration, % Total Dry Solids Exclusive of Polymer

1.0 - 3.2, average 2.5

Volatile solids concentration, % Volatile Solids Dry Weight Basis

60 - 70, average 65

Temperature, deg F 90-109, average 100 pH 6 – 8

E. The centrifuges shall be optimized for dewatering with continuous addition of polymer as a conditioning chemical.

F. Polymer make-up and feed systems are being provided by the Contractor for conditioning of the digested sludge feed solids prior to dewatering. Separate make-up systems are being provided for dry and emulsion polymers. Dry polymer will be utilized during performance testing. The design parameters for the polymer system include: 1. Polymer Dosage Rate: See Table 2. 2. Polymer Solution Feed Pumps

a. Capacity: 18 gpm 3. Polymer Solution Feed Concentration: 0.5 percent active polymer solids (no post-dilution

shall be used during performance testing).

G. (Addendum #1) Each centrifuge shall be capable of the following performance for a minimum 45-calendar-day continuous Reliability Acceptance Testing (RAT): 1. All performance targets are listed in Table 2. It is the intent of the RAT to operate the

equipment to demonstrate the performance listed in Table 2. The Performance Expectation Testing (PET) specified in Part 3 is intended to be done as part of the RAT where the equipment is tested at the loading conditions specified in Table 2 for each centrifuge.


TABLE 2. PERFORMANCE REQUIREMENTS PARAMETER REQUIREMENT

Hydraulic loading rate, gpm 225 Minimum solids loading rate, dry lb/hr1 3600 Minimum total solids capture2, % 95 Minimum dewatered solids concentration, % total dry solids 18 Maximum Polymer Dose, lb Active Polymer Solids per Dry Ton of Feed Solids (to be confirmed by Manufacturer)

22

Table 2 notes: 1. Based on 225 gpm hydraulic loading rate and 3.2% feed solids 2. The percent solids capture shall be determined as follows:

(QR)(SSR) – (QR + QP)(SSC)

Capture rate (%) = _____________________ x 100

(QR)(SSR) Where: QR = flow rate of digested sludge solids, gpm QP = flow rate of polymer (including dilution water) SSR = suspended solids content of digested sludge feed, mg/l SSC = suspended solids content of centrate, mg/l

2. Noise shall not exceed the limits specified in paragraph 2.16, Noise. 3. Vibration shall be below 0.28 inches/second RMS for all performance conditions and

shall not be exceeded at any time during factory and field testing (horizontal and vertical).

1.04 SUBMITTALS

A. A pre-submittal meeting shall be required. Topics of discussion will include specification provisions, proposed equipment overview, submittal preparation, electrical and I&C standards and requirements, access to factory assembly and testing by the Owner and Design Engineering staff personnel, and exceptions to the specifications.

B. Submit Drawings and equipment data in accordance with General Requirements sections entitled “Submittal Procedures” and “Shop Drawing Submittals” and the following. All documents to be in English or with all captions in foreign languages translated into English. Documents with any un-translated captions will be automatically rejected.

C. Shop Drawings: 1. A copy of this Section, with addendum updates included, and all referenced and

applicable sections, with addendum updates included, with each paragraph check-marked to indicate Specification compliance or marked to indicate requested deviations from Specification requirements. A copy of Contract Process and Instrumentation Diagrams and Electrical Control Schematic Diagrams for all components being supplied, with addendum updates included, noting any exceptions or deviations. Check marks () shall denote full compliance with a paragraph as a whole. Where multiple options are provided


in a paragraph, circle the choice that matches what is to be supplied. If deviations from the Specifications are indicated, and therefore requested by the CONTRACTOR, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The ENGINEER shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the CONTRACTOR with the Specifications. Failure to include a copy of the marked-up Sections, along with justification(s) for any requested deviations to the Specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.

2. Certificate of Unit Responsibility attesting that the CONTRACTOR has assigned, and that the manufacturer accepts, unit responsibility in accordance with the requirements of this paragraph 11000 1.02 Unit Responsibility. No other submittal material will be reviewed until the certificate has been received and found to be in conformance with these requirements.

3. A copy of the contract document process and instrumentation diagrams relating to the submitted equipment, with addendum updates that apply to the equipment in this Section, marked to show specific changes necessary for the equipment proposed in the submittal. If no changes are required, the Drawing or Drawings shall be marked "no changes required". Failure to include copies of the relevant Drawings with the submittal shall be cause for rejection of the entire submittal with no further review.

4. System P&IDs showing all system components including proposed tagging of equipment shall be submitted. Fabrication of system shall not begin until tagging has been reviewed and approved by the Owner.

5. A copy of the contract document bowl drive, scroll drive, and lubrication system electrical schematic diagrams relating to the submitted equipment, with addendum updates that apply to the equipment in this Section, marked to show specific changes necessary for the equipment proposed in the submittal. If no changes are required, the Drawing or Drawings shall be marked "no changes required". Failure to include copies of the relevant Drawings with the submittal shall be cause for rejection of the entire submittal with no further review.

6. Documentation of ISO 9001 certification as specified in paragraph 1.6. 7. Certificate of Compliance signed by an officer of the manufacturing corporation as

specified in paragraph 1.6. 8. Equipment data sheet and detailed shop drawings for all equipment supplied, providing

dimensions, gross and net weight, and minimum required clearances. 9. G-volume calculations; provide calculations based 1) bowl only and 2) bowl and cone at

rpm values that correspond to achieving the specified performance. 10. Design data for bowl drive and bearings, including details of the lubrication system

demonstrating compliance with these Specifications. 11. Materials of construction/abrasion protection features 12. Anchor bolt calculations for centrifuges and stands 13. Structural calculations for the centrifuge stands per 01900 14. Vibration isolator details 15. Operating and maintenance information as specified in Section 01730, Equipment

Service Manuals, including the information required to be submitted with the initial equipment submittal. At a minimum, this information shall include the following:


a. Manufacturer’s standard instruction manual b. Detailed centrifuge installation instructions and details c. Accurate and complete instructions for changing out the main bearings and the

conveyor bearings. d. Lubrication and preventive maintenance schedule e. Equipment shipment, storage, unloading and handling instructions

16. Special tools, supplies and accessories 17. List of recommended spare parts 18. Part lists and bills of materials of all equipment 19. Proposed test procedures and test reports for:

a. Laboratory testing of abrasion resistant materials b. Witness shop tests of centrifuges c. Field tests of centrifuges d. Performance tests of centrifuges, including the PET Testing Plan

20. Field wiring diagrams and outline drawings showing field wiring, requirements for conduit locations, stub-ups, and physical sizing information. Physical location of the electrical devices on the centrifuge and its ancillary equipment should be shown on the Drawings, which shall be made specifically for this Project. Wiring instructions shall be in English. NEMA and ANSI standards shall be used for all electrical connections. Typical drawings are not acceptable.

21. Surface preparation and painting details 22. Sample factory test report 23. Certification of calibration for the shop test instruments and field test instruments 24. Discharge chute details 25. Electric motor submittal in accordance with Section 11060. 26. Control panel engineering submittal per the requirements of Section 17110. 27. Sequence of operations, including normal shutdown, shutdown on loss of permissive,

safety shutdowns, and shutdown on loss of power. 28. Vibration sensor and monitoring system details 29. Variable frequency drive submittals in accordance with Section 11069. 30. Centrifuge Optimization Report and “Results of Performance Expectation Testing” report

in accordance with Part 3. 31. Process & Instrumentation Diagrams, electrical diagrams, elementary diagrams, and

control loop diagram drawings. Typical drawings are not acceptable. 32. Warranties for the Work performed under this Contract and the equipment. 33. Evidence of welder’s qualifications 34. Listing of each instrument with the testing method for the instrument, location of the

instrument, and how to access the instrument for the testing. 35. Training lesson plan as specified in Section 01664. 36. Test procedures for the control panels, VFDs, motors and centrifuge for different phases,

including FAT and RAT per Section 01660 and Section 13000. 37. Test reports as required in Section 01660. 38. Programming submittals as required in Division 17 and coordination with the System

Integration Sub-Contractor.


39. As-built P&ID Drawings 40. As-built control strategies 41. Manufacturer’s Installation Certification (Form 11000-A specified in Part 3)

D. Instrument calibration submittal per Division 17.

E. For equipment or material for which specific tests are not requested in this Section, the manufacturer’s standard quality control test reports shall be submitted. The tests shall have been performed not longer than three (3) years before the date of submittal of the reports for acceptance.

F. Operation and maintenance manuals and final As-built Drawings including final calibration submittal data per Division 17 shall be provided in accordance with Section 01730.


A. The centrifuge shall be the product of manufacturers regularly engaged in the design, fabrication, service, and repair of high-speed centrifuges. The centrifuge shall be manufactured utilizing the latest manufacturing machine tool technology. The bowl, scroll, rotating assembly, and frame shall be manufactured to precise tolerances and shall be readily interchangeable with those components of like models currently installed at other facilities in the United States.

B. Certificate of Compliance: The manufacturer shall warrant that the centrifuge shall be manufactured in accordance with the Specifications.

C. All manufacturing facilities shall be ISO 9001 certified for quality assurance in the design, development, production, installation, and servicing of machines and installations for mechanical separations.

D. The centrifuge and ancillary equipment shall be designed and manufactured in accordance with the following listed Standards and specifications, including applicable addenda in effect as of the date of bid submission. They shall be considered an integral part of this Section and shall govern the design, fabrication, testing and inspection of equipment, except as otherwise shown or specified herein: 1. American Gear Manufacturers Association (AGMA) 2. American Welding Society (AWS) D1.1-82, Structural Welding, and ASME Boilers and

Pressure Vessels 3. Deutsches Institute for Normal Standards (DIN), if applicable 4. Verein Deutsche Inginieure (VDI), if applicable 5. National Electrical Manufacturers Association (NEMA) 6. Anti-Friction Bearing Manufacturers Association (AFBMA) 7. American National Standards Institute (ANSI) 8. National Fire Protection Association (NFPA) 9. Joint Industrial Council (JIC) 10. American Society of Mechanical Engineers (ASME) 11. Underwriters Lab oratory (UL) 12. Institute of Electrical and Electronics Engineers (IEEE)


13. American Society of Testing Materials (ASTM) 14. American Institute of Steel Construction (AISC)

E. Proof of qualification of the technicians that the centrifuge manufacturer shall provide for the installation, testing, and startup of the centrifuge assemblies, shall be submitted to the ENGINEER for acceptance before the installation is initiated. Welders shall have passed AWS qualification tests, or equivalent tests in Countries other than the United States such as DIN, within the last 12 months prior to the time they are employed. Evidence of compliance must be submitted to the ENGINEER.

1.06 EQUIPMENT GUARANTEES

A. Provide manufacturer’s warranty, with the Owner named as beneficiary, in writing. Guarantee shall provide for correction, or removal and replacement of Work provided under this Section (including but not limited to the centrifuges, drive motors, gear boxes, lubrication systems, Local Control Panels, and variable frequency drives) found defective during a warranty period of 24 months from project completion or 36 months from the completion of centrifuge performance testing, whichever occurs first.

B. Equipment Wear: The manufacturer shall furnish a guarantee for equipment wear based upon 16,000 hours of operation for abrasion resistant protection system. The equipment shall not exhibit wear exceeding the manufacturer’s tolerances after 16,000 hours of operation. Warranty certificates in English, or accompanied by certified translation, shall be submitted as part of the shop drawing submittal. Manufacturer shall provide labor and materials to disassemble and inspect each supplied machine after 16,000 hours of operation or 24 months after initiation of RAT, whichever comes first. If inspection reveals greater wear than guaranteed, manufacturer shall repair as necessary at no cost to the Owner. This warranty covers wear and is not intended to provide coverage for damage from nuts, bolts or other material foreign to typical municipal treatment plant sludge.

PART 2–PRODUCTS

2.01 CENTRIFUGE EQUIPMENT SUPPLIER

A. A centrifuge manufacturer has been pre-selected by the Owner as Flottweg Separation Technology, Inc., Independence, KY. The selected centrifuge is the C5E-4 decanter with SIMP-DRIVE. A copy of the scope and cost of work negotiated between the Owner and the Manufacturer will be provided as an appendix to the Contract Documents and shall be incorporated into the Contractor’s bid proposal as directed in the Instructions to Bidders.

2.02 GENERAL DESCRIPTION

A. The centrifuge shall be a solid bowl, horizontal, continuous feed, scroll type unit. The centrifuge equipment shall be designed and built to operate continuously or intermittently. The centrifuge shall be designed for counter-current flow characteristics such that no centrate tubes are required. The centrifuge layout should match the existing layout with minimal modifications to connect to existing inlets and outlets. The bowl/scroll design shall utilize the conical section for optimal dewatering of the dewatered solids. The dewatering centrifuge shall be able to separate at a normal operating G-force between 2,700 and 3,300.

B. Individual parts shall be identical in design and workmanship and shall be interchangeable among all units supplied.


C. The centrifuge shall have a Type 304 stainless steel nameplate securely fastened to the base or other visible location. The nameplate shall indicate the manufacturer’s name, date manufactured and installed, model number and serial number. Minimum size of the nameplate shall be 4.5 inch x 5.5 inch.

D. The centrifuge manufacturer shall be responsible for providing a complete centrifuge system, as described herein. The equipment shall be installed by the CONTRACTOR who shall be responsible for off-loading the equipment, providing any temporary storage, and installing the equipment in place. Installation shall include mounting the unit, piping the unit, providing power to the panels and all inter-connected wiring and piping required between the various components. Any disassembly and reassembly of the centrifuges to facilitate moving the centrifuge into the operating room through the access hatch for installation shall be completed by the centrifuge manufacturer.

E. Individual parts shall be manufactured to standard sizes and gauges. Components of the centrifuge shall be designed for the stresses, which may occur during fabrication, shipping, erection or maintenance. Materials shall be suitable for service conditions and as described herein.

F. The dimensions of dewatering centrifuge and its components shall be such that the equipment can be installed/removed through the existing floor opening as shown on the Drawings.

G. The centrifuges shall be suitable for installation in the existing biosolids building centrifuge room using the building’s 5-ton crane. Total machine weight (empty) shall not exceed 10,500 pounds. Machines exceeding the lifting capacity of the crane or the access hatch dimensions shall be partially disassembled and reassembled in place by the manufacturer, including any necessary adjustment and alignment to factory tolerances. In addition, the removal and replacement of the largest centrifuge components for maintenance shall be able to be accomplished with the building’s 5-ton capacity overhead crane with a high hook 115 inches above the centrifuge level operating floor and utilizing a floor opening down that is 6’6” wide by 10’8” long. Provide lifting devices, as necessary, to accommodate performing removal, replacement, and maintenance activities given the crane high hook position.

2.03 MATERIALS

A. Materials of Construction: Unless otherwise specified, materials shall conform to the following: 1. Bowl: Duplex stainless steel, Grade 2205 (UNS S32205) centrifugal castings. 2. Bowl Lining: Ribbed liner or bowl strips: stainless steel, Type 304. 3. Scroll Conveyor: Duplex stainless steel, Grade 2205 (UNS S32205) centrifugal castings

or Type 304 stainless steel. 4. Scroll Conveyor Flights: Duplex stainless steel, Grade 2205 (UNS S32205) or type 304

stainless steel. 5. Scroll Conveyor Tips: Sintered Tungsten Carbide tiles, from two wraps past the sludge

entry point to the solids discharge. Beyond that point flame sprayed tungsten carbide hard surfacing may be used. Tiles shall meet testing requirements specified in paragraph 2.05.

6. Front and Rear Hub: Duplex stainless steel, Grade 2205 (UNS S32205). 7. Feed Tube: Stainless steel, Type 304. 8. Base: Powder coated carbon steel or cast steel with replaceable Type 304 stainless steel

cladding on all surfaces in contact with process material.


9. Upper Case: Stainless steel, Type 304. 10. Bottom Case: Fabricated carbon steel or cast steel with Type 304 stainless steel cladding

on all surfaces in contact with process fluid and material. 11. Bowl Centrifuge Bearings: Automatically oil mist or grease lubricated; L 10 life of

100,000 hours minimum. 12. Scroll Conveyor Bearings: Grease lubricated; L 10 life of 100,000 hours minimum. 13. Feed Compartment: Stainless steel, Type 316 or 317. 14. Feed Compartment Liner: Devcon applied ceramic tile and ceramic set or sintered

tungsten carbide. 15. Sludge Feed Nozzles: Replaceable Sintered Tungsten Carbide, SiC ceramics or chilled

cast alloy. 16. Solids Discharge Nozzles: Replaceable Sintered Tungsten Carbide. All sintered tungsten

carbide abrasion resistant materials shall be tested in accordance with the ASTM G65, Procedure A, Standard Practice for Conducting Dry Sand/Rubber Wheel Abrasion Tests with volume loss less than 3 cubic millimeters.

17. Case Protection, Solids Discharge End: Field Replaceable Adiprene, Urethane, or Type 304 stainless steel liner, or equal. The liners shall extend down enough to protect the flexible boot.

18. Fasteners (Wetted): Minimum Type 304 stainless steel. 19. Anchor Bolts, Nuts and Washers: Stainless steel, Type 304, minimum 3/4 inch in

diameter for all anchor bolts under the centrifuge frame.

B. The manufacturer may propose alternate materials to those specified above accompanied by justification. Materials so proposed must be equal or superior to those specified for the purpose, and will be subject to review and acceptance by the ENGINEER.

2.04 BOWL

A. The bowl shall be designed to withstand, with an adequate factor of safety, all forces encountered during operation. The bowl shall be supported on each end by pillow block bearings, each of which shall oil mist or grease lubricated. 1. The minimum bowl wall thickness shall be 0.7 inches. All surfaces shall be examined for

cracks, shrinkage, porosity, or other defects by means of a liquid penetrant test. 2. Pool depth level must be readily adjustable via weir plates (dams) located at the large

diameter end of the bowl where liquid is discharged. 3. Solids shall be conveyed through a conical section of the bowl and discharged from the

small diameter end of the bowl through multiple solids discharge ports spaced evenly around the bowl end. Solids discharge ports shall be protected against abrasion by field replaceable, weight balanced, mechanically attached sintered tungsten carbide lined wear nozzles.

4. Centrifugally cast bowls shall be 100 percent dye penetrant inspected. Casting certificates for each component will be required with each centrifuge. Rolled and welded or statically cast bowls shall not be allowed.

5. The bowl shall be provided with strips to initiate a layer of sludge on the bowl wall that stays in place throughout the operating cycle.

6. Material to be processed shall be introduced to the bowl through a compartment which shall evenly distribute the feed. The feed compartment shall be protected against abrasion with Devcon ceramic tile and ceramic set.


2.05 SCROLL CONVEYOR

A. Each centrifuge shall include a horizontal cylindrical-conical scroll conveyor supported by anti-friction bearings and equipped with helical flights independently mounted concentrically within the centrifuge bowl. Bearings shall have externally greased fittings. 1. Conveyor shall include solids feed ports protected against abrasion by field replaceable,

weight balanced, mechanically attached wear nozzles. 2. The conveyor edge and face of the flights shall be protected against abrasion as specified

in paragraph 2.18 Abrasion Protection. 3. After attachment of the abrasion protection tiles on the scroll conveyor flights, the scroll

shall be installed on a full speed balancing machine for balancing. Following balancing, the tiles shall be inspected for damage or cracks using the dye penetrant method and any damaged tiles shall be replaced. Following replacement of damaged tiles, the scroll assembly shall be rechecked for balance and rebalanced as required. The manufacturer shall keep and submit a record of this test.

4. All sintered tungsten carbide tiles shall be able to meet ASTM G65, Test Procedure A, with a volume loss less than 3 cubic millimeters.

2.06 GEAR BOX

A. Gear Box: Gear box shall consist of a conveyor drive system consisting of an electric scroll drive system. The gear unit shall maintain a differential speed between the conveyor and bowl between 1 and 15 RPM. Each of the above devices shall be suitable for 24 hours per day continuous service. The gear box shall have a torque capacity to meet the specified service conditions and performance requirements in continuous service with a conservative factor of safety. The design required torque to achieve the specified dewatering performance at design loading and maximum throughput, whichever is greater, shall not to exceed 80 percent of the torque where the feed shutdown alarm engages (“high torque”). The design required torque to achieve optimum dewatering performance at design loading shall not exceed 85 percent of the torque where the feed shutdown alarm engages (“high torque”). If using cycloidal gears, gear boxes shall be capable of withstanding a 500 percent momentary overload and 150 percent intermittent overload. A torque overload control system shall be provided to initiate first a feed shut down, and if the torque continues to increase, a centrifuge shutdown in the event of conveyor overload (“high-high torque”) shall be initiated. Manufacturer shall select the reduction gear ratio as required for the solids to be handled and to be consistent with satisfactory operation.

2.07 BEARINGS

A. Centrifuge shall be supported by two main bearings. The bearings shall be spherical roller bearings. Main bearings shall have an ABMA L-10 rating life of at least 100,000 hours. Main bearings shall be housed in one piece or split type pillow blocks. 1. The two main bearings on the centrifuge shall be automatically lubricated by a centrally-

located, centrifuge-manufacturer furnished package lubrication system. The manufacturer shall be responsible determining adequate space, design, performance, electrical power and controls, and all other utilities to operate the lubrication system.

2. All main drive and scroll drive bearings on the centrifuge shall be grease lubricated.


3. RTD type bearing temperature monitors will be provided on each main bearing pillow block, with an analog output signal to the centrifuge PLC for display and monitoring. Bearing temperature shall not exceed 140 degrees Fahrenheit during normal operation. RTDs shall be 3-wire 100 Ohm Platinum.

2.08 CASE

A. Each centrifuge shall be enclosed in a fabricated case, the purpose of which shall be to contain and direct the solids and liquid discharge from the centrifuge, to act as a protective guard, and to provide complete enclosure for noise reduction and odor control. The casing assembly shall be provided with a stainless steel upper case cover, specifically designed for rigidity and noise reduction, and Type 304 stainless cladding on wetted parts in the lower casing. The case top shall be bolted in place or hinged style arrangement. Lifting eyes shall be provided for lifting of the upper case cover. The cover foul air vent connection will not be used and the manufacturer shall supply a cap. The case cover shall have a closed indication limit switch to be used as safe operation prestart permissive inside the vendor package.

B. The centrifuges shall be designed to limit air leakage into or from the body of the centrifuges by providing gaskets on the casing flange and labyrinth-type seals on both hub ends.

2.09 FRAME

A. Each centrifuge shall be supported individually on a fabricated carbon steel or combination cast iron and steel base which shall in turn be mounted on vibration isolators. The centrifuge frame shall not be artificially weighted to dampen vibration. 1. The vibration isolators shall be provided to isolate the centrifuge from the building

structure. Vibration isolators shall provide at least a 90 percent reduction of vibration from source to the structure. The number, capacity, and vibration constant of the isolators shall be as recommended by the isolator manufacturer for the load and impact resulting from operation of the centrifuge provided. If required, each isolator shall be provided with built in leveling bolts and built in resilient shocks to control oscillations and withstand lateral forces, including seismic forces, in all directions. Vibration isolator anchorage shall be designed in accordance with the requirements specified in ANCHORAGE AND SUPPORTS, below.

2. The bottom portion of the frame shall be provided with machined outlets for the attachment of the solids and centrate flexible connectors.

3. Lifting eyes or solid lifting bars shall be provided for lifting of the frame. 4. Anchor bolts templates shall be provided for anchor bolt installation if applicable.

Centrifuge manufacturer shall coordinate with CONTRACTOR the required delivery time frame of the templates.

2.10 MAIN/BOWL DRIVE SYSTEM

A. For each centrifuge, the bowl drive system shall consist of an electric bowl drive inverter duty motor with adjustable frequency drive and V-belt drive system complete with necessary vibration isolators for the individual support of the motor and centrifuge. The belt drive system shall consist of multiple V-belts as required to provide full load capacity and to withstand the full starting torque of the system.


2.11 SCROLL DRIVE SYSTEMS

A. Backdrive 1. Backdrive Motor: An electric motor and gear box shall be supplied to drive the scroll. 2. In the automatic mode, it shall continuously monitor changes in internal torque created by

variations in influent feed solids and automatically maintain a preset torque input to the scroll by allowing the differential speed to vary. The scroll drive shall operate in a manner such that, as the reactive torque of scroll shaft increases due to an increase in solids inventory in the bowl, the scroll differential speed shall gradually increase and, conversely, as the inventory of solids in the bowl and resultant reactive torque decreases, the scroll differential speed shall decrease. The net effect of this system, when operated in the automatic mode, shall be to maximize the time that sludge solids are under the influence of accelerated gravitational force to ensure that the driest possible dewatered sludge product is produced without plugging the centrifuge.

3. Torque-based adjustment shall be a function of input to the driven unit. The maximum torque input and rate of change of scroll differential speed shall be adjustable.

4. The system shall be designed such that automatic centrifuge shutdown is initiated in the event that excessive torque is detected. Two (2) sets of contacts shall be provided.

2.12 MAIN BEARING LUBRICATION SYSTEM

A. The two main bearings on the centrifuge shall be grease lubricated by an automatic grease pump. Automatic grease pump shall be mounted on the centrifuge skid. The manufacturer shall be responsible determining adequate space, design, performance, electrical power and controls, and all other utilities to operate the lubrication system. 1. Any electrical power feed to the lubrication system shall be provided via the centrifuge

control panel.

2.13 GUARDS

A. Fabricated guards shall be provided for all gear boxes, pulleys, and belt drives. 1. The guards shall meet OSHA standards and completely enclose the rotating parts of drive

system and shall be designed to minimize vibration and noise. 2. Guards, except for the bowl drive motor, shall have 1-inch diameter holes coincident with

the shafts of all equipment to allow the shaft speed to be checked. 3. Guards shall be designed so that conveyor can be greased without removing the guard. 4. Guards shall be fabricated from carbon steel. 5. Fasteners shall be externally accessible.

2.14 SLUDGE FEED

A. Centrifuge shall have a removable feed tube. The feed connection to the centrifuge shall be a 150-pound ANSI flange connection. The maximum inlet pressure required at the centrifuge inlet flange shall be 15 psig at 150 gpm (when based on water with the viscosity of 1 Centipoise).

2.15 FLEXIBLE CONNECTIONS

A. All mechanical and electrical connections to the centrifuge, including, but not necessarily limited to, the feed sludge, polymer, centrate and dewatered sludge connections, and


electrical raceways shall be equipped with flexible connections supplied by the manufacturer. All flexible connections shall isolate centrifuge vibrations from fixed, rigid external connections. No external loads shall be transferred to a centrifuge by external connections to the machine. Centrate and dewatered sludge flexible connections shall be flanged and fabricated from neoprene, with Type 304 stainless steel bolts with Type 304 stainless steel retainer plates at each end. Chutes for solids and centrate discharge shall be designed to provide a smooth interior surface for optimum vertical transport of solids without buildup. Piping flexible connectors shall be metal reinforced elastomer with NTP treaded connections. Tubing flexible connectors shall be Type 304 stainless steel braided hose.

2.16 NOISE

A. Centrifuge shall be designed such that when running at the nameplate speed equivalent to the maximum design g-force inside the bowl wall, the average noise level measured at 3 feet around the periphery of the complete centrifuge assembly shall not exceed 91 dBA at any time during factory and field testing. Considerations will be made for environmental noise not caused by the centrifuge system during field testing if deemed necessary by the ENGINEER or OWNER.

2.17 TEMPERATURE AND VIBRATION MONITORING SYSTEM

A. Additional vibration sensors shall be provided for each centrifuge to perform the following functions: 1. Provide one accelerometer type vibration sensor installed on each centrifuge and wired to

a common terminal junction box. One sensor shall be rigidly attached to the machine, positioned per the manufacturer’s recommendation. Vendor recommended vibration sensors are acceptable. The Centrifuge Manufacturer is to match these components, and provide communication to the industrial network via Ethernet/IP by connecting both the PLC rack and the monitor platform to an Ethernet switch located within the manufacturer supplied control cabinet. The monitoring platform shall be mounted in the manufacturer’s cabinet on a DIN-rail adjacent to the PLC. Alarms shall be made available to the manufacturer’s PLC for safety interlock purposes, but also to the industrial network for monitoring purposes.

B. Each centrifuge, when running at the nameplate speed equivalent to the maximum design g-force inside the bowl wall, shall not produce vibration velocities greater than 0.28 inches/second RMS at the main bearing pillow blocks when tested at the manufacturing the rotating assembly filled with water. The manufacturer shall submit the results of a factory floor certificated vibration test demonstrating compliance with these requirements.

C. The centrifuge instrument and control system signals shall be wired to a separate Type 304 stainless steel NEMA 4X junction box on the equipment skid which is connected to the vendor control panel PLC monitoring system allowing connection to the Owner’s SCADA system via Ethernet. Vibration monitoring system signal wire shall be shielded against RF interference in accordance with Division 16 requirements.

2.18 ABRASION PROTECTION

A. In order to minimize wear due to abrasive materials in the feed, replaceable hard surfacing shall be provided at all points where the abrasive action of the sludge will cause wear on the metal parts of the centrifuge. The following shall be considered a minimum degree of hard surfacing required.


1. Bowl Wall: The bowl wall and conical extensions shall be protected with minimum of eight (8) welded ribs designed to trap a protective layer of solids between the bowl wall and the conveyor.

2. Conveyor Feed Ports: The conveyor feed ports shall be protected from abrasion by field replaceable solid sintered tungsten carbide elements or SiC ceramic or chilled cast alloy.

3. Solids Discharge Ports: The solids discharge ports shall be protected from abrasion by field replaceable tungsten carbide wear saddles or SiC ceramic or chilled cast alloy.

4. Solids Discharge Casing: A replaceable stainless steel shall protect the solids discharge casing.

5. Scroll Conveyor Flights: The edge and face of the conveyor flights shall be protected against abrasion from the solids by a series of sintered tungsten carbide tile assemblies, with coverage from two wraps beyond the feed zone (towards the liquids discharge end) through to the solids discharge end. Each tile assembly shall be weight correct, and consist of a solid sintered tungsten carbide wear part attached to a stainless steel backup holder. Spray hard surfacing applied to a backup plate is not allowed. Each assembly shall be individually replaceable, and shall include the ability to monitor wear by means of visual inspection. The tile assemblies shall extend a minimum of 0.75 inches beyond the radial edge of the conveyor flight. The remaining scroll conveyor edge and face shall be protected from abrasion by flame sprayed hard surfacing containing a minimum of 40 percent tungsten carbide particles. Stellite or ceramic hard surfaced tiles are not acceptable.

2.19 ANCHORAGE AND SUPPORTS

A. Centrifuge anchorage, including vibration isolators, shall be designed in accordance with the IBC and the ASCE-7, and Section 01900, Design Requirements for Non-structural Components and Non-Building Structures.

B. Component Importance Factor (Ip) – 1.00.

C. Seismic structural calculations shall comply with Section 01900.

2.20 CENTRIFUGE BOWL TRUCK AND WOOD CRADLES

A. The manufacturer shall supply one (1) cart for moving the rotating assembly and scroll.

B. The manufacturer shall supply two (2) wood cradles and necessary fixtures to support the rotating assembly and allow pulling of the scroll conveyor from within the bowl assembly.

2.21 PAINTING 1. Painting and coating shall be per Section 09900- Coating Systems. 2. Metal surfaces shall be coated using system EU-1, specified in Section 09900, rather than

the default E-1 due to potential for corrosive enviornment.

2.22 DISCHARGE GATE ASSEMBLIES

A. No discharge gates shall be supplied for this system.


2.23 CENTRATE AND DEWATERED SOLIDS CHUTES

A. The centrifuges shall continuously receive, condition, and dewater the feed sludge specified herein, and continuously discharge the dewatered solids into a chute that discharges directly into a hauling trailer. Each unit shall be able to operate continuously on demand and shall operate without spillage of sludge or centrate beyond the nominal solids discharge chute or beyond the liquid (centrate) discharge chute and piping envelope. The entire solids chute shall be designed to prevent accumulation of dewatered sludge within the chute.

B. The centrifuge manufacturer shall supply the dewatered sludge chute flexible coupling and the dewatered sludge chute to connect from the centrifuge to the floor slab level. 1. The dewatered sludge chute shall be provided with an access point that allows for

collection of a sample of dewatered sludge. The access point shall be located for convenient access by operators above the centrifuge level operating floor and shall be fitted with a 2-inch diameter sealed sample port. The sample port shall seal when not in use to prevent escape of odors when samples are not being collected.

C. The centrifuge manufacturer shall supply the centrate flexible coupling and the centrate discharge chute to connect from the centrifuge to the floor slab level.

D. Both the dewatered sludge chute and centrate discharge chute shall completely seal each of the existing floor penetrations to prevent the escape of materials and odors. Chutes shall be supplied with a flange ring and gasket to bolt to the concrete around existing floor penetrations.

E. Flexible connections for the discharge chutes shall be elastomeric bellows type with an insert to provide a smooth interior surface. All chutes to be fabricated from minimum 3/16-inch thick 304 L stainless steel plate. Chutes and supports shall conform to Section 05560.

2.24 CENTRIFUGE STAND

A. The Manufacturer shall supply a structural steel stand for each centrifuge. Overall stand height shall be 3 feet.

B. Stands shall be constructed such that the centerline of the centrifuge aligns with the centerline of the existing floor penetrations for the discharge chutes.

C. Stands shall not interfere with existing floor penetrations.

D. Stands shall allow unimpeded access to at least one side of each centrifuge for discharge sampling.

E. Stands shall comply with Sections 01900, 05100, and 05502.

2.25 SPECIAL TOOLS, SUPPLIES, AND ACCESSORIES

A. Manufacturer shall supply all tools, supplies, and special equipment as described in Schedule 11365-1 and below.

B. Provide one year’s supply of all lubricating oils and greases recommended by the manufacturers, and as per accepted shop drawings, for all components for a continuously operating machine.


C. Provide 10 percent spare fuses and breakers for manufacturer-supplied control panels.

D. The following tools, supplies and spare parts shall be provided. Additionally, provide all required special tools not listed that are required to change the main bearings and the conveyor bearings.

1- TOOLS, SUPPLIES, AND LIST OF RECOMMENDED SPARE PARTS

ITEM NO.

MINIMUM REQUIREMENTS QUANTITY

DESCRIPTION OF ITEM Tools 1 Set of Special Tools for Centrifuge Maintenance 1 2 Bowl Lifter 1 3 Conveyor Extracting Tools 1 4 Torque Wrench 1 5 Bearing Puller 1 6 Pillow Block Lifting Eyebolts 1 7 Pillow Block Bearing Remover 1 8 Pillow Block Dowell Pin Remover 1 9 Seal Holder Puller 1

10 Gear box Adaptor Removal Aid Kit 1

Supplies

11 One Year’s Supply of Centrifuge Lubricants 1 Spare Parts

12 List of Recommended Spare Parts 1

2.26 ELECTRICAL

A. Main/Bowl Drive Motor: 1. Motor shall meet the following specific requirements:

a. Motor Horsepower: – 75 (maximum). b. Synchronous Speed: Manufacturer’s standard. c. Voltage Rating: 460V, three-phase. d. Enclosure Type: TEFC, Low-Voltage AC Induction Motors, and shall meet IEEE

841. e. Mounting: Horizontal. f. Inverter duty rated motor g. Meet all other applicable requirements of Section 11060 except as entailed herein.

2. Provide motor features as follows: a. With the motor at ambient temperature (COLD), it shall be capable of making two

complete starts in succession with coasting to rest between starts within a 1-hour time period. With the motor running (HOT), it shall be capable of at least one restart within 1 hour after any shutdown. The motor insulation temperature classification shall not be exceeded.

b. The motor shall be of the quiet type design. The noise level shall not exceed 85 dBA sound pressure measured at 3 feet from the motor in all directions.


c. Motor thermal protection shall be monitored by the drive. d. Provide temperature monitoring and over temperature relay at the main drive VFD

enclosure.

B. Main/Bowl Drive VFD: Bowl drive motor shall be controlled by an adjustable frequency drive. 1. The system shall be sized in accordance with manufacturer’s design requirements. 2. The motor shall be capable of delivering full load torque across a 2:1 turndown ratio. 3. Drive system shall be capable of flying restart.

C. Scroll Drive Unit Motor: 1. Motor shall meet the following specific requirements:

a. Motor Horsepower: 20 (maximum). b. Nominal Speed: Manufacturer’s standard. c. Voltage Rating: 460V, three-phase. d. Enclosure Type: TEFC; shall meet IEEE 841. e. Inverter duty rated motor. f. Meet all other applicable requirements of Section 11060 except as entailed herein.

2. Provide motor features as follows: a. Provide bi-metallic thermostat for thermal protection.

D. Scroll Drive VFD: Scroll Drive motor shall be controlled by a variable frequency drive. 1. The Scroll Drive system shall provide infinite speed variation between the scroll

conveyor and bowl shell of the centrifuge between 1 and 15 RPM. 2. The system shall be sized in accordance with manufacturer’s design requirements. 3. The motor shall be capable of delivering full load torque across a 2:1 turn down ratio. 4. Drive systems shall be capable of flying restart.

E. VFD’s: 1. Shall meet the requirements of section 11069. 2. Shall be stand alone, NEMA 12 ventilated and filtered enclosure. 3. Shall have a flanged mounted disconnect, rated for a minimum of 42 KAIC. 4. Shall include Ethernet IP communications to the respective centrifuge control panel VCP

for monitoring. 5. The control from the VCP PLC shall be hardwired; start/stop, speed control and fault

status as a minimum. 6. Shall have the VFD OIT on the front door along with:

a. Run, Off and Fault lights. b. E-stop pushbutton. c. No HOA or manual speed pot is required for these VFD’s since the monitoring and

control of each is by the respective centrifuge vendor control panel.


A. General:


1. Each centrifuge shall include a dedicated centrifuge control panel to be located in the electrical room as shown on the drawings. The control panel shall include all controls for a complete system including: a PLC with Ethernet IP connection to the remote located variable frequency drives for both the main drive motor and the scroll drive motor. The Centrifuge PLC and remote mounted color, touch screen Operator Interface Terminal (OIT) with E-stop pushbutton, will be used to control the centrifuge machine. Should a disruption occur, the centrifuge monitoring system shall indicate the cause with a first out sequence and define the fault. The vendor-provided PLC shall be connected to the process Ethernet IP network as shown on the drawings to allow remote monitoring. Coordinate with the systems integrator for system monitoring and control as specified. The respective VFD’s shall be hardwired from the PLC for the Start/stop and speed control as a minimum.

2. A separate stand-alone operator interface terminal (OIT), color, touch screen type, with E-stop pushbutton in a NEMA 4X, 316SST enclosure shall be located in the centrifuge operating room for each centrifuge. Each centrifuge OIT will connect to the respective centrifuge VCP using Ethernet IP communications. The E-stop pushbutton will be hardwired.

3. Interlocks are provided between the Centrifuge PLCs, the existing biosolids building PLC (ACP-73) and electrical equipment to coordinate the start, stop, and pacing of feed pump equipment. These are described on the P&IDs.

4. The configuration and development of the graphical operator interface shall be based on standards prepared by the Owner specifically for this application. The interface standards shall be consistently applied to the development of the interface to insure optimum usability. The Systems Integrator and the centrifuge manufacturer shall adhere to the Owner’s graphical standards during the creation of new OIT control screens and alteration of any existing screens. Reference Division 17 specification requirements for further details.

5. All OIT development including tag naming scheme, screen navigation methods, use of pop-ups, etc. shall be implemented in a manner that is consistent with OIT systems in use elsewhere in the Owner’s existing operations at other facilities. Graphic screens shall utilize the same colors, symbols, fonts, and features to provide an interface to operators that is uniform and consistent with existing OIT screens serving Owner’s other facilities.

6. Prior to substantial completion of this project, the CONTRACTOR shall re-register all provided software packages to the OWNER and provide the ENGINEER and OWNER with written confirmation of having done so.

B. Control System Features & Requirements: The centrifuge control system shall meet the following requirements 1. All control relays shall be IDEC or equal and shall include 10 amp DPDT contacts and an

LED indicator. 2. All Centrifuge Manufacturer provided Programmable Logic Controller (PLC) CPU and

IO Hardware shall be in accordance with Section 17310. The PLC shall be Allen Bradley Compact Logix.

3. PLC Programming and OIT Software shall be in accordance with Division 17. Each shall be submitted for review and comment. Color graphic displays are required for each submittal. The PLC program shall include comments for each rung with its functional description.

4. All Vendor supplied PLCs shall be connected to the local area PLC process control network via Ethernet/IP as shown on the network diagrams.


5. Memory register mapping of data shared with Plant Supervisory Control and Data Acquisition (SCADA) shall be in accordance with Section 17310 such that all points monitored or controlled via the centrifuge OIT may also be read or written to via the SCADA system.

6. All PLC panel drawings shall be in accordance with Division 17 requirements. 7. The centrifuge vendor shall provide PLC & OIT programming support for minor

modifications and support during the warranty period, after the testing as defined in Section 01660. The vendor shall correct all programming errors or software bugs discovered during warranty period.

C. Centrifuge Control Panel: 1. NEMA 12, free standing enclosure: The Centrifuge Control Panel design shall be as

indicated in the instrumentation Drawings and located in the electrical room. Included in the remote OIT enclosure front door shall be: an E-stop pushbutton and alarm horn. All pushbuttons and pilot lights shall be water tight, corrosion resistant, heavy duty, 30mm type such as Allen Bradley 800H or equal. The OIT shall be utilized for major operational adjustments, monitoring, control and alarm history with date and time stamp. The VCP in the electrical room will house the PLC and industrial hardware components. The PLC panel Ethernet switch shall be industrial type, manufactured by MOXA or Ewon, supporting Device Level Ring topology. All field wire labeling shall be per the Owner’s standards. Upon power failure, the unit shall restore to the ready state when power is returned. Power for the controls shall be 120V. There will be one, 480V power supply provided to the centrifuge main control panel. This shall then be distributed to the two VFD’s.

2. Centrifuge Control Panel Programming Requirements a. All Programmable Logic Controller (PLC) CPU and IO Hardware shall be Allen

Bradley CompactLogix PLC hardware meeting the requirements of Section 17310 to match existing Owner standards.

b. All PLCs shall be connected and configured for communications to the Plant PLC network and Ethernet Process networks as shown on the network diagrams. The VFD’s shall be connected using Device Level Ring (DLR) topology.

c. Memory register mapping of data shared with Plant Supervisory Control and Data Acquisition (SCADA) shall be in accordance with Owner standards, in accordance with Division 17.

3. All components in the control panel shall be completely factory wired. All external control connection points shall terminate on a terminal strip. There shall be a minimum of 10 percent spare terminal connections supplied.

D. Centrifuge Power Equipment: Separate VFDs shall be provided for each of the bowl drive and scroll drive motors. VFDs shall be networked to the PLC via Ethernet/IP as shown on the Drawings for monitoring. Centrifuge manufacturer-provided VFDs shall be housed in a NEMA 12 ventilated and filtered enclosure in the electrical room. The centrifuge manufacturer-provided PLCs shall be housed in NEMA 12 enclosures in the electrical room.

E. Field Instruments: 1. Frequency Current Converter:

a. Centrifuge bowl and speed sensors shall be provided to monitor speed. The control module shall transmit a current output proportional to an input frequency.

b. Key features shall include:


1) 120 VAC supply voltage. 2) Adjustable input frequency range of .001 Hz to 999 Hz. 3) 4-20 mA output signal.

c. Units shall be Pepperl and Fuchs Model WEM/EX-FSU, Electro Sensors or equal. 2. Vibration Sensors 3. Temperature Sensors

F. Operator Interface Terminals: 1. Operator Interface Terminal (OIT): The OIT shall meet the following specifications:

a. Operator Input – Touch, Analog resistive, rated for 1 million presses b. Display – TFT Color, 12.1 inches diagonal, 1280x800 WXGA, 18-bit graphics, 16:10

aspect ratio. c. Backlight – White LED, 50,000h minimum to half-brightness d. Battery – 4 year life minimum for real time clock backup. e. Memory – 512 MB RAM, 512 MB storage, 80MB nonvolatile storage for

applications, plus SD card slot for additional expansion f. USB Ports – Two USB 2.0 type A, One USB 2.0 type B. g. OS – Windows CE with MS Office Viewers h. Ethernet ports – Two 10/100Base-T Ethernet ports supporting Device Level Ring. i. Power Supply – 24V DC, 50W j. Manufacturer – Allen Bradley PanelView Plus 7, 12-inch color touch screen

terminal. 2. Local OITs shall be provided for each centrifuge in NEMA 4X, 316SST enclosure. Each

shall be networked to the respective centrifuge PLC and set up to display information graphically and provide control graphics to completely monitor and control the centrifuge. The OIT shall be located in the centrifuge operating room with an Emergency Stop maintained-position pushbutton.

2.28 SEQUENCE OF OPERATIONS

A. General: 1. As part of the Centrifuge submittal process the Centrifuge Vendor will refine this written

strategy for the specific machine selected for this project. The Owner reserves the right to make changes to the basic control strategy described below during shop drawing review at no additional cost to the Owner. A minimum of Ten (10) days on site engineering shall be provided by the centrifuge manufacturer for making changes to the Control strategy, process optimization, and coordinating with the Owner’s auxiliary control system. The cost of providing this service shall be included in the Centrifuge Manufacturer's lump sum price for this Contract as indicated in the Bid Documents.

2. The Dewatering Centrifuges shall operate with minimal operator intervention. The START sequence shall be initiated from the Centrifuge LOCAL OIT. Under alarm or "EMERGENCY STOP" conditions, the shutdown sequence shall be automatically triggered.


3. All centrifuge control panel programming will be performed to Owner standards such that all data from the centrifuge machines can be read and displayed at plant control system operator interface. All status signals available at the Centrifuge OIT shall be programmed such that they may be read by the plant control system. All set points, selections and control inputs available at the Centrifuge OIT shall be programmed such that they may be written to and read by the plant control system. Centrifuge VFDs will be polled by the centrifuge control panel using Ethernet/IP for monitoring and control as described in the drawings. Drive configuration and PLC programming required for polling of the VFDs over Ethernet/IP will be by the Centrifuge Vendor.

4. Centrifuge output is comprised of centrate and dewatered sludge. a. Centrate is piped to the centrate storage tank b. Dewatered sludge drops through a chute and to a dewatered sludge trailer one floor

below the centrifuge.

B. Control Strategy Overview: 1. Key components controlled directly by the centrifuge control panel are as follows:

a. Centrifuge Bowl Drive b. Centrifuge Scroll Drive c. Centrifuge Feed Flushing valve

2. Control and interlocks are provided between the Centrifuge PLCs and the other Centrifuge Facility PLCs and equipment to coordinate the start, stop and pacing of related equipment is as follows: a. Signals from the process control network to the Centrifuge

1) Centrifuge stop commands 2) Sludge Flow 3) Polymer flow pace rate

b. Signals from Centrifuge to plant control system 1) Request for sludge feed 2) Sludge feed rate request 3) Request for polymer feed 4) Sludge flow for polymer pacing 5) Centrifuge Ready 6) Centrifuge Trouble

3. The Centrifuge OIT provides start stop control of the centrifuge as well as a location to enter operator adjustable centrifuge set up parameters.

4. Start and stop of a centrifuge machine is initiated manually by the operator at the centrifuge control panel Operator Interface Terminal (OIT).

5. Key parameters controlled by the centrifuge control panel are bowl speed, scroll speed, bowl/scroll differential speed, bowl torque, and scroll torque. a. These parameters are controlled by the centrifuge control panel in order to provide

the desired dewatering performance. b. Bowl speed, scroll differential, and torque set point may be adjusted by the operator

to achieve the desired dewatering performance. c. It is expected that these centrifuge control parameters will be selected and tuned

during initial facility commissioning and subsequently adjusted very infrequently.


C. Centrifuge Operation: 1. Normal Operation

a. In steady state operation, the bowl and scroll drives are controlled by the Centrifuge control panel to maintain set point speeds for the bowl and scroll, the differential speed between bowl and scroll and also torque at the operator selected values. The set point values for bowl speed, scroll differential speed and scroll torque are set in accordance with manufacturer recommendations and then tuned to achieve for the desired dewatering performance.

b. The Centrifuge control panel monitors and indicates that all support equipment such as the centrifuge feed pump and polymer solution feed pumps are ready for operation. If any of these are in alarm or not in Auto the centrifuge may not be started; the respective status is to be displayed on the OIT. If a condition exists within the process equipment or loss of control network, the feed of sludge and polymer solution to the centrifuge shall be stopped. The centrifuge will continue to run awaiting sludge feed to resume.

c. If the Centrifuge control panel is unable to maintain any controlled variable within acceptable limits, a centrifuge fault alarm will be triggered and a centrifuge shutdown cycle will be initiated. Depending on the severity of the alarm, the Centrifuge Vendor controls may put the centrifuge machine into a normal shutdown cycle or an abbreviated shutdown which may bypass flushing and ramp down steps associated with a normal shutdown.

d. Sludge is fed to the centrifuges by the sludge feed pumps at an operator selected feed rate, along with polymer.

e. The cake produced by the centrifuge drops directly into the trailer for hauling. f. The centrate produced by the centrifuge drains to the centrate storage tank. g. Flushing water is used by the centrifuge machine during start up and shutdown

cycles. The Centrifuge Control panel controls the position of the water valve to provide water when required.

h. The operator may select manual polymer mode at the centrifuge VCP if the operator chooses to run the polymer feed system in manual. If the manual polymer mode is activated, the centrifuge shall continue normal operations independent of the polymer system operations. In this case, the polymer feed operations will be controlled manually at the dry polymer system VCP-7410 (Section 11770).

2. Startup Operation: a. After all pre-start configuration and setup steps are completed; a centrifuge start

cycle may be initiated by the operator. Startup of the centrifuge is initiated at the Centrifuge Vendor OIT.

b. Prior to starting the centrifuge all permissive conditions must be met in order to allow the operator to initiate a centrifuge start at the Centrifuge Vendor OIT. The permissives to start are as follows: 1) All Centrifuge Vendor defined permissives are met (to be refined by Centrifuge

Vendor) 2) Centrifuge PLC Ready 3) Scroll Drive VFD Ready 4) Bowl Drive VFD Ready 5) Lubrication Unit Ready 6) Centrifuge Feed Flushing Valve Ready


7) No Centrifuge fault or trouble alarms 8) Plant Control System and respective equipment interlocks are ready.

c. When all permissives are met and equipment is ready, the operator initiates start up at the Centrifuge OIT. When start up is initiated the following key steps will occur: 1) The Centrifuge will begin its startup/flushing cycle 2) The scroll and bowl will simultaneously begin ramping up to operating speed 3) Flush water will start and run for a pre-set time period as recommended by the

manufacturer. 4) When acceptable operating speed is achieved, the centrifuge is ready to receive

sludge and will issue: a) A start command for the centrifuge feed pump and the polymer solution feed

pump. Control sludge pump speed to facilitate delivery of the feed setpoints entered at centrifuge operator interface. Send the sludge flow signal to the polymer system control panel to request polymer flow pacing.

d. A second centrifuge may be started after first centrifuge has completed its start-up cycle and is operating in a steady state condition.

3. Sludge Feed Interruptions: a. For non-critical faults (as defined by Centrifuge Vendor), the centrifuge will stop the

sludge feed, when the fault clears, sludge feed will be resumed. The centrifuge may run without sludge feed for an extended period of time due to the long time involved in stopping and starting a centrifuge to interrupt the sludge feed. This will allow the operator to clear the fault before initiating an automatic shutdown.

b. The Centrifuge control panel will accumulate the time in operation without sludge feed. If sludge feed is interrupted for extended period (continuously for 30 minutes) when the centrifuge is at normal operating speed, the centrifuge will automatically enter a normal shutdown cycle.

4. Normal Shutdown: a. A normal centrifuge shutdown cycle will be triggered if any of the following

conditions occur: 1) Normal Shutdown button and Centrifuge Vendor OIT Pushed 2) Centrifuge Shutdown Fault detected by Centrifuge control panel. Faults which

trigger a shutdown are defined by the Centrifuge Vendor 3) Extended sludge feed interruption

b. A typical shutdown cycle (detailed cycle to be defined by Centrifuge Vendor) will consist of the following key steps: 1) The Centrifuge control panel will issue a stop command for the centrifuge feed

pump and the polymer solution feed pump. 2) Centrifuge READY Status removed. 3) Flush water will be enabled and continue for an operator adjustable pre-set time

as controlled by the Centrifuge control panel. The machine will go through its vendor specific shutdown/flush cycle.

4) The scroll and bowl will simultaneously begin a controlled ramp down. 5) Flush water will stop after flush timer duration is satisfied, and the machine’s

vendor specific shutdown/flush cycles have been completed. 6) The scroll and bowl are stopped. 7) The Centrifuge is considered OFF.


5. Emergency Shutdown: a. In an emergency shutdown condition all centrifuge equipment is simultaneously de-

energized. Vendor specific shutdown and flushing functions may remain active during an emergency shutdown cycle. An emergency stop may be triggered by the following conditions: 1) Loss of power 2) Emergency Stop Button at OIT Pushed 3) Scroll Drive READY status lost 4) Bowl Drive READY status lost 5) Other vendor defined emergency shutdown alarms.

6. Abnormal Operations: None 7. Emergency Operations:

a. Unless specifically noted otherwise in the control strategy, following a power failure the process equipment running in remote-automatic or remote-manual should only restart with operator intervention following restoration of power.

b. There is no standby power provided to the centrifuge facility. Machine shutdown upon power failure shall include a power loss feature that utilizes the inertia of the bowl to power the scroll drive and maintain a differential to scroll solids out of the machine during coast down if this feature is an available option for the equipment supplied.

c. System Maintenance Mode: The system maintenance mode shall be designed to allow the operator to individually jog motors. It shall be intended for troubleshooting purposes only. The system shall not be operated in this manner when processing sludge.

d. Refer also to Emergency Shutdown above.

D. Centrifuge Alarm/Interlock Conditions 1. Below is a partial list of centrifuge alarms.

a. Main/bowl motor VFD fault. b. Main/bowl motor winding temperature High. c. Main/bowl motor Circuit Breaker Trip. d. Scroll motor VFD fault. e. Lubrication unit fault f. Torque alarm HI. g. Torque alarm HI HI. h. Bearing temp HI. i. Bearing temperature HI HI. j. Vibration alarm HI. k. Vibration alarm HI HI.

PART 3–EXECUTION

3.01 GENERAL

A. The manufacturer is responsible for all aspects of the centrifuge system, with the exception of the installation of the major components and external wiring. All internal wiring and skid-


mounted wiring required in the shop shall be the responsibility of the manufacturer. Responsibilities include design and fabrication, shop performance tests, safe delivery to the site, check out the installation by the CONTRACTOR, field checkout tests, field performance tests, equipment startup services, furnishing all special tools, supplies, and special equipment, and proper training of Owner personnel.

B. Inspection of Assembly: The manufacturer shall provide access for the Owner to inspect the machine during its assembly at the point of manufacture. The CONTRACTOR shall provide the Owner with 30 days advance notice of the manufacturing and assembly schedule and locations.

3.02 FACTORY/SHOP TESTING

A. Factory testing of each centrifuge shall be performed at the centrifuge manufacturer’s facility to demonstrate the absence of mechanical or electrical defects and that the centrifuge operates within the specified limits. Equipment to be shop tested including the centrifuge, bowl drive motor, scroll drive motor, control panels, and VFDs. Test requirements for control and drive panels are in Division 17.

B. Shop Testing Procedure: 1. Centrifuge manufacturer shall allow inspection and witness of the shop test of the

equipment by the ENGINEER and the Owner. Travel and subsistence related expenses are not the responsibility of the CONTRACTOR or manufacturer. However, in case of a failure of a test and consequent necessity to repeat the test, all related expenses shall be borne by the manufacturer.

2. Equipment to be shop tested and witnessed by the ENGINEER shall include: a. Centrifuge b. Control Panels c. VFDs

3. Centrifuge manufacturer shall notify ENGINEER of the test schedule not less than 14 days in advance for testing taking place within the United States. Centrifuge manufacturer shall provide a minimum of 45 days advance notice of the test schedule for testing taking place outside of the United States.

4. Test Conditions: a. The following tests shall be completed before the centrifuge is released for shipment.

Testing shall consist of a four-hour dry run followed by a two-hour wet run. During the test the machine shall be run at maximum, minimum, and 3 rpm differential speeds. Factory testing shall demonstrate that the centrifuges running at the g-force required to achieve the specified dewatering performance, operate within the tolerances specified in Article 1.3 before shipping and delivery. 1) Vibration measurement with bowl empty. 2) Vibration measurement with bowl filled with water. 3) Operation of machine for 2 hours with water. 4) Motor starting amperage. 5) Test equipment/procedures:

a) Test equipment shall be calibrated. 6) In a separate shop test, all circuits on the control system panel shall be checked

and all alarms and shutdown conditions simulated to check the alarm circuits.


5. Certified test results shall be submitted after completion and prior to shipping and delivery.

3.03 SHIPMENT AND DELIVERY TO SITE

A. The manufacturer is responsible for shipment and delivery of the equipment. Shipping, storage and handling shall comply with Section 01605. Shipping shall include the special monitoring (including accelerometers) specified in Section 01605. The manufacturer shall coordinate with the CONTRACTOR as needed to allow effective delivery to the area of Work.

3.04 INSTALLATION REQUIREMENTS

A. The manufacturer shall provide written guidance and on-site advisory assistance in the installation of all equipment supplied herein. 1. Submit detailed instructions on preparation and installation of the centrifuge assemblies.

Provide technical assistance to the CONTRACTOR as requested to clarify or expand information as needed.

2. Observe CONTRACTOR during unloading of the centrifuge assembly. Inform the CONTRACTOR in method of storage and notify when storage does not conform to manufacturer’s requirements. Provide all necessary maintenance on centrifuge assemblies during period of storage.

3. Provide technical assistance to the CONTRACTOR for coordination of all conduit stub-up locations, connections, and terminations. Manufacturer shall provide field inspection and certification services to assure the CONTRACTOR has terminated all components correctly prior to field start-up and commissioning services.

4. Coordinate with the CONTRACTOR to arrange a mutually acceptable schedule to ensure substantial and final completion of special services consistent with the construction completion dates.

5. The Supplier shall be responsible for partial disassembly and reassembly of the centrifuges onsite in order to facilitate moving the centrifuges into the operating room through the existing access hatch. The Supplier will complete this partial disassembly and reassembly to move both of the new centrifuges into the operating room during the same trip. The CONTRACTOR shall coordinate with the Supplier for storage of the second centrifuge in the operating room.

B. Installation sequence 1. The centrifuge installation shall be sequenced such that one centrifuge shall be available

for use at all times. 2. The CONTRACTOR shall demolish one existing centrifuge, and then install the new

centrifuge in it’s place. The other centrifuge shall continue to operate during contruction. 3. The CONTRACTOR and the Supplier shall complete PET on the first centrifuge as

specified. 4. (Addendum #1) After performance testing is complete to the Owner’s satisfaction, the

CONTRACTOR shall proceed to demolish the second existing centrifuge and install the second new centrifuge in it’s place. The first new centrifuge shall be available for operation during this time. While the first new centrifuge must successfully pass PET before demolition of the second existing centrifuge can begin, the RAT period may continue during new centrifuge #2 installation. The ENGINEER/Owner may


provide approval to proceed with demolition of the second centrifuge before the formal acceptance of the PET report.

3.05 FIELD MECHANICAL TESTING

A. The manufacturer shall conduct field testing of the centrifuge to confirm all equipment is properly installed and ready for operation. The manufacturer shall certify the installation on Form 11000-A specified in Section 11000. Field inspection and testing shall demonstrate: 1. The equipment was not damaged during storage, transportation, or installation. 2. The equipment is properly installed and aligned. 3. There are no mechanical defects in any parts. 4. The equipment is free of overheating, objectionable vibration, and overloading. The

centrifuges and ancillary equipment shall operate without overheating, overloading of any parts or systems, and within the specified limits of vibrations, noise, temperature, pressures, and torque. Noise testing shall be done during the FAT (Section 01660) or during the PET subject to Engineer acceptance with a single centrifuge train operating.

5. The proper interaction and effective control of the centrifuge, drive motor, scroll drive, and control panel, and drive panel will also be demonstrated, including all interlocks, safeties, and controls function as intended.

6. That the centrifuges can operate without problems within the specified limits of solids feed and polymer feed flow rates producing dewatered sludge of the specified consistency.

7. Field Electrical Testing: Manufacturer supplied PLC communication devices, motors, cables, and circuit breakers shall be tested in accordance with the requirements of Divisions 11 and 17.

B. The test procedure, submitted by the manufacturer and accepted by the Engineer or the Owner, shall be run by a qualified representative of the centrifuge manufacturer in the presence of the Owner and/or Engineer and/or the Contractor. Testing shall comply with Section 01660.

C. The field tests shall consist of: 1. Preliminary testing of control circuits, shutdowns, and control loops to verify correct

interconnecting wiring to alarms by opening various field device contacts at the device and verifying loss of continuity at the appropriate control panel terminals.

2. A preliminary two-hour water run of the centrifuge as part of the manufacturer’s initial startup and checkout procedure.

3. A four-hour wet run of the centrifuge together with the polymer system, sludge feed system, wash water system, and associated instrumentation and controls. Water shall be used in this test for both the polymer and sludge feed lines. Refer to Section 01660, for additional requirements.

4. (Addendum #1) A four-hour sludge run during which dewatered sludge solids concentration shall be a minimum of 20 18 percent. Polymer and sludge feed will be employed to dewater the sludge produced. Sludge feed system and polymer feed system shall be part of this test. Refer to Section 01660, for additional requirements.

5. (Addendum #1) FAT protocol as specified in Section 01660. Dewatered sludge solids concentration shall be a minimum of 20 18 percent during RAT.


3.06 PERFORMANCE REQUIREMENTS TESTING, SAMPLING AND ANALYSIS

A. As part of the Reliability Acceptance Testing for the Project specified in Section 01660, the centrifuge equipment shall be subjected to Performance Expectation Testing as described below to demonstrate the dewatering performance capabilities of the installed equipment.

B. (Addendum #1) The total RAT period shall consist of a minimum of 6, 6-hour days of operation at the maximum throughput capacity of the centrifuge. The maximum capacity is determined as the maximum hydraulic throughput or the maximum solids throughput based on the digestered sludge feed solids concentration on that day, whichever is governing. A minimum of 3 of these 6 days at maximum capacity shall be during the PET. The remainder of the RAT period shall demonstrate throughput capacity throughout the operating range of the centrifuge, as determined by the ENGINEER/Owner.

C. Performance Expectation Testing (PET): 1. PET will consist of an initial centrifuge optimization period followed by a period of

performance demonstration in which an intensive sampling program will be conducted. 2. The manufacturer shall develop a detailed procedure and schedule for PET and submit to

the ENGINEER for review and acceptance, in accordance with Section 01660 and the requirements specified in this Section. This submittal shall be called the PET Testing Plan, and shall be reviewed and accepted by the ENGINEER prior to the start of PET.

3. The CONTRACTOR and centrifuge manufacturer shall coordinate the detailed PET schedule with the ENGINEER.

4. Representatives of the Owner and the CONTRACTOR will be present for the PET. 5. Unless otherwise specified, the Owner will supply and bear the cost for supply of water,

dewatered sludge hauling, polymer and electric power during commissioning, including the PET period.

6. The CONTRACTOR shall coordinate with the Owner and provide the ENGINEER with four weeks’ advance notice before testing to allow the Owner to order and supply the polymer. The CONTRACTOR shall work with the Owner to startup the new system with the preselected polymer product at the time of startup.

7. The manufacturer shall conform to the PET testing requirements as follows: a. Provide all test equipment, including instruments, analyzers, chutes, sample drums,

and bins required to conduct sampling and analysis during the PET period. Samples and data recorded shall include the following: 1) Centrifuge feed sludge – total solids 2) Centrate – total solids, total suspended solids 3) Dewatered sludge – total solids 4) Polymer feed rate – gallons per minute, and concentration 5) Sludge feed rate – gallons per minute 6) Centrifuge discharge rate – pounds per hour 7) Solids capture – percent 8) Setting for polymer feed pump 9) Setting for sludge feed pump 10) Differential speed, torque setting 11) Motor amperage


12) Power draw 13) Noise

b. During the entire Performance Test period, all samples will be split, with one sample provided to the Owner and the second sample delivered by the CONTRACTOR to a certified laboratory for analysis. Laboratory tests shall be performed by a certified lab agreed upon by the CONTRACTOR, ENGINEER, and the Owner. The cost for independent laboratory analysis shall be paid by the CONTRACTOR.

8. (Addendum #1) The manufacturer shall optimize the operation of the centrifuge for up to two weeks, and establish objectives for operating parameters and machine settings. The manufacturer shall summarize in a Centrifuge Optimization Report and provide to the ENGINEER for review and acceptance. Fully automatic operation is required, including all associated equipment and controls. Upon ENGINEER’s acceptance of the Report, the centrifuge equipment manufacturer shall proceed with PET. The ENGINEER/Owner will provide conditional approval of the optimization period for the centrifuge equipment manufacturer to proceed with the PET. Formal optimization report and report acceptance shall follow, but is not required in order to start the PET.

9. Manufacturer shall subject each of the centrifuges to PET. A maximum of one (1) centrifuge at one time can undergo PET. Refer to paragraph 1.03 for anticipated operating conditions for dewatering.

10. The procedure for the PET is as follows: a. (Addendum #1) Operate dewatering centrifuge equipment at steady state with sludge

and polymer feed for a period of two hours prior to start of testing. Test using a shift-based operation (minimum 8 6 hours per day performance run) for a period of at least 3 consecutive days, Monday through Thursday. If the dewatering centrifuge equipment does not exhibit stable operation during this period, or if more data is required to fulfill the obligations of PET, the ENGINEER will direct the centrifuge equipment manufacturer to extend the testing period at no cost to the Owner. The ENGINEER/Owner reserves the right to shorten PET testing periods at the Owner’s discretion.

b. Document system performance during this period and conduct sampling and analyses as specified in this Section. Provide all raw data to the ENGINEER, so that the Owner can independently monitor system performance.

c. During the course of the PET test period, samples and/or measurements shall be taken by the CONTRACTOR at least once per hour (starting one hour after the centrifuge has reached stable operation each day) over the course of each operating day. The CONTRACTOR may extend the PET test period up to three additional days for each trial, at no additional cost to the Owner.

d. Evaluation of centrifuge performance will be based on an average of all samples taken, minus the highest and lowest value data points in each performance category: dewatered sludge solids, percent capture, and polymer usage.

e. During the course of the PET, the centrifuges must be operated within the solids and hydraulic loading specified in paragraph 1.03. Solids loading to the centrifuge shall be reported simultaneously with collection of each sample.

f. The ENGINEER reserves the right to assess the results. At the ENGINEER’s sole discretion, if the statistical deviation is considered in excess of acceptable levels, additional testing and analysis may be stipulated at no additional cost to the Owner.

g. The manufacturer shall compile the results and descriptions into a bound report entitled "Results of Performance Expectation Testing".


D. Incorporate final PET data in concise tabular form in the PET Report submitted at the conclusion of the test period.

3.07 TECHNICAL SERVICES

A. Technical services of the manufacturer’s representative shall be supplied in the following areas:

B. Field Service Technician Qualifications: 1. The manufacturer shall dispatch factory-trained technicians to service the equipment. The

technicians shall be in the direct employ of the manufacturer. 2. All field service shall be supported by a fully qualified field service department. The field

service department shall be fully staffed with at least 20 full time employees, all of whom are factory-trained for the equipment.

3. Field service department shall have spare parts readily available. 4. Field service shall be available 24 hours per day, 7 days per week.

C. Start-Up Services: 1. Furnish the services of authorized technical representatives of the manufacturer to

assist/inspect the equipment, conduct pre-operational mechanical checkout of the equipment, place equipment into operation, optimize the performances of the equipment and perform the field performance testing.

DEWATERING CENTRIFUGE START-UP SERVICES

Installation Inspection Inspect Piping, Chutes, and Flexible Connections Installation Inspect Wiring and Controls Installation PLC Programming and Trouble-Shooting Mechanical Start-Up (Checkout) Process Start-Up (Checkout)

D. Emergency Services: 1. Provide the services of the manufacturer to be present within 24 hours for on-site

emergency services of all the furnished equipment. Emergency service shall be required for failure of any major component of the centrifuge equipment.

2. Emergency service shall be provided at no charge throughout the 2-year warranty period from the day of Owner acceptance.

E. Training: 1. The manufacturer shall provide operation and maintenance training as specified in

Section 01664. Training provided during one trip shall include 4 hours of centrifuge equipment training and 4 hours of PLC training.

2. Additional training is defined in Section 01664. System integreator training is defined Division 17.


3.08 OWNER ACCEPTANCE

A. The Owner will accept only complete, workable equipment and systems under the following conditions: 1. After receipt by the Owner of all the Drawings in “Accepted” or “Accepted as Noted”

status by the ENGINEER. 2. After receipt by the Owner of all centrifuge documentation required by the contract. 3. After completion of all specified factory testing and receipt of all factory test reports

accepted by the ENGINEER. 4. After completion of all specified equipment cleaning, start-up, field testing and

acceptance of performance runs as specified herein and receipt by the Owner of all Specification certifications accepted by the ENGINEER.

5. After completion of PET. 6. After receipt by the Owner of all special tools, supplies and accessories and complete

final draft of equipment service manuals as specified herein. 7. After completion of Operation and Maintenance training as specified in this Section.

3.09 (ADDENDUM #1) DAMAGES

A. If the equipment fails to meet the performance criteria during PET and the Contractor is unable to cure the default, the Contractor shall be liable to the Owner for the remedy set forth in this subsection. In the case of multiples defaults, the Owner will be entitled to a remedy for each separate default.

TABLE 3. DEFAULT ON DEWATERED SOLIDS CONCENTRATION

DEWATERED SOLIDS CONCENTRATION, PERCENT TS REMEDY

18 None 17 Liquidated damages in the amount of $35,338 16 Liquidated damages in the amount of $70,676 15 Equipment subject to rejection

TABLE 4. DEFAULT ON SOLIDS CAPTURE RATE

SOLIDS CAPTURE RATE, PERCENT REMEDY 95 None 94 Liquidated damages in the amount of $6,173 93 Liquidated damages in the amount of $12,346 92 Liquidated damages in the amount of $18,518 91 Equipment subject to rejection

TABLE 5. DEFAULT ON SOLIDS LOADING RATE

SOLIDS LOADING RATE, DRY LB/HR REMEDY 2304 None 2281 Liquidated damages in the amount of $18,518 2258 Liquidated damages in the amount of $37,037


TABLE 3. DEFAULT ON DEWATERED SOLIDS CONCENTRATION 2235 Liquidated damages in the amount of $55,555 2212 Liquidated damages in the amount of $74,073 2189 Equipment subject to rejection

B. Should total liquidated damages exceed 12% of the total package purchase price, the Owner shall have the right to accept that value as total settlement, or the Contractor shall remove and return equipment for a full refund of the purchase price at no additional cost to the Owner.

**END OF SECTION**

150141 – 2017 Upgrades and Rehabilitation 11546-1 Digester Fixed Steel Dome Cover James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 11546

DIGESTER FIXED STEEL DOME COVER

PART 1–GENERAL

1.01 DESCRIPTION

A. The OWNER has purchased one (1) digester cover described in this Section from WesTech Engineering for installation by the Contractor. The Contractor shall re-view the WesTech scope of supply and shop drawing information and provide any components, materials, and labor that is not specifically listed in the WesTech scope of supply and shop drawing information for a complete and functional installation.

B. Furnish one (1) gastight fixed dome steel cover including design, supply, installation, erec-tion, and testing of fabricated steel subassemblies, piping, and associated appurtenances required for complete installation. Steel cover is to be fastened to the existing concrete di-gester walls. Design and furnish all anchor bolts and other attachments required to properly attach the cover to the digester wall. The existing roof mounted mechanical draft tube mixer will be relocated to the new cover.

C. Type: The digester covers shall be of the custom designed gastight fixed dome type utiliz-ing radial arched ribs and purlins (if required) with a peripheral thrust ring and center ring to form the basic structural element.

D. General Requirements: The drawings and details depict a cover configuration that will sat-isfy performance and operational characteristics described and required by these specifica-tions. The cover shall provide a seal over the digester's contents to maintain anaerobic conditions using a side sheet attached to the cover at the rim and an annular seal consisting of a seal membrane and fill layers between the tank wall and cover.

E. Operating Conditions: The equipment furnished under this section shall be suitable for in-stallation under the following conditions:

Outside wall diameter at base 53-feet

Outside wall diameter at top of wall 54-feet

Inside wall diameter 50-feet

Wall thickness 18-inches with 6-inch projection at top of wall

Top of wall elevation 4658.83-feet

Minimum liquid level elevation 4655.33-feet

Normal liquid level elevation 4655.83-feet

Maximum liquid level elevation 4657.83-feet

150141 – 2017 Upgrades and Rehab 11546-2 Digester Fixed Steel Dome Cover James R. DiIorio Water Reclamation Facility Construction Bid Set

Side water depth 32-feet

Tank wall height (from wall toe to top of wall) 35-feet

Top of cone elevation 4623.83-feet

Nominal digester gas pressure 13-in water column

Maximum allowable digester gas pressure 18-in water column

Bottom of side sheet elevation 4654.33-feet (1-foot be-low minimum liquid level)

F. Ports and Manholes: The cover furnished under this section shall provide necessary open-ings for the following ports and manholes:

Mixer Mounting Ring

Number 1

Diameter (inches) 102

Access manholes Number 2 Diameter (inches) 30 Emergency Pressure Relief Hatch a Number 1 Diameter (inches) 18

Sample hatches a Number 4 Diameter of flanged connection (inches) 8

Gas Bonnet

Number 1

Diameter of flanged connection (inches) 20

Pressure/vacuum relief assemblies a Number per digester 1 Diameter of flanged connection (inches) 6 (1 connection) a See Section 11556 for requirements.

G. Design Requirements: 1. Structural Design: The cover dome shall be supported on top of the tank wall and shall

be designed to impose no radial loads on the wall. Wind, snow, and seismic loads shall be determined in accordance with IBC 2015 and ASCE 7-10. The cover shall be designed to withstand the following loads:


Item Value

Live load 50 psf, See Section 1.01.F.2 for mixer load require-ments.

Design vacuum pressure (inches water column):

3

Dead load: Weight of fabricated steel assemblies, PRV assem-blies, sample hatches, access manholes, piping and appurtenances, mixer mounting ring, insulation (as-sume 10 psf), draft tube mixer, and all other compo-nents that are part of the cover assembly.

Digester operating temperature (de-grees F):

95-135

Design ambient air temperature (de-grees F):

-30-110

Wind Load: Basic Wind Speed: 120 mph Ultimate

Risk Category: III

Exposure Category: C

Consider wind loads acting both inward and outward as required.

Snow Load: Ground Snow Load: 20 psf

Importance Factor: 1.1

Thermal Factor, Ct: 1.2

Exposure Factor, Ce: 1.0

Seismic Load: Site Class: D (assumed)

Risk Category: III

SDS: 0.18g

SD1: 0.10g

Seismic Design Category: B

Consider the vertical seismic load components as re-quired.

2. The roof structure shall provide lateral and vertical support for the removable draft

tube mixer mounted at the center of the digester cover. The draft tube mixer has rotat-ing parts that impart dynamic loads to the cover. The structural analysis and design of the cover shall include a structural dynamic analysis and investigation that considers the natural frequencies of the cover and draft tube mixers as well as the range of oper-ating speeds and dynamic loads imparted by the draft tube mixer. Per the manufac-turer’s information, mixer torque is 120 foot-pounds and the mixer cover load, inclu-sive of thrust, mixer weight, and draft tube, is 4,700 pounds.

3. Configuration: The arrangement of equipment shown on the drawings is not intended to show exact dimensions particular to a specific manufacturer. The drawings are, in part, diagrammatic and some features of the illustrated equipment installation may re-quire revision to meet actual equipment installation requirements. The Contractor shall verify radial dimensions of the digesters for fitting the digester covers to the


tanks. Cover design is required to accommodate existing structural supports, con-nected piping, and valves. The cover shall be dome-shaped and shall have a dome ra-dius between 1.5 and 2.0 times the cover diameter. The dome framework shall consist of arched radial ribs and purlins held in position by a peripheral thrust ring and a cen-ter ring. A closed section shall be used for the peripheral thrust ring to ensure maxi-mum torsional stiffness. The dome framework shall be covered by a minimum 1/4-inch plates welded to the arched ribs and purlins, side sheet, and to each other to form a gastight cover. A vertical side sheet, peripheral thrust ring and steel shell structure properly proportioned to match deflections and stresses shall be provided along the periphery of the fixed dome cover. Side sheet sections shall be welded to each other. The annular space between the side sheet and the tank wall shall provide a gastight seal under the gas pressure specified in Paragraph 11546-1.01 D.

4. Exterior Roof Coatings and Insulation: Exterior roof coatings and insulation shall be fluid-applied. Insulation for the digester roofing system shall be sprayed polyurethane foam (PUF) in accordance with Section 07545. Elastomeric roof coating shall be ap-plied to the exterior surface of the digester roofing system in accordance with Section 07540. Exterior steel surfaces shall be first coated with system EA-1 per Section 09900 and then per the requirements of Section 07545 prior to insulation installation. Exposed steel cover surfaces/structures not coated by the digester roofing system shall be coated per Section 09900.

5. Joints and Seams: All interior joints and seams shall be continuously welded. Exterior joints and seams shall be continuously welded where required by the Manufacturer for structural purposes and/or gas tight construction and where top application of insula-tion is not performed. a. All exterior and cover plate to radial beam assembly welds shall be skip welded.

After skip welding is completed, all skip welds shall be caulked by Contractor. 6. Underside Cover Surface: To form a smooth uniform underside cover surface, gastight

seal, and for ease of protective coating applications weld the beams to the top of the cover plates.

7. Maximum Stress: The maximum stresses shall not exceed limiting stresses as set forth in the American Institute of Steel Construction (AISC) specifications.

8. All radial thrust loads shall be resolved by a peripheral thrust ring. As a minimum, the thrust ring and lower rim angle splice joint welds shall be complete joint penetration (CJP).

9. Additional Sections and Paragraphs required for compliance: The following additional sections and paragraphs relate to the equipment specified in this section. This is not a comprehensive list of related and referenced sections and paragraphs and additional related and referenced sections and paragraphs requiring compliance may be specified throughout this section and within other sections. This list is provided as a conven-ience for the Contractor. Related and referenced sections shall be reviewed and sub-mittal information provided as required in paragraph 1.04 of this section. a. Section 01300 – Submittals b. Section 01660 – Equipment and System Functional and Performance Testing c. Section 01662 – Commissioning d. Section 01662A – Manufacturer’s Certificate of Compliance e. Section 01662B – Manufacturer’s Certificate of Proper Installation f. Section 01730 – Operation and Maintenance Information g. Section 01800 – Environmental Conditions


h. Section 01999 – Reference Forms i. Section 03730 – Concrete Rehabilitation j. Section 07540 – Fluid-Applied Elastomeric Roof Coatings over Polyurethane

Foam k. Section 07545 – Sprayed Polyurethane Foam for Roofing Systems l. Section 09900 – Coating Systems m. Section 11000 – General Requirements for Equipment n. Section 11556 – Gas Handling Equipment


A. Performance and Design Requirements: The cover shall be of the fixed dome design com-prised of radial ribs and purlins connected to a thrust ring girder at the center and to a thrust ring at the periphery. The cover shall provide a gastight seal over the digester tank's contents to ensure maintenance of anaerobic conditions. The cover shall have mounting brackets attached to the digester tank wall with anchor bolts supplied by the Manufacturer.

B. Appurtenances to be furnished with the fixed dome cover shall include manholes, sample hatches, piping and valves shown on top of the cover including assembly bolts and anchor bolts with hex nuts and washers, and miscellaneous pipe and instrument penetrations as shown.

C. The contents in the digester will be a mixture of digested sludge fed with thickened pri-mary and secondary solids and thickened scum. The mixture will contain organic and in-organic solids, grit, grease, scum and industrial solvents. The tank will be heated to oper-ate as a completely mixed high-rate anaerobic mesophilic or thermophilic digester.

D. The sludge gas may be expected to contain significant quantities of fine particulate matter, moisture and greasy oils. Small quantities of hydrogen sulfide, hydrogen and nitrogen may also be expected. Carbon dioxide concentrations are expected to range between 30 and 50 percent by weight with the remainder comprised primarily of methane. The gas is expected to have a specific gravity of approximately 0.84 and a net heating value of 600 Btu per standard cubic foot. Occasionally, the cover can be expected to be in contact with foam generated by the digestion process.

E. References: This section contains references to the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall pre-vail. 1. Unless otherwise specified, references to documents shall refer to the documents in

effect at the time of issuance of the Contract. If referenced documents have been dis-continued by the issuing organization, references to those documents shall refer to the replacement documents issued or documents otherwise identified by the organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall refer to the specific document version associated with that date, whether or not the document has been superseded by a version with a later date, discontinued or replaced.


Reference Title

ASCE 7-10 Minimum Design Loads for Buildings and Other Structures

AISC Manual of Steel Construction

American Institute of Steel Construction, Manual of Steel Construction --14th Edition

ANSI/AWS A2.4 Standard Symbols for Welding, Brazing, and Nondestructive Examination

ANSI B1.1 Unified Screw Threads

ANSI B1.20.1 Pipe Threads, General Purpose (Inches)

ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings, Class 125

ANSI B18.2.1 Square and Hex Bolts and Screws, Including Askew Head Bolts, Hex Cap Screws and Log Screws

ANSI B18.2.2 Square and Hex Nuts

ASTM A36/A36M Standard Specifications for Carbon Structural Steel

ASTM A53/A53M Standard Specifications for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A276 Standards Specifications for Stainless Steel Bars and Shapes

ASTM A500/A500M Standard Specifications for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

ASTM A992/A992M Standard Specifications for Structural Steel Shapes

ASTM C273 Standard Test Method for Shear Properties of Sandwich Core Materials

ASTM C518 Steady-State Heat Flux Measurements and Thermal Transmission Proper-ties by Means of the Heat Flow Meter Apparatus

ASTM C794 Test Method for Adhesion-in-Peel of Elastomeric Joint Sealants

ASTM C920 Standard Specification for Elastomeric Joint Sealants

ASTM D412 Test Method for Vulcanized Rubber and Thermoplastic Rubbers and Ther-moplastic Elastomers-Tension

ASTM D413 Standard Test Methods for Rubber Property—Adhesion to Flexible Sub-strate

ASTM D624 Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers

ASTM D696 Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics Between -30°C and 30°C with a Vitreous Silica Dilatometer

ASTM D751 Standard Test Methods for Coated Fabrics

ASTM D1056 Specification for Flexible Cellular Materials—Sponge or Expanded Rubber

ASTM D1204 Standard Test Method for Linear Dimensional Changes of Nonrigid Ther-moplastic Sheeting or Film at Elevated Temperature

ASTM D1622 Standard Test Method for Apparent Density of Rigid Cellular Plastics

ASTM D1623 Standard Test Method for Tensile and Tensile Adhesion Properties of Rigid Cellular Plastics

ASTM D2126 Standard Test Method for Response of Rigid Cellular Plastics to Thermal and Humid Aging


Reference Title ASTM D2240 Test Method for Rubber Property-Durometer Hardness

ASTM D2842 Standard Test Method for Water Absorption of Rigid Cellular Plastics

ASTM D3776 Standard Test Methods for Mass Per Unit Area (Weight) of Fabric

ASTM D4533 Standard Test Method for Trapezoid Tearing Strength of Geotextiles

ASTM D4833 Standard Test Method for Index Puncture Resistance of Geotextiles, Ge-omembranes, and Related Products

AWS D1.1 Structural Welding Code

IBC 2015 International Building Code

F. Unit Responsibility: The Contractor shall assign unit responsibility as specified in para-graph 11000-1.02C to the cover manufacturer for all equipment and work under this sec-tion. Provide a Certificate of Unit Responsibility (Form 11000-C, Section 01999).

G. Standards: 1. Maximum stresses shall not exceed the Allowable Stress Design values set forth in

AISC Specifications for Structural Steel. 2. Welding and welding qualification procedures shall conform to the standards set forth

in Parts 8 and 16 of the AISC Manual of Steel Construction. 3. All shop and field welding shall conform to the AWS D1.1 “American Welding Soci-

ety” codes using qualified AWS certified welders and procedures. Welds shall be 3/16 inch continuous fillets unless otherwise noted on the plans or the Manufacturer’s shop drawings. Welding electrode shall be E70xx or equal wire. Field weld inspec-tion shall be per AWS and with AWS CWI inspectors.

1.03 ENVIRONMENTAL CONDITIONS

A. The equipment specified in this section will be located in an outside open area having a NEMA Class I, Division 1, Group D Hazardous Classification. Environmental conditions shall be as described in Section 01800. The cover will be subject to weather exposure: di-rect sunlight, wind, rain, freezing winter conditions, etc.

1.04 SUBMITTALS

A. Submit shop drawings and installation drawings that shall show details of installation and connections. All material specified in this section shall be submitted in accordance with Sec-tion 01300. The submittal shall consist of the following data, drawings, and descriptive mate-rial: 1. Contractor shall provide a copy of this specification section, with addendum updates in-

cluded, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indi-cated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Construction Manager shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the


part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the spec-ification requirements, with the submittal shall be sufficient cause for rejection of the en-tire submittal with no further consideration.

2. Cover Manufacturer shall provide shop drawings bearing the signature and seal of a currently registered Professional Engineer in the State of Colorado, as follows: a. Overall assembly, plan and sections, showing dimensions and location of appurte-

nances. b. Fabrication details, along with calculations. c. Complete information regarding location, type, size and length of all shop and

field welds in accordance with AWS A2.4. Special conditions shall be fully ex-plained by notes and/or details.

d. Details of all appurtenances, including sampling hatches, pipe penetrations, pipe supports, instrument penetrations, and manholes.

e. Anchor bolt details including diameter, embedment length, adhesive system, quantities, and locations.

3. Contractor shall provide coating and insulation system details and technical data sheets.

4. Cover Manufacturer shall provide structural calculations and stress diagrams showing component stresses with design maximum internal pressure and without live loads. Include shop weights of components and weight of equipment appurtenances. All cal-culations shall be signed and sealed by a currently registered Professional Engineer in the State of Colorado. The Professional Engineer shall have designed a minimum of ten (10) fixed covers of 50-feet in diameter or greater. Structural calculations and stress diagrams showing component stresses of the cover under the following condi-tions considering live, wind, snow and seismic requirements: a. On an empty tank. b. In service with the liquid level at normal operating level with normal gas pressure. c. In service at maximum liquid level and maximum gas pressure. d. In service at minimum liquid level and minimum internal pressure. e. Any other applicable condition or load combination that may result in maximum

stresses of the cover. 5. Cover Manufacturer shall provide anchor bolt design calculations signed and sealed

by a Professional Engineer registered in the State of Colorado. 6. Contractor shall provide annular seal top fill, middle fill, and bottom fill layer details

including technical data sheets for all seal components. 7. Cover Manufacturer shall provide annular seal bottom seal details including technical

data sheets. 8. Contractor shall provide annular seal top fill, middle fill, and bottom fill layer manu-

facturer product data, including installation instructions and required surface prepara-tions for all components comprising the annular seal.

9. Cover Manufacturer shall provide calculations signed and sealed by a Professional En-gineer registered in the State of Colorado showing the support reactions for thermal expansion and contraction.

10. Cover manufacturer shall provide fabrication assembly plans and details.


11. The Contractor shall provide as a submittal for review and approval by the Engineer the plan for removal and replacement of the digester cover to specifically address the following points: a. Proposed staging area for the existing digester cover to be placed during disassem-

bly. Include approximate duration. b. Proposed staging area for the new digester cover to be placed during assembly.

Include approximate duration. c. Proposed staging area for crane. Include approximate duration. d. Proposed methods of protection of asphalt surfaces, existing digester, and any

other infrastructure in the vicinity. e. Proposed provision of any temporary traffic controls or any other pertinent infor-

mation related to the Owner’s access to the facilities. 12. Operating and Maintenance Data: Cover Manufacturer shall provide service manuals

conforming to Section 01730. Standard operations and maintenance instructions typi-cally provided by manufacturers shall not be accepted as fulfilling this requirement.

13. Manufacturers Certificate: Letter from the Cover Manufacturer confirming proper in-stallation, proper commissioning, performance limits, covered components, and war-ranty effective dates in accordance with Section 01662A and Section 01662B.

1.05 SPARE PARTS, SPECIAL TOOS, AND SUPPLIES

A. If there are any, provide special tools for the equipment specified in this Section.

1.06 WARRANTY

A. The Cover Manufacturer shall warrant to the Contractor or Owner that the equipment pur-chased from the Manufacturer is free from defects in materials and workmanship for a pe-riod of twelve (12) months from the date of acceptance by the Owner.

PART 2–PRODUCTS

2.01 COVER MANUFACTURERS

A. The following candidate Cover Manufacturers are capable of producing equipment and/or products that will satisfy the requirements of this section. This statement, however, shall not be construed as an endorsement of a particular Cover Manufacturer’s product, nor shall it be construed that a named Cover Manufacturer’s standard product will comply with the requirements of this section. Qualified Cover Manufacturers shall have a mini-mum of twenty (20) operating installations, having digesters of similar pressure, and 50-foot diameter or greater that have operated successfully for more than five years. The Cover Manufacturer may not use installations that were designed and furnished as a con-tractor to another manufacturer.

B. The digester covers shall be by OTI, Ovivo, WesTech, or equal.


2.02 MATERIALS

Component Material

Structural steel S-shapes, channels, angles, bars and plate

ASTM A36; all plates shall be minimum 1/4-inch-thick; minimum 3/8-inch-thick for side sheet

Structural rolled steel wide flange sections and WTs

ASTM A992

Hollow structural sections ASTM A500, Grade B (Fy = 46 ksi)

Annular seal Top fill layer Two component polyurethane elastomeric sealant, Sikaflex

2C SL, or equal. 6-inch thick Middle fill layer Expanding polyurethane chemical grout Sikaflex HH, or

equal. Bottom fill layer Two-component polyurethane elastomeric sealant, Si-

kaflex-2C SL, or equal. Bottom seal Geomembrane, Seaman Corp XR-5, 8130, or equal. 2

layers.

Gas dome cover plate Steel

Threaded Rods ASTM F593, Type 316 stainless steel

Anchor Bolts ASTM A193, Type 316 stainless steel

Concrete Adhesive Anchor System Hilti HIT-RE 500 V3, Simpson Strong-Tie SET XP, or ap-proved equal

2.03 MANUFACTURE

A. Fabrication of Assemblies: Structural steel sections and plates required to form the cover shall be fabricated and shipped in subassemblies as large as practical with the unassembled members fabricated for assembly by bolting or field welding. Fabricated assemblies shall include side sheet and thrust ring sections, center ring, manhole frames, mixer ports, co-vers, sample hatches, and appurtenances. Unassembled members shall include main and intermediate arch ribs, purlins, internal bracing, clip angles and wall anchors. The cover shall be designed and fabricated for assembly by bolting or field welding all framing members and field-welding of the cover plates to the framing members and to each other to form a gastight cover. Welds shall be continuous, gastight, seal welds and shall be on the exterior and interior of the cover and its associated components including but not lim-ited to side sheet, pipe penetrations, manholes, instrument penetrations, and sampling hatches, or as required by the Cover Manufacturer. 1. Any “fill pieces” required to provide complete and contiguous surfaces on the under-

side of the digester cover shall be provided by the Manufacturer and be fabricated for this specific purpose. Fill pieces shall be of the same material and thickness as the di-gester cover plates.

2. Steel plates, structural shapes, and fabricated assemblies shall be shipped for field painting after final erection.


B. Appurtenances: 1. Manholes: The 30-inch and 102-inch diameter manholes shall be located as shown on

the drawings. Each manhole riser shall extend not less than 6 inches above the insu-lated finished roofing level and shall be fitted with a gasketed, non-sparking, hinged cover equipped with gastight hinged hold-down bolts.

2. Mixer Ports: Mixer port shall be of the size and location as shown in the digester cover drawings.

3. Sampling Hatches: Sample hatches shall be as specified herein and located as shown on the drawings. Sample port risers shall extend not less than 6 inches above the insu-lated finished roofing level. Sample hatches shall be fitted with seal tubes which ex-tend down to 1-feet below the minimum liquid level. Seal tubes shall be minimum ¼-inch steel and shall be supported from the digester cover. Provide lateral support such that a horizontal uneven distributed load of 6 pounds per square foot will provide a maximum deflection of 0.375 inch at the bottom of the seal tube.

4. Piping: Coordinate piping supply, pipe penetrations, and pipe supports with the Con-tractor.

5. Pressure-Vacuum Relief Assemblies: Pressure-vacuum relief assemblies, as specified in Section 11556, shall be mounted on the gas dome as shown.

6. Emergency Pressure Relief Hatch: Emergency Pressure Relief Hatch, as specified in Section 11556, shall be mounted as shown in the digester cover drawings.

7. Instrumentation: Provide riser and flange connection as shown on the drawings to ac-commodate the limit switch. Riser and flanged connection shall extend not less than 6 inches above the insulated finished roofing level.

C. Anchors and Fasteners: 1. Wall Supports: The entire weight of the cover and the specified loadings shall be car-

ried by evenly spaced wall supports. The wall supports shall be fabricated from closed steel sections and shall bear on the top of the digester wall. The supports shall be designed to prevent any radial loads from being transmitted to the digester wall. The wall support brackets shall be designed to distribute the vertical loads evenly over each of the support bracket anchor bolts.

2. Anchor Bolts: All anchor bolts, including nuts and washers, shall be a minimum of 1-1/4-inch thick and made of Type 316 stainless steel. The equipment supplier shall fur-nish all anchor bolts, nuts, and washers required for the equipment. Anchor bolts shall be located at the centerline of the 18-inch wall with a bolt circle diameter of approximately 51.5-feet (to be field verified). Anchor bolts shall be installed using an adhesive anchor system, such as Hilti HIT-RE 500 V3, that is appropriate for the applied loads and condi-tions. There shall be a total of 20 anchor points, equally spaced around the perimeter. The anchor points shall be located such that they are equal distance from the existing an-chor bolts/anchor holes.

3. Anchor bolts shall be provided by the Cover Manufacturer. Epoxy adhesive shall be pro-vided by the installing Contractor.

4. Fasteners: All structural fasteners, including nuts and washers, in contact with di-gester sludge or digester gas shall be a minimum of 1/2-inch diameter and made of Type 316 stainless steel. All other fasteners, nuts and washers shall be Type 316 stainless steel. Temporary fasteners used only for erection purposes shall be Type A307 steel. The equipment supplier shall furnish all fasteners required for the assem-bly of the equipment.


D. Surfacing: The entire surface of the cover shall be surfaced to perform as a walking sur-face. Insulation, coating, and surfacing shall be as specified in Section 07540 and Section 07545. The cover, insulation and surfacing shall be such that no water accumulates on the cover and drainage is free flowing to the edge of the tank.

E. Interior Coating: The cover bottom (digester interior), the outside of the side sheet, and the exterior of the cover shall be field coated with System EA-1 in accordance with Section 09900.

F. Annular Seal: The gap between the digester wall and cover side sheet shall be 3-inches, with a maximum allowed variation of 1-inch in either direction, for a minimum gap of 2-inches and a maximum gap of 4-inches. The annular seal that fills the gap between the di-gester wall and cover side sheet shall be composed of a bottom seal layer and three fill lay-ers. The bottom seal layer shall be provided by the Manufacturer. 1. Bottom Seal Layer: The bottom seal layer shall be the primary seal between the di-

gester tank contents and the outside atmosphere. It shall comprise two layers of ge-omembrane attached to the cover side sheet and digester wall to create a gastight seal. The geomembrane shall be Seaman Corporation, XR-5, 8130, or equal, and have the following physical specifications:

Property Requirement ASTM Method

Base fabric type Polyester D3776

Base fabric weight (nominal) 6.5 oz/yd2 D3776

Thickness 30.0 mils minimum D751

Weight 30.0 +/- 2 oz/yd2 D751

Tear strength, trapezoid tear 35/35 lbf minimum D4533

Breaking yield strength, grab tensile 550/500 lbf minimum D751

Dimensional stability, 212 °F – 1 hour

1.5 % maximum, each direction D1204

Adhesion – heat sealed seam, dielec-tric weld

35 lbf/2 in minimum D751

Dead load – seam shear strength 2 in seam, 4 hours, 1 in strip, 210 lbf @70°F, 105 lbf @ 160°F

D751

Bursting strength, ball tip 650 lbf min, 800 lbf typical D751

Hydrostatic resistance, method A 800 psi minimum D751

Adhesion – ply 15 lbf/in minimum or film tearing bond D413

Bonded seam strength, as modified by NSF 54

550 lbf minimum D751

Puncture resistance 250 lbf minimum D4833

Coefficient of thermal expansion/con-traction

8 x 10-6 in/in/°F maximum D696

2. Bottom Fill Layer: Above the bottom seal layer geomembrane, a two-component poly-

urethane elastomeric self-leveling sealant shall be placed. The sealant shall be Sika


Corporation, Sikaflex 2C SL, or equal, conforming to ASTM C-920, Type M, Grade P, Class 25, and have the following physical specifications:

Property Requirement ASTM Method

Tensile strength at break, minimum 175 psi D412

Tensile elongation, minimum 650 % D412

Modulus of elasticity, 100% elonga-tion, minimum

100 psi D412

Shore A hardness 40 +/- 5 D2240

Tear strength 100 lbs/in D624

Adhesion in peel (concrete and steel), minimum

30 lbs, 0 % adhesion loss C794

Service range -40 °F to 170 °F

3. Middle Fill Layer: Above the bottom fill layer, a high-solids, hydrophobic, polyure-thane, liquid chemical grout shall be placed. The chemical grout shall be Sika Corpo-ration, SikaFix HH, or equal and have the following physical specifications:

Property Requirement ASTM

Method Shear strength 11.7 psi C273 Tensile strength 15.5 psi D1623 Elongation +25 % D1623 Shrinkage 0 % D2126 Water absorption 0.09 lbs/ft2 D2842 Density, free rise (#10 cup) 1.64 lbs/ft3 D1622 Density, molded overall 4.20 lbs/ft3 D1622

4. Top Fill Layer: Above the middle fill layer, a two-component polyurethane elasto-

meric self-leveling sealant shall be placed. The sealant shall be Sika Corporation, Si-kaflex 2C SL, or equal, and meet the specifications of the paragraph 11546-2.03 F 2. Top fill layer shall be a minimum of 6-inch thick.

2.04 PRODUCT DATA

A. The following product data shall be provided in accordance with Section 01300: 1. Installation Certification Form 11000-A as specified in paragraph 11546-3.03. 2. The roof deck manufacturer's written guarantee of the coating system covering all

costs of repair of any defects for a period as specified in Section 07540.

PART 3–EXECUTION

3.01 ASSEMBLY

A. Upon shipment to the site, the Contractor shall unload the shipment and subassemblies they shall be placed upon false-work, carefully constructed to the cover's final dimensions, and joined into a single unit. Welding shall be in accordance with the previously specified


standards. All major structural inspections shall be completed, and the cover will be capa-ble of functioning as an integral structural unit prior to removing the false-work supports.

3.02 INSTALLATION

A. Site Visit: Cover Manufacturer shall perform one site visit to field verify dimensions asso-ciated with the digester cover prior to shop drawings and fabrication.

B. Contractor shall remove the three (3) existing mixers from the existing digester and turn them over to the Owner for refurbishment. The Owner will return the mixers to the Con-tractor for re-installation when the refurbishment is complete.

C. Contractor shall demolish the existing digester cover and dispose of all waste materials. Contractor shall perform the demolition work in a manner so as to avoid damage to the ex-isting digester tank, mechanical equipment, appurtenances, and surrounding infrastructure.

D. The Owner will empty the contents of the digester prior to the Contractor beginning work.

E. The Contractor shall be aware that the interior of the digester is a hazardous environment and shall exercise appropriate safety precautions during the course of the work.

F. The Contractor shall clean the interior surfaces of the digester to the extent required to per-form the work. The cleaning work will need to be performed prior to removal of the exist-ing cover and after the cover is removed.

G. The Contractor shall provide as a submittal for review and approval by the Engineer the plan for removal and replacement of the digester cover to specifically address the follow-ing points: 1. Proposed staging area for the existing digester cover to be placed during disassembly.

Include approximate duration. 2. Proposed staging area for the new digester cover to be placed during assembly. In-

clude approximate duration. 3. Proposed staging area for crane. Include approximate duration. 4. Proposed methods of protection of asphalt surfaces, existing digester, and any other

infrastructure in the vicinity. 5. Proposed provision of any temporary traffic controls or any other pertinent infor-

mation related to the Owner’s access to the facilities.

H. (Addendum#1) The Contractor will be allowed to block or partially block the Owner’s access to the Maintenance Shop for short durations of up to one (1) week. Additional time may be granted if needed, but will be dependent upon the Owner’s activities at that point in time and will be subject to review and approval.

I. (Addendum#1) The Contractor may elect to demolish a portion of the stormwater berm to the North of the digester as part of this work. The Contractor will be re-quired to restore the berm to its original condition once the work is completed. The Contractor will be required to have the capability to temporarily restore the berm on short notice in the event of a significant rainfall event.

J. Concrete repair: Contractor shall repair existing digester concrete walls as specified in Section 03730.


K. Cover: Fabricate cover, coat exterior of side sheet, and pressure test digester cover for leaks prior to coating the cover interior (under side). The anticipated sequence of construc-tion is as follows: 1. Clean, prepare, and coat the digester interior wall surface as specified in Section

09900. 2. Fabricate cover, inclusive of side sheet 3. Coat exterior of side sheet as specified in Section 09900. 4. Install cover on existing digester walls 5. After the digester cover has been installed with the exterior side of the cover sheet

coated, and prior to coating the interior (under side) and exterior of the digester cover, the cover shall be tested for leaks as specified herein.

6. Following a successful cover test for gas tightness, the interior of the digester cover shall be prepared and coated as specified in Section 09900.

L. Annular Seal: After the digester cover has been installed, tested, and the interior coated, then the annular seal shall be installed. 1. Bottom Seal Layer: The geomembrane layers comprising the bottom seal layer shall

be installed in accordance with sealant manufacturer’s recommendations, to create a gastight seal between the side sheet and the digester wall. a. It is expected that the walls of each digester are round and plumb to within +/-4

inches. Prior to construction of the bottom seal layer, the Contractor shall measure the tank walls for roundness and plumbness. The seal shall be fabricated to match field conditions. If the tank walls are found to be out-of-round or out-of-plumb by more than +/-4 inches, and it affects the fabrication of the bottom seal layer, make suitable corrections to conform to the technical requirements of the project.

b. Water, dirt, and debris shall not be allowed to pond on top of the installed mem-brane prior to placement of the bottom fill layer.

2. Fill Layers: The bottom fill layer shall be installed, and then testing of the annular seal shall be performed as specified herein. The middle and top seal layers shall not be in-stalled until testing has been completed.

3. Installation of all seal layers shall be performed by a firm certified by the sealant and grout manufacturers. The sealant and grout manufacturers’ representatives shall be present during critical stages of the application and testing. The manufacturers’ repre-sentatives shall ensure that all necessary measures are being taken to comply with the specifications and the manufacturers’ recommendations.

3.03 TESTING

A. Cover: The digester cover shall be tested for gas tightness. The test shall be performed and passed prior to coating the interior surface of the cover. The exterior side of the cover side sheet shall be coated prior to installation of cover and testing. 1. The digester tank shall be filled with water to the normal overflow elevation above the

bottom of the side sheet and then the air space pressurized to the maximum design pressure. a. Pressure within the digester tank must be maintained for a minimum of 24 hours.

The allowable leakage rate shall be five percent at the test pressure throughout the test period. Pressure inside digester is dependent on ambient temperature and at-


mospheric pressure. Atmospheric pressure can vary significantly over a short du-ration and therefore retention of certain pressure in digester is not a reliable indi-cation of gas-tightness.

b. Installation shall be certified on Form 11000-A specified in 01999.

B. Annular Seal: The bottom seal of the annular space shall be tested for gas tightness. This test shall be performed and passed prior to installing the middle and top fill layers within the annular space. 1. Testing shall be performed using a calibrated test gage with a range such that the test

pressure falls within the upper half. 2. The digester tank shall be filled to the normal overflow elevation above the bottom of

the side sheet and then the air space pressurized to the maximum design pressure. The pressure within the digester tank must be maintained for a minimum of 24 hours. The allowable leakage rate shall be five percent at the test pressure throughout the test pe-riod. Pressure inside digester is dependent on ambient temperature and atmospheric pressure. Atmospheric pressure can vary significantly over a short duration and there-fore retention of certain pressure in digester is not a reliable indication of gas-tight-ness.

3. Visual inspection and moisture probes shall be used to locate leaks in the annular seal. Areas where leaks occur shall be repaired by installing more bottom fill layer material until the test is satisfactorily passed. No additional compensation will be given for bot-tom fill layer material required to repair leaks. Installation shall be certified on Form 11000-A specified in 01999.

3.04 ROOF DECK COATING AND INSULATION

A. General: Following the completion of testing specified herein and the installation of the remaining annular space fill layers, the cover shall be coated, insulated, and then coated as specified in Section 07540, Section 07545, and Section 09900. The application of the roof deck insulation and coating shall be performed by a firm certified by the insulation and roof coating manufacturers. The insulation and roof coating manufacturer's representative shall be present during the entirety of the insulation and coating of the digester cover. The manufacturer’s representative shall ensure that all necessary measures are being taken to comply with this specification and the recommendations of the manufacturer.

B. Inspection and Surface Preparation: Surfaces to receive roof insulation and coating shall be prepared in accordance with Section 09900 and coating and insulation manufacturer’s recommendations. The Construction Manager shall be advised of any unsatisfactory con-dition, and the Contractor shall affect any necessary corrections. Start of the work shall imply acceptance of the surface, and the Contractor shall assume responsibility for and rectify any of the resulting work found to be unsatisfactory.

C. Primer: Primer shall be applied in conformance with the coating system manufacturer's instructions to all surfaces receiving roof insulation. The rate of application shall be as recommended by the coating manufacturer.

D. Sealing of Cracks, Joints and Flashing: These items shall be caulked and/or grouted as specified by the coating system manufacturer.


E. Insulation: Polyurethane shall not be applied when the measured roof deck temperature is below 40 degrees F; relative humidity is greater than 90 percent, or when wind velocities exceed 15 miles per hour.

F. Surface texture of installed foam shall range from smooth to medium coarse finish. "Pop-corn" or "tree bark" finish are not acceptable. Filleting of foam to roof mounted equip-ment, etc., shall provide a smooth transition to roof, shall be of uniform cross section thickness, and meet above surface texture requirement.

G. Roof Coating: The roof base coat shall be applied the same day the foam insulation has been applied. Coating shall be applied in two separate coats to ensure a pinhole-free con-tinuous film. Coating shall coat all foam and extend up and over all foam on appurte-nances a minimum of 2-inches creating a self-terminating flashing.

3.05 FIELD SERVICE

A. The equipment supplier shall provide the service of a qualified representative for a mini-mum of three trips for a minimum 3-day duration each to inspect the cover installation, assist in start-up, and instruct plant personnel in the proper operation and maintenance of the unit.

**END OF SECTION**



150141 – 2017 Upgrades and Rehabilitation 11770-1 Polymer Equipment James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 11770

POLYMER SYSTEM EQUIPMENT

PART 1–GENERAL

1.01 SUMMARY

A. This section includes the following major dry polymer equipment components and any associated local motor starter and drive panel control stations, vendor control panels and packages, valves, and appurtenances: 1. Dry polymer feeder unit, including the following subcomponents:

a. Manual feed hopper with 50 lb. bag dump station b. Volumetric feeder c. Feed funnel d. Pneumatic conveyance system e. Handling system base and frame f. Hopper loading apparatus g. Dust collector

2. Dry polymer wetting device and dilution water system 3. Hydration tank with mixer and level controls 4. Polymer transfer pump 5. Two polymer feed tanks with level controls 6. Three centrifuge polymer feed pumps 7. Post-dilution system 8. Static Mixers

B. The polymer system layout shown on the contract drawings is preliminary, and shall be refined by the Contractor for the final selected equipment. The Contractor shall submit proposed layout drawings when equipment is selected. These drawings will be reviewed and approved by the Engineer before starting construction of the system.

C. System Purpose 1. The dry polymer system shall be utilized to prepare activated polymer solution within a

concentration range of 0.3 to 0.5 percent, by weight of active polymer. 2. The purpose of this dry polymer system is to prepare batches of polymer for the sludge

processing building processes; either the centrifuge system or the DAF system as selected by the operator. Polymer solution will be applied to anaerobically digested sludge as it is fed to dewatering centrifuges. When centrifuges are not operating, the dry polymer batching system and transfer pump will send batches of polymer from the hydration tank to the existing polymer feed tanks for the dissolved air floatation thickener (DAF) on operator request.


D. (Addendum #1) Equipment List: Item Equipment Number

Dry polymer batch system MME-7406 Manual feed hopper T-7406-1 Hopper low level switch LSL-7406 Polymer system main control panel, 120V (for Dry Polymer and Emulsion System)

VCP-7410

Polymer system control panel, 480V VCP-7406-1 Volumetric feeder VMF-7406 Feeder unit blower B-7406 Dry polymer wetting device DPWD- 7406 Polymer hydration tank T-7406-2 Polymer hydration tank level transmitter LIT-7406-1 Polymer hydration tank discharge control valve FCV-7406-3 Polymer hydration tank high level switch LSH-7406 Hydration tank mixer MX-7406 Polymer transfer pump P-7406 Transfer pump discharge high pressure switch PSH-7406 Transfer control valve to DAF feed tanks FCV-7413 Feed control valve to T-7401 FCV-7401-2 Feed control valve to T-7402 FCV-7402-2 PW to wetting head control valve FCV-7406-1 PW to wetting head flow switch FSL-7406-1 PW to wetting head rotameter FI-7406-1 PW to rapid fill control valve FCV-7406-2 PW to rapid fill flow switch FSL-7406-2 PW to rapid fill rotameter FI-7406-2 Centrifuge polymer feed tank 1 T-7401 Centrifuge polymer feed tank 1 outlet valve FCV-7401-3 Centrifuge polymer feed tank 1 level transmitter LIT-7401 Centrifuge polymer feed tank 1 high level switch LSH-7401

Centrifuge polymer feed tank 2 T-7402 Centrifuge polymer feed tank 2 outlet valve FCV-7402-3 Centrifuge polymer feed tank 2 level transmitter LIT-7402 Centrifuge polymer feed tank 2 high level switch LSH-7402

Centrifuge polymer feed pump 1 P-7403 Centrifuge polymer feed pump 2 P-7404 Centrifuge polymer feed pump 3 P-7405 Pressure Switch- Centrifuge polymer feed pump 1 PSH-7403

Pressure Switch- Centrifuge polymer feed pump 2 PSH-7404


Item Equipment Number Pressure Switch- Centrifuge polymer feed pump 3 PSH-7405

Dilution water assembly pressure regulating valve 1 PRV-7412

Dilution water assembly rotameter 1 FI-7412 Dilution water assembly pressure regulating valve 2 PRV-7413

Dilution water assembly rotameter 2 FI-7413 DAF polymer feed tank 1 level transmitter LIT-7328 DAF polymer feed tank 1 high level switch LSH-7328 DAF polymer feed tank 2 level transmitter LIT-7329 DAF polymer feed tank 2 high level switch LSH-7329

(Addendum #1) Containment area level detection- DAF polymer LE/LSH-7430 Containment area level detection- centrifuge polymer

LE/LSH-7440

Horn and beacon for VCP-7410 UA-7440

E. Equipment Tagging: 1. All new components of the system shall be tagged in accordance with Owner tagging

standards.

F. All equipment shall be installed, adjusted, performance tested, and placed in operation in accordance with these Specifications, the manufacturer’s recommendations, and as shown on the Drawings.

G. Unit Responsibility: 1. The Contractor shall assign unit responsibility as specified in Section 11000 to the dry

polymer feeder unit manufacturer for all equipment specified in this section. A completed, signed, and notarized certificate of Unit Responsibility shall be provided (Form 11000-C, Section 01999).

1.02 RELATED SPECIFICATION SECTIONS AND PROCESS AND INSTRUMENTATION DIAGRAMS

A. The equipment specified in this section shall be provided in accordance with the following additional sections and paragraphs. This is not a comprehensive list of related and referenced sections and paragraphs and additional related and referenced sections and paragraphs requiring compliance may be specified throughout this section and within other sections. This list is provided as a convenience for the Contractor. Related and referenced sections shall be reviewed and submittal information provided as required in paragraph 1.05 of this section. 1. Section 01071, Standard References 2. Section 01300, Submittal Requirements 3. Section 01605, Product Storage and Handling Requirements 4. Section 01660, Equipment and System Performance and Operational Testing


5. Section 01664, Demonstration and Training 6. Section 01730, Operation and Maintenance Data 7. Section 01800, Environmental Conditions 8. Section 01900, Structural Design and Anchorage Requirements for Non-Structural

Components and Non-Building Structures 9. Section 05502, Anchors to Concrete 10. Section 05560, Metal Fabrications 11. Section 11000, General Requirements for Equipment 12. Section 11002, Rigid Equipment Mounts 13. Section 11060, Electric Motors 14. Section 11069, Adjustable Frequency Drives 15. Section 11390, Progressive Cavity Pumps for Polymer Service 16. Section 11772, Emulsion Polymer Equipment 17. Section 11777, Tank Mounted Polymer Mixers 18. Section 15095, Piping Appurtenances 19. Section 15320, Fiberglass Reinforced Plastic Tanks 20. Division 16 21. Division 17

B. The process and instrumentation for the equipment in this section are shown on the following diagrams: 1. I-74-02 2. I-74-03 3. I-74-04

1.03 REFERENCES

A. This Section contains references to the following documents. They are a part of this Section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this Section as if referenced directly. In the event of conflict between the requirements of this Section and those of the listed documents, the requirements of this Section shall prevail.

B. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, whether or not the document has been superseded by a version with a later date, discontinued or replaced.

Reference Title AISC American Institute of Steel Construction AISI – 1045 American Instrumentation Standard Institute


Reference Title ANSI - B105.1 American National Standard Institute ANSI - B20.1 American National Standard Institute - Safety Standards

for Conveyors and Related Equipment ASTM A 240 Chromium and Chromium-Nickel Stainless Steel Plate,

Sheet, and Strip ASTM A276 Stainless Steel Bars and Shapes ASTM A36/A36M Carbon Structural Steel ASTM A 370 Standard Test Methods and Definitions for Mechanical

Testing of Steel Products ASTM A569 Welding Quality Mild Carbon Steel AWS D1.1 Structural Welding Code IBC (2012) International Building Code ICEA Insulated Cable Electric Association IEEE Institute of Electrical and Electronic Engineers NEC National Electrical Code NEMA 250 Enclosures for Electrical Equipment (1,000 volts

maximum) NFPA 70 National Electrical Code (NEC) OSHA Operations Safety and Health Association

1.04 SUBMITTALS

A. The contractor shall provide the submittal materials required in Specification Section 11000 in accordance with Section 01300. In addition, the following information shall be provided in accordance with Section 01300: 1. Action Submittals:

a. Shop Drawings and Product Data: 1) A copy of this specification section, with addendum updates included, and all

referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. A check mark shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Construction Manager shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.

2) List of proposed system components. 3) A signed letter from the manufacturers of the polymer solution preparation

system indicating that the proposed equipment is suitable for the intended application and has been coordinated for physical connection.


4) Make, model, weight, and horsepower of each equipment assembly. 5) Manufacturer’s catalog information, descriptive literature, specifications, and

identification of materials of construction. 6) Standard and specialized equipment assembly cuts. 7) Performance data showing compliance with specification requirements. 8) Dimensional drawings, showing required access and clearances, including any

layout requirements of the equipment. 9) Complete design and seismic calculations for dry polymer unit feeder and

subcomponents. Calculations shall be signed and sealed by an engineer currently registered in the State of Colorado.

10) Detailed structural, mechanical, and electrical drawings showing the equipment fabrications and interface with other items. Include: a) Dimensions, size, and locations of connections to other work, and weights of

equipment associated therewith. b) Revisions to structural, mechanical, electrical, or other work necessary to

adapt the layout and details shown to the equipment actually furnished. 11) System P&IDs showing all system components including project equipment tag

numbers. 12) Proposed system layout drawings showing the arrangement of the final selected

equipment, piping, and appurtenance. 13) Outside utility requirements such as water, power, etc., for each component. 14) Detailed written control sequence of operation for the dry polymer system

components and operating parameters, written specifically for this project. This written control sequence of operation shall be sufficient to follow the PLC controls and logic.

15) Complete manufacturer’s catalog data on all ancillary electrical and instrument components including component connection diagrams showing function and identification of terminals.

16) Rotameter sizing calculations. 17) Pressure regulating valve sizing calculations. 18) Proposed plan for pipe supports, including supports for valves and instruments. 19) Power and control wiring diagrams using NEMA standards, including terminals

and numbers. 20) Complete motor nameplate data, as defined by NEMA, motor manufacturer, and

including any motor modifications. See Section 11060, Electric Motors, for motor submittal requirement.

21) Bills of Materials and catalog cut sheets hi-lite the proposed equipment, installation, and placing drawings.

22) Shop and Field Painting Systems Proposed: Include manufacturer’s descriptive technical catalog literature and specifications, hazardous communication data sheets, and written certification that the factory-applied coating system(s) is identical to the requirements specified.

23) Where system proposed is different from that specified or where, in the manufacturer’s opinion, the coating system(s) exceed(s) the requirements specified, submit complete technical literature of the proposed system(s) to the Engineer for review.


24) See Section 01300 Submittals and electrical, instrumentation, and controls specifications in Divisions 11, 15, and 17 for additional submittal requirements. These include but are not limited to Section 11060 Electric Motors, Section 11069 Adjustable Frequency Drives, Section 15185 for valve actuators, Division 16 Electrical requirements, Section 17000 Process Control System General Provisions, Section 17110 Control Panels and Section 17310 Programmable Logic Controllers.

b. Anchor and Bracing data sheets, calculations, and drawings as required by Section 01900 Design Requirements for Non-Structural Components and Non-Building Structures.

c. Tank submittals as required in Section 15320 Fiberglass Reinforced Plastic Single Wall Tanks.

d. Operation and Maintenance Data: As specified in Section 01780, Operation and Maintenance Data.

2. Informational Submittals: a. Quality Control Submittals b. Manufacturer’s Certificate of Compliance: Applicable OSHA requirements,

Underwriters’ Laboratory (UL) requirements, and other materials requirements of these Specifications.

c. Factory test results, reports, and certifications. Include: d. Functional Test Certificates. e. Copies of fabrication, quality control, and testing records for actual tanks and

equipment. f. Special shipping, storage and protection, and handling instructions as per Section

01600, Common Product Requirements. g. Manufacturer’s written/printed installation instructions. h. Routine maintenance requirements prior to plant startup. i. Field Performance Test Procedures. j. Manufacturer’s Field Service Report and Certificates in accordance with Section

11000,General Requirements for Equipment. Include: 1) Manufacturer’s Certificate of Proper Installation. 2) Field Functional Test Certificates

k. Operation and maintenance manuals. l. Suggested spare parts list to maintain the equipment in service for a period of 1 year

and 5 years. Include a list of special tools, materials, and supplies required for checking, testing, parts replacement, and maintenance with current price information.

m. Copy of Manufacturer’s warranty and statement of ability to meet warranty requirements of this Section.


A. Qualifications: Manufacturer shall have at least three comparable dry polymer feeder units (minimum 90 lb/hr capacity, dry basis) and wetting devices (minimum 90 gpm capacity) for the makedown of dry polymer (at solution concentrations up to 0.5%) that have been in continuous, successful operation in the U.S. for at least 3 years at the time of bid.


Manufacturer shall furnish a list of installations with corresponding references with contact information.

B. Factory Inspection: Equipment may be inspected at the factory by a representative of the Engineer or the Owner prior to shipment to the site to determine conformance to the specified dimensional tolerances and other requirements. Should the equipment be found in non-compliance with the aforesaid tolerances, the Manufacturer shall repair or replace with new equipment until all equipment meets the dimensional tolerance requirement. All refurbishing and payments necessary for ascertaining the dimensional tolerance of repaired or new replacement equipment to be borne by the Manufacturer.

C. Structural Standards: 1. Structural Steel and Welds: All structural steel used for equipment fabrication shall

conform to the requirements of Section 05100, Structural Metal Framing. All welding shall conform to the latest standards of the American Welding Society (AWS). AWS D continuous seal welds shall be provided at all welded joints. Skip welds will not be permitted.

2. Structural Design: All steel structural components shall be designed so that the stresses developed under the specified conditions will not exceed the allowable stresses defined by the AISC standards and aforementioned design criteria under the maximum loading condition specified. All structural components shall also comply with seismic standards and other requirements as outlined in Section 01900, Design Requirements for Non-Structural Components and Non-Building Structures. Structural design and calculations shall be performed and stamped by a registered professional engineer registered in the State of Colorado.

1.06 DELIVERY, STORAGE AND HANDLING

A. See Section 01605, Product Storage and Handling Requirements for delivery, storage, and handling specifications.

1.07 SPECIAL WARRANTY

A. Provide a Special Warranty in accordance with contract General Provisions. Manufacturer shall guarantee in writing that the dry polymer system equipment furnished is appropriate for the intended service and shall be free of manufacturing and fabrication defects in material and workmanship for a period of 24 months from the completion of performance testing.

PART 2–PRODUCTS

2.01 EXISTING EQUIPMENT

A. Contractor shall reference the contract drawings for further clarification of new and existing equipment.

B. Existing equipment for the DAF system, including two DAF polymer feed tanks, three DAF polymer feed pumps, and existing appurtenances shall be integrated to function with the new dry polymer equipment specified in this Section.


2.02 MANUFACTURERS

A. The following candidate Manufacturers are capable of producing equipment and/or products that will satisfy the requirements of this Section. The Manufacturer’s standard products may require modifications to conform to specified requirements: 1. Velocity Dynamics, Inc. 2. Fluid Dynamics

B. Polymer systems from Manufacturers other than those listed may be considered upon approval of the Owner and Engineer provided they are of similar design, performance and quality to the system specified and that the alternate Manufacturer can show an equivalent amount of experience to those named herein. The Manufacturer of any alternate system shall agree to pay all costs for the Engineer for any potential redesign of the dry polymer system layout, electrical, mechanical, or instrumentation drawings.

2.03 PERFORMANCE/DESIGN CRITERIA

A. General Design Conditions 1. As a total system, the dry polymer system shall be sized to prepare and deliver a

minimum of 90 dry pounds per hour of polymer in 0.5% active, solution form to the dewatering centrifuge system. This equates to 45 dry pounds per hour of polymer in active, solution form to each of two dewatering centrifuges simultaneously.

2. The following general conditions apply to the dry polymer system.

Parameter Value

Maximum wet bulb temperature 70 Maximum dry bulb temperature 95 Dry polymer room temperature range, °F 60 to 90

B. General Operating Conditions 1. The following general operating conditions apply to the dry polymer system. The dry

polymer system is used for dewatering of anaerobically digested sludge.

Parameter Value Dry polymer type Cationic

Approximate bulk dry polymer density, lb/cf 43-45 Polymer solution makedown and aging concentration range, % active polymer solution (APS)

0.3 to 0.5

Polymer solution centrifuge feed concentration range, % APS 0.3 to 0.5 Polymer solution viscosity range, cp 525-975 Anaerobically digested sludge design concentration, % TS 1.0-3.2, average 2.5 Polymer system operations, hrs/day Up to 24, average 8

2.04 MATERIALS

A. General: Materials employed in the equipment described in the remainder of this section shall be suitable for the intended applications. Materials for each component shall be high-grade, standard commercial quality, and free from defects and imperfections that might affect the


serviceability of the product for the purpose for which it is intended. Materials not specifically listed in the associated equipment tables should adhere to the following: 1. Corrosion resistance: Materials submerged in water or polymer solution, in contact with

water or polymer solution, or subject to corrosion shall be Type 304 or 316 stainless steel unless otherwise indicated. All nuts, bolts, and washers shall be 316 stainless steel.

2. Electrical raceways, boxes, and supports shall meet the requirements of Section 16110, Raceways and Boxes for Electrical Systems.

3. Skid mounted electrical cable shall meet the requirements of Section 16120, 600 Volt or Less Wires and Cable Conductors, Wires, and Cables.

4. Control panel construction shall meet the material and construction standards in Section 17110 Control Panels.

5. Piping and valves shall meet the requirements of Division 15.

2.05 DRY POLYMER FEEDER UNIT

A. Components 1. Polymer Storage and Feeder Skid Components

a. Provide a fabricated steel skid incorporating the dry polymer storage hopper system, volumetric feeder, dry polymer pneumatic conveyance system, and hopper loading apparatus.

2. Dry Polymer Storage Hopper a. A polymer storage hopper shall be provided having a minimum capacity as described

in Operating Conditions below. b. The storage hopper shall be designed for manual feed of 50-pound bags of dry

polymer. The storage hopper loading station shall have a loading hatch cover so that the hopper can be closed when loading is not in progress.

c. The storage hopper shall also be designed to accept loads of dry polymer from the hopper loading apparatus.

d. The hopper shall be fabricated of not less than 12 gauge 304 stainless steel with the lower portion of the hopper tapering to facilitate flow of the dry product to the ensuing screw feeder.

e. The storage hopper shall include a capacitance-type low level switch positioned at approximately 2 cubic feet of remaining polymer storage.

f. Provide a stainless steel screen in the hopper to prevent foreign material from entering auger. The screen shall have 1/4" square area openings and be constructed of 12-gauge wire. The screen shall not be the woven type prone to separation and fouling of the auger conveyor.

g. Hopper shall be provided with a shelf to allow operators to place one bag of polymer on while opening the bag.

h. Hopper shall be supplied with an integrated, fan-powered dust collector system to suppress dust during hopper loading.

i. Hopper shall be capable of supporting the full weight of the hopper loading apparatus (specified below) and full load of dry polymer while loading apparatus is discharging into hopper. Hopper shall have guide to align the loading apparatus into the correct position for discharging into the hopper.

3. Volumetric Screw Feeder a. Provide a volumetric screw feeder to accurately meter dry product from the storage

hopper to the pneumatic transfer line through the feed funnel described below.


b. The screw auger shall be direct driven by a motor and a heavy duty right angle gear reducer. Chain drives shall not be used.

c. The screw feeder shall be sized to supply dry polymer at a minimum feed rate as described in Operating Conditions below.

d. The volumetric feeder design shall allow the motor, gear reducer and auger to be removed as a single unit.

e. The auger conveyor and housing shall be fabricated from 304 stainless steel and shall be of rugged design for long life under continuous use.

f. The discharge port of the volumetric feeder shall be completely enclosed in an acrylic chamber to prevent inadvertent drifting of airborne polymer dust and protect feeder discharge from environment.

g. The motor shall be not less than ½ H.P., 90 VDC, TEFC. h. The Manufacturer-selected and furnished auger conveyor variable speed drive shall

be housed in the VCP starter/drive compartment. 4. Feed Funnel

a. A feed funnel shall be supplied to receive metered product from the auger conveyor and allow for smooth transition of the product into the pneumatic conveying line.

b. Feed funnel shall be heated with thermostat control. c. The feed funnel shall be fabricated of 304 stainless steel.

5. Blower a. Provide one regenerative blower to pneumatically convey the dry polymer from the

feed funnel to the polymer wetting device via the conveyance system eductor. The blower shall be designed to meet the process requirements specified and shall be designed for continuous operation. When not batching, the blower will lower speed to prevent moisture out of conveyance pipe.

b. The blower shall be equipped with a minimum 2.5 HP TEFC electric motor, operation on 480 volt, 3 phase, 60 Hz.

c. The Manufacturer selected and furnished blower starter shall be housed in the VCP starter/drive compartment.

6. Eductor a. Provide one eductor, designed to pneumatically convey dry polymer at the capacity

specified in operating conditions below. b. The eductor shall have quick disconnect fittings on the inlet and outlet. c. The air intake shall be designed to prevent the backflow of dry polymer onto the floor

in the event of clogs. d. The eductor shall be constructed of 304 stainless steel.

7. Pneumatic Conveyance System a. Provide as much pneumatic conveyance tubing and associated long radius elbows

and couplings as necessary to connect the dry polymer feeder unit to the wetting device. See Drawings.

8. Hopper Loading Apparatus a. The Manufacturer shall supply a hopper loading apparatus to facilitate monorail-

aided hopper loading of dry polymer. Operators shall manually load 50-pound bags of polymer into the feed apparatus, and then use the overhead ½ -ton monorail to lift the apparatus and empty it into the hopper.

b. Loading apparatus features:


1) Designed to manually load 50-pound bags of dry polymer into the feed apparatus at a maximum loading height of 3’ above the floor

2) Integrated lifting lugs for rigging with overhead monorail 3) Lid to suppress dust when lifting and discharging 4) Legs so that the hopper can rest on the floor in a level, stable position when

empty and full. 5) Discharge chute and manual flow control to facilitate discharge into hopper 6) Guide to align loading apparatus into position above hopper for unloading 7) Capability to rest fully on hopper during discharge while without support from

monorail. c. Loading apparatus shall meet the operating conditions and materials specified below.

B. Operating Conditions

Parameter Value Polymer storage hopper minimum capacity, cf 10 Hopper loading apparatus minimum capacity, cf

7

Auger conveyor minimum feed rate, lb/min 10 Eductor minimum design feed rate, lb/min 10

C. Design Requirements

Parameter Value Number of dry polymer feeder units 1 Feeder type volumetric feeder Maximum width per feeder assembly, ft 5 Maximum length per feeder assembly, ft 7.5 Maximum height per feeder assembly, excluding equipment pad, ft

8

D. Materials 1. Materials specified are considered the minimum acceptable for the purposes of durability,

strength, and resistance to erosion and corrosion. The Contractor may propose alternative materials for the purpose of providing greater strength or to meet required stress limitations. However, alternative materials must provide at least the same qualities as those specified for the purpose.

Item Material Feeder unit frame Carbon steel Polymer storage hopper 304 stainless steel, 12-gauge minimum Hopper loading apparatus 304 stainless steel, 12-gauge minimum Feed hopper screen 304 stainless steel,12-gauge wire Auger conveyor and housing 304 or 316 stainless steel Feed funnel 304 stainless steel Eductor 304 or 316 stainless steel


Camlock disconnect fittings on inlet and outlet of eductor

Cast aluminum or stainless steel

Pneumatic conveyance tubing 304 stainless steel

2.06 DRY POLYMER WETTING DEVICE

A. Components 1. Wetting Device

a. The hydration tank shall have one wetting device and one rapid fill line. The furnished wetting device shall have a minimum capacity as described in Operating Conditions below.

b. Dry polymer shall be pneumatically conveyed to a hydro-dynamic, non-motorized dry polymer disperser within the wetting device mounted atop the hydration tank. 1) The wetting device shall have a proven track record and shall be specifically

designed for dry polymer wetting. c. The design of the mixing chamber shall provide plug flow to prevent polymer build

up and mixing chamber plugging. d. The flow to the wetting device shall be constant (on/off), with water flow adjustment

using a manual globe valve. The rapid fill line will add potable water to the hydration tank at a constant rate (on/off), with flow adjustment using a manual globe valve. The control system shall monitor total dilution water addition between the wetting device water rate and rapid fill water rate by measuring the tank level. The control system will modulate dry polymer flow and water addition to produce the desired polymer solution concentration of the batch.

2. Dilution Water Assembly a. All dilution water valves and instruments shall be positioned for easy access by

operators. b. Provide an electric, slow-closing, 2-inch motorized PVC ball valve for dilution water

to the wetting head, per Section 15099- Valves. c. Provide an electric, slow-closing, 3-inch motorized PVC ball valve for rapid fill

water, per Section 15099- Valves. d. Provide rotameters for both water addition lines, per Section 17211- Process Taps-

FVA, specifically sized for the Operating Conditions listed below. e. Provide thermal flow switches for both water addition lines, per Section 17206-

Process Switches.


Parameter Value Maximum nominal capacity of dry polymer wetting device, gpm of water

90

Capacity range of rapid fill line, gpm of water 15 to 150 Expected water supply pressure, psi 90


Parameter Value Number of dry polymer wetting devices 1


Water inlet diameter, in 2 Maximum operating pressure of wetting device, psi 50 Rapid fill dilution water assembly pipe and valve size, in 3



Item Material Wetting device except for containment cylinder and spray nozzles

304 stainless steel

Wetting device spray nozzles Brass Wetting device containment cylinder Clear PVC

2.07 HYDRATION TANK AND MIXER

A. Components 1. Hydration Tank:

a. One tank of the capacity defined under Operating Conditions below shall be provided for the initial hydration and activation of the dry polymer. The polymer shall be wetted by the wetting device as it enters the hydration tank.

b. The hydration tank shall provide a minimum of 30 minutes of aging, after all of the polymer has been delivered to the hydration tank, and shall effectively and thoroughly mix the polymer solution without damaging its molecular structure prior to transfer to the feed tank.

c. The hydration tank shall be cylindrical with flat top, with a sloped bottom to facilitate complete discharge of tank contents. Top shall be normally closed, with a hinged cover section as specified on Drawings. The tank shall have blade-gusseted, flanged connections as follows. Tank details attached to Section 15320. 1) One 4-inch discharge connection for the hydration tank transfer pump suction

header. 2) One 3-inch overflow connection 3) One 2-inch connection for level indicator transmitter. 4) One 3-inch flange on top of the tank for rapid fill line 5) One 2-inch flange on top of the tank for fill from the wetting head 6) One 4-inch flange on top of the tank for level switch

d. Tank shall include internal 3” fill pipe to limit splashing and noise from the rapid fill line. 1) Internal pipe shall have 1/2” minimum perforations above the maximum liquid

level in order to vent the fill line and break potential siphon. 2) Internal pipe shall be supported off of the tank wall with non-metallic supports.

Pipe support locations, size, and number shall be by the tank manufacturer.


e. Provide a tank bridge to support the mixer and wetting device above the tank. Provide detailed normal operation loading calculations with the bridge submittal to support the proposed design.

f. The tank mixer shall be mounted off-center such that no internal baffles shall be required for complete mixing. Tank mixer shall be shall be mounted so that it is accessible by an operator from the access platform, and can be lifted using the polymer room monorail.

g. Refer to Section 11777, Tank Mounted Polymer Mixers, for mixer specifications. h. Refer to Section 15320, Fiberglass Reinforced Plastic Single Wall Tanks, for further

tank specifications. However, components, operating conditions, and materials listed in this Section take precedence over those listed in Section 15320.

i. Tank must be completely pre-fabricated before delivery to site. Note that tank, including flanges, must fit through existing room door with dimensions of 6’4” wide and 7’4” high. These are the maximum dimensions with door frame removed. Tank should be designed so that height is minimized while tank can still fit through doorway without modifications or damage to the existing structure.


Parameter Value Hydration tank minimum active volume, gal 2,120 Minimum nominal volume of hydration tank, gal 2,400


Parameter Value Number of hydration tanks 1 Hydration tank maximum outer diameter, ft 6 Maximum tank footprint, including flanges 6’3” x 7’3” Equipment pad height minimum, in 12



Item Material Hydration tank Fiberglass reinforced plastic Hydration tank bridge 304 stainless steel Mixer impellers and shaft 316 stainless steel

2.08 TRANSFER PUMP

A. Components 1. Provide one polymer solution transfer pump to transfer polymer solution from the

hydration tank to the centrifuge or DAF feed tanks.


2. The transfer pump shall be progressive cavity type with a VFD, per Section 11069- Adjustable Frequency Drives.

3. Provide a high discharge pressure switch assembly with pressure gauge and stainless steel diaphragm seal to sense high discharge pressure and shut the pump down. The pressure gauge shall be stainless steel, liquid filled with a range of 0-60 psi. The pressure switch shall be rated NEMA 4X, have an adjustable range from 0-50 psi and a minimum burst pressure of 200 psi. Manufacturer shall verify pressure ranges with selected transfer pump parameters.

4. Transfer pump shall be supplied with a pressure relief valve, routed back to the suction of the pump.

5. See Section 11393, Progressive Cavity Pumps for Polymer Service, for additional requirements.

2.09 FEED TANKS

A. Components 1. Feed Tanks:

a. Two feed tanks of the capacity defined under operating conditions below shall be provided to store activated polymer solution prior to and during solution feed to the dewatering centrifuges. Polymer solution shall be fully aged and ready for use prior to transfer to a feed tank. Feed tanks shall operate on an alternating basis, with one tank feeding polymer to the centrifuges while the other tank fills.

b. The feed tanks shall be cylindrical with flat top, with a sloped bottom to facilitate complete discharge of tank contents. Tank tops shall be normally close with a hinged cover section as specified on the Drawings. The tank shall have blade-gusseted, flanged connections as follows. Tank details are attached to Section 15320. 1) One 2-inch discharge connection for the feed pump suction header. 2) One 3-inch overflow connection 3) One 3-inch drain connection. 4) Two 4-inch connections on top for ultrasonic level transducer and LSH float

switch. 5) 4-inch connection on top for fill from dry polymer system 6) 2-inch connection on top for fill from emulsion polymer system (Section 11772)

c. Tank feed shall include internal fill pipes inside of the tank to limit splashing and noise during loading. Internal pipe shall be supplied for the 4” dry polymer system fill line and the 2” emulsion polymer system fill line. 1) Internal pipe shall have 1/2” minimum perforations above the maximum liquid

level in order to vent the fill line and break potential siphon. 2) Internal pipes shall be supported off of the tank wall with non-metallic supports.

Pipe support locations, size, and number shall be by the tank manufacturer. d. Refer to Section 15320, Fiberglass Reinforced Plastic Single Wall Tanks, for further

tank specifications. However, components, operating conditions, and materials listed in this Section take precedence over those listed in Section 15320.

e. Tank must be completely pre-fabricated before delivery to site. Note that tank must fit through existing room door with dimensions of 6’4” wide and 7’4” high. These are the maximum dimensions with door frame removed. Tank should be designed so that


height is minimized while tank can still fit through doorway without modifications or damage to the existing structure.


Parameter Value Feed tank minimum active volume, gal 2,120 Minimum nominal volume per feed tank, gal 2,400


Parameter Value Feed tank maximum outer diameter, ft 6 Maximum tank footprint, including flanges 6’3” x 7’3” Equipment pad height minimum, in 12 Mixing none



Item Material Feed tanks Fiberglass reinforced plastic

2.10 LEVEL SENSORS

A. Refer to the equipment list in 1.01 for the list of level switches, level transmitters, and level elements that are to be supplied for the dry polymer feeder units and hydration tanks.

B. Instruments: 1. The float switches shall be Flygt ENH-10 or equal 2. The level transmitter shall be Rosemount Model 2051 or equal.

C. The hydration tank has the following additional requirements: 1. Provide a hydrostatic level indicator transmitter mounted to a 2-inch pipe at the tank

bottom. Nozzle centerline for hydrostatic level indicator transmitter connection shall be a maximum of 6” above the tank bottom.

2. Level transmitter shall have a 2” ball valve for isolation and 1½” ball valve for bleed.

D. The centrifuge polymer feed tanks have the following additional requirements: 1. Provide an ultrasonic level indicator transmitter mounted to a 4-inch flange on top of the

tank. 2. Float-style high level switch mounted to a 4-inch flange on top of the tank.

E. The existing DAF polymer feed tanks have the following additional requirements:


1. Provide an ultrasonic level indicator transmitter mounted to a new 4-inch flange on top of the tank.

2. Float-style high level switch mounted to a new 4-inch flange on top of the tank.

2.11 EQUIPMENT MOUNTS

A. The dry polymer feeder units, transfer pump, and tanks will all require equipment mounts. Their requirements are specified below. The Manufacturer is responsible for determining the adequate mounting requirements for the wetting devices and hydration tank mixer.

B. Equipment Pads: Equipment pads shall be provided in accordance with the standard detail shown on the drawings.

Equipment Item Standard Detail Feeder Unit M7006 Transfer Pump M7006 Centrifuge Polymer Feed Pumps M7006 Hydration and Feed Tanks M7006

C. Mounting Plates: The structural steel channel, plate, and mounting hardware for the mounting plates shall be constructed of carbon steel. Additional mounting plate details are found in Section 11002, Rigid Equipment Mounts. Mounting plate criteria is shown in the table below per equipment item. The Manufacturer shall conform to this criteria or Manufacturer recommended leveling criteria, whichever is less.

Equipment Item Mounting plate shall be leveled to _ inches or less

Feeder Unit 1/8 Transfer Pump 1/8 Centrifuge Polymer Feed Pumps 1/8 Hydration and Feed Tanks N/A

D. Grout Type: Details for the grout type are found in Section 03600, Grout.

Equipment Item Grout Type Feeder Unit Cementitious non-shrink grout Transfer Pump Cementitious non-shrink grout Centrifuge Polymer Feed Pumps Cementitious non-shrink grout Hydration and Feed Tanks N/A

E. Equipment Anchors: Equipment anchors shall be provided in accordance with the standard detail shown on the drawings.

Equipment Item Standard Detail Feeder Unit M7004 Transfer Pump M7004 Cementitious non-shrink grout M7004 Hydration and Feed Tanks M7004


F. The Manufacturer shall provide anchor bolt templates to the Contractor before equipment pads are poured. Contractor shall coordinate with Manufacturer on the required timeline for anchor bolt templates.

2.12 FEED PUMPS AND POST-DILUTION ASSEMBLY

A. Components 1. Feed Pumps

a. Provide three polymer solution feed pumps to meter polymer solution from the feed tanks to the point of application at two dewatering centrifuges. Each dewatering centrifuge has a dedicated polymer solution feed line. Two metering pumps will be duty pumps, with one swing pump to be used as an inline spare for either centrifuge.

b. See Section 11393 Progressive Cavity Pumps for Polymer Service, for additional requirements and design criteria.

c. For each metering pump, provide a high discharge pressure switch assembly with pressure gauge and stainless steel diaphragm seal to sense high discharge pressure and shut the metering pump down. The pressure gauge shall be stainless steel, liquid filled with a range of 0-60 psi. The pressure switch shall be rated NEMA 4X, have an adjustable range from 0 to 50 psi and a minimum burst pressure of 200 psi.

d. Each metering pump shall be supplied with a pressure relief valve, routed back to the suction of the pump.

e. Each metering pump shall be capable of accepting feed from a common header from either of the two centrifuge polymer feed tanks, as shown on the Drawings.

f. Manual 2-inch PVC ball valves and ball check valves, per Section 15099- Valves, shall be supplied as specified on the Drawings. Manual valves will be used to direct swing pump to desired centrifuge.

2. Post-Dilution Assembly a. The post dilution assembly shall provide the ability to add water for additional

dilution of polymer solution. One post-dilution assembly shall be supplied for each of the two dewatering centrifuge feed lines.

b. Each post-dilution assembly shall include: 1) Water rate adjusting globe valve per 15099- Valves. 2) Manual ball valves as indicated on P&ID per 15099- Valves. 3) Rotameter type flow indicator, per Section 17211- Process Taps- FVA: sized for

2 to 24 GPM 4) Pressure regulating valves, per Section 15153- Pressure Regulating Valves, sized

for 24 GPM. 3. Static Mixers

a. Inline static mixers shall be supplied downstream of each of the two post-dilution assemblies for blending polymer solution with post-dilution potable water. Each static mixer shall be a complete assembly with mixer body ring, mixing plate, injection fittings, gaskets, and specified appurtenances that are suitable for mounting between two flanges located on a pipeline carrying polymer solution.

b. Manufacturers 1) Manufacturer shall have at least two comparable static mixers for the blending of

polymer solution (at concentrations up to 0.5%) and water that have been in continuous, successful operation in the U.S. for at least 3 years at the time of bid.


Manufacturer shall furnish a list of installations with corresponding references with contact information.

2) The following candidate Manufacturers are capable of producing equipment and/or products that will satisfy the requirements of this Section. The Supplier’s standard products may require modifications to conform to specified requirements: a) Komax Systems, Inc. b) Sulzer Chemtech c) Westfall Manufacturing Company d) Approved equal

c. Components 1) General: The mixer shall be of static or motionless type consisting of a series of

fixed, rigid elements enclosed in a section of pipe. Mixing elements shall be specifically designed for mixing of potable water and polymer solution. The mixer plates shall be computer designed to provide a geometric shape that creates the mixing vortices to effectively mix the injected potable water with the polymer solution. The mixer assembly shall be of a compact ring body design for mounting between two standard pipe flanges.

2) Gaskets shall be furnished and adhered to both sides of the mixer body. The mixer plate shall be mounted in a machined cavity on the upstream side of the ring body.

3) Mixing Elements: Mixers shall consist of a series of non-fouling elements designed to intimately contact the liquid.

4) Mixer Housing: Mixers shall be suitable for installation in any position ranging from horizontal to vertical. Mixer housings shall be capable of bearing and resisting all hydrodynamic, pressure, and other loads imposed by the pipeline geometry and operating conditions described in this Section.

d. Design Requirements 1) Design flows:

Component Polymer Dilution

Water Mixture

Min, gpm 1.5 1.5 1.5 Average, gpm 14.1 14.1 14.1 Max, gpm 17.65 17.65 17.65 Viscosity at operating conditions, cP 750 1 1 Density at operating conditions, g/cm3 1.02 1 1

2) Nominal pipe diameter: 2” 3) Static mixers shall be capable of disassembly for cleaning 4) 316 SST mixing elements 5) 316 SST mixer pipe

4. Skid and Mounting a. Feed pumps and post-dilution assembly shall be supplied on a common skid unit.

Skid may be as shipped in two pieces in order to facilitate installation through


polymer room door, but should be easily combined by the Contractor to form a single skid unit.

b. Manufacturer shall be responsible for anchoring skid to equipment pad.

B. Materials 1. Materials specified are considered the minimum acceptable for the purposes of durability,


Item Material Feed pumps Stainless steel and Viton or

Nitrile

2.13 CONTROL VALVES

A. The polymer system Manufacturer shall supply motor-operated ball valves as specified on the Drawings and in the equipment schedule at the beginning of this Section.

B. Motor-operated ball valves shall function to direct polymer from the transfer pump to the centrifuge and DAF feed tanks. Control valves shall be controlled by the master polymer system control panel, VCP-7410, as part of the vendor program. Control valves shall also have manual controls mounted on the door of the master VCP as well as a local manual over-ride at the valve. Each valve shall be provided with Open and Closed limit switches.

C. Motor-operated ball valves and actuators shall comply with requirements of 15099- Valves and 15185- Power Actuated Valve and Gate Operators. Each actuator shall be adequately supported with pipe supports provided by the Contractor.

2.14 ELECTRICAL COMPONENTS AND ACCESSORIES

A. Provide all necessary electrical components and wiring for a complete, functional system. Electrical components and wiring shall be provided and installed in accordance with the National Electric Code (NEC) and additional requirements by the Local authority having jurisdiction.

B. Note that the equipment in this Section will be installed in a corrosive, and wet area.

C. The dry polymer batching skid and the centrifuge polymer feed pump skid shall be supplied with a terminal box for each skid. All components on the skids shall be wired to the main terminal box. The only components that are not required to be wired to skid-mounted terminal boxes are the control valves and motors.


A. GENERAL: 1. Provide the Control Panel as specified in this Section and as shown on the Contract

Drawings. Each control panel shall be NEMA 4X with 3 point latching handle, fiberglass if skid mounted, otherwise 316 stainless steel, and shall be UL-508A approved. The


480V control panel shall be supplied with one 480 Vac, 60 Hz, 3-phase power; power supply shall be provided under Division 16. The control panel shall be provided with a control power transformer to power the controls at 120 VAC. Control panels shall be constructed in accordance with Divisions 16 and 17. The local control panels shall contain operator interface, programmable logic controller, control relays, indicating lights and other panel devices as specified herein, in Division 17, and as shown on the contract drawings. The control system shall be configured where upon loss of power and return of power the system shall return to the ready state. Provide a main circuit breaker, with flange type handle, 480 V, 60 Hz, three phase, with minimum 42K AIC. Motor starters, NEMA rated (NEMA Size 1 minimum), shall be supplied as part of the manufacturers control panel. 480 VAC power equipment shall be separated from the 120 VAC equipment using a separate enclosure.

2. Coordinate with the Systems Integrator to integrate the monitoring and control features with the plant SCADA System as specified.

3. Pilot devices shall be NEMA 4 rated, 30mm type, Allen Bradley 800H or equal. 4. Control relays shall be rated at 10amps and include an indicator. 5. As required by Division 17, the following is a MINIMUM:

B. The Main Polymer Control Panel, VCP-7410: 1. Shall be NEMA 4X, 316 SST. 2. Shall be PLC based using Allen Bradley CompactLogix model. 3. The plant network interface shall be Ethernet IP. 4. Ethernet switch shall be as manufactured by MOXA. 5. The OIT shall be an Allen Bradley PanelView Plus 7, 12”, color with touchscreen or

equal. All monitoring and control is to be done using this OIT and using the pilot devices noted below.

6. This VCP is to control the Dry Polymer Skid and the Emulsion Polymer Skid. The Dry polymer skid is hardwired to this PLC. The Emulsion Polymer Skid is networked to this VCP over Ethernet IP.

7. Control valves, 120V power is provided from this panel. Provide one circuit breaker for each valve.

8. Provide one circuit breaker, 120V, for each of the following level transmitters: LE/LIT-7401 and LE/LIT-7402.

9. OCA (Open/Close/Auto) selector switch for each motorized valve on the OIT and a 30mm type hand switch. Also provide an Open and Closed indicating light on the OIT and 30mm type pilot device. The 30mm hand switch and pilot lights are to operate independently of the PLC.

10. Provide an HOA for each motor. On the OIT and a 30mm type hand switch. The 30mm hand switch is to operate independently of the PLC.

11. Centrifuge Polymer Feed Pumps, Swing Pump 2 to, Centrifuge 1/Centrifuge 2 selector switch. Feed Pump 1 or 3 will be off in the respective mode when Pump #2 is in service.

12. Polymer System select (Dry Polymer/Emulsion), System start stop pushbutton and Last Batch pushbuttons; as noted above.

13. Display Centrifuge Polymer Feed Tank 1, Tank 2 and Hydration Tank level indication. 14. Display Centrifuge Polymer Feed Tank 1 and Tank 2 low level warning and alarm. On

alarm shutdown the respective downstream pump shall shut down.


15. Display DAF Feed Tank 1 and Tank 2 level indication. 16. Display DAF Feed Tank 1 and Tank 2 low level warning, low level alarm and high level

alarm. 17. System Run light, green. 18. System Off light, red. 19. System Fault light, amber. 20. Reset pushbutton. 21. Status indication for each of the following:

a. System Ready b. Each Tank Low Level indication, Warning and Alarm status c. Alarm Outputs at the VCP and SCADA: Discrete alarms as specified in this Section

and specific to the equipment provided. 22. (Addendum #1) Alarm horn and indicating beacon

C. The Polymer Mixer, Transfer Pump and Polymer Feed Pumps VFD Control Panel, VCP-7406-1:

a. The panel shall be NEMA 4X, 316 SST. b. This panel shall have each of the VFD’s connected to VCP-7410 over ethernet IP; or

hardwired for non-ethernet devices. Coordinate with VCP-7410 provided under this section. The mixer motor starter shall be hardwired.

c. Provide a 30mm Hand/Off/ Auto selector switch for local operation with Run light and Off light for each motor. These are to control the motors in Hand independent of the PLC. Note, these 30mm devices do not need to be repeated on VCP-7410.

d. Run light for each motor, green. e. Off light for each motor, red. f. Manual speed pot for each VFD motor, (polymer pumps and transfer pump) g. Fault light for each motor, amber. h. Pump High Pressure for each Polymer Pump motor. i. Stator Temperature Alarm High, amber, for each Polymer Pump.

2.16 SPARE PARTS

A. Dry Polymer system transfer pump 1. One (1) complete spare transfer pump with motor (See Section 11393)

B. Electrical and Controls: 1. One set of each type fuse used.

2. Two of each type relay used.

3. Five (5) of each type pilot light bulb used.

4. One Ethernet switch.

5. One PLC CPU, communications card, input and output card of each type.


2.17 SEQUENCE OF OPERATIONS

A. General 1. As part of the dry polymer system submittal process the Manufacturer will refine this

written strategy for the specific machine selected for this project. The Owner reserves the right to make changes to the basic control strategy described below during shop drawing review at no additional cost to the Owner. A minimum of five (5) days of on-site engineering shall be provided by the Manufacturer for making changes to the control strategy, process optimization, and coordinating with the Owner’s auxiliary control system.

2. Controls that are the specific responsibility of the Manufacturer are noted in this Section with required control strategies in 17900.

3. The operator will select using the operator interface: a. Which Polymer system to use: Dry Polymer / Emulsion b. Select the Feed Tanks to fill: Centrifuge / DAF c. Select the Concentration of the polymer for the selected destination: 0.3%-0.5% d. Once the above items are selected, each day the operator is to:

1) Initiate a Start cycle. The equipment automatically starts the batching system including auger, blower, mixer, wetting head valve, rapid fill valve, etc. The specific control strategy for this operation shall be defined and determined by the Manufacturer, and shall provide for a fully functional and operational system. The Manufacturer shall also include as part of this control strategy the necessary logic for all failure modes.

2) Batches will continue automatically based on hydration tank level until the Stop Batch is initiated or the Last Batch Cycle is initiated.

3) When the Last Batch Cycle is initiated, the system shall finish the current batch, transfer the batch, and then complete an orderly shutdown sequence.

4) At any time the Stop cycle can be initiated; the batching and transfer sequence equipment is to stop.

4. The dry polymer batching system shall be programmed to make the full batch size only. Differences in tank capacity and available tank volume shall be accommodated by controlling the batch transfer to the feed tanks.

5. Transfer to DAF polymer feed tanks will occur when the operator has selected DAF as the batch destination. a. Note that each DAF polymer feed tank has a volume of 600 gallons, and can fill

together or separately depending on the position of manual tank inlet valves. If the operator has selected the DAF polymer feed tanks for transfer, the transfer pump will initiate a transfer assuming that both DAF tanks are filling. The transfer to the DAF tanks will end when the level setpoint on either DAF tank is achieved.

b. When a transfer is ended based on tank level, the operator shall have the capability to select any of the four feed tanks that is below the level setpoint and manually initiate a transfer to that tank.

c. Because the DAF polymer feed tank filling relies on manual valves to direct polymer solution between the two DAF polymer feed tanks, a transfer from the hydration tank shall automatically pause if either of the two DAF polymer feed tanks reaches the high-high level setpoint.


6. Transfer to centrifuge polymer feed tanks shall occur when the operator has selected centrifuge as the batch destination. a. Each centrifuge polymer feed tank has a working volume of approximately 2120

gallons. Centrifuge polymer feed tanks fill individually, and polymer solution is directed by motor-operated valves controlled by the VCP.

b. The transfer system shall automatically fill centrifuge polymer feed tanks in alternating order, or as selected by the operator, or bypass is a tank is out of service; the valves shall operate automatically in this mode with the valve OCA selector switch in the Auto mode. When one centrifuge polymer feed tank has reached the level setpoint, the transfer system shall automatically switch to filling the other centrifuge polymer feed tank. If both centrifuge polymer feed tanks have reached the level setpoint, the transfer shall pause until additional fill volume is detected.

7. The dry polymer system serves as the primary polymer solution activation system for the dewatering process with the emulsion polymer system serving as a backup system. The dry polymer batching system and the emulsion polymer system will not operate simultaneously.

8. Polymer feed to the centrifuges a. For each of the three polymer feed pumps, the operator shall designate an assignment

at VCP-7410: centrifuge 1, centrifuge 2, or spare. This designation shall correspond with the position of manual valves at the polymer feed pump discharge.

b. The operator shall input the desired polymer dosage rate to the centrifuges, in pounds of active polymer per dry ton of sludge.

c. In auto mode, the centrifuge control panels (Section 11365) shall send requests over the network to the VCP-7410 to start or stop polymer flow to a given centrifuge. VCP-7410 shall start the polymer feed sequence for the specified centrifuge based on this request. 1) Before starting any polymer feed pump, VCP-7410 shall check that the discharge

valve on one of the two polymer feed tanks (T-7401, T-7402) is open. If neither valve is open, VCP-7410 shall select a polymer feed tank and open the associated tank discharge valve. When selecting a tank, VCP-7410 shall first check if a transfer is occurring to either polymer feed tank. If a transfer is occurring, select the other feed tank. Otherwise, automatically select the feed tanks in alternating order. Polymer feed shall continue out of the selected tank until the tank reaches the low level set point, and then automatically select the other tank and switch the discharge valve positions to feed out of the other tank.

2) Once a feed tank discharge valve has been opened to supply polymer solution to the feed pump suction header, VCP-7410 shall start the polymer feed pump that has been designated for the centrifuge associated with the request.

3) The centrifuge control panels will also send a signal to indicate the sludge flow to each centrifuge. VCP-7410 shall receive this signal and calculate the required polymer solution flow to each centrifuge based on the operator input for polymer dose and for polymer solution concentration. For this calculation, assume that the sludge feed to the centrifuges is 2.5% solids. Approximate sludge density and a polymer solution density at 8.34 pounds per gallon. VCP-7410 shall automatically control the speed of the appropriate polymer feed pump to produce the calculated polymer flow based on the sludge flow signal. VCP-7410 shall include a selection for the operator to increase or decrease the polymer dose setpoint by 10% based on sampling.


4) When VCP-7410 receives a stop signal from the centrifuge control panels, it shall stop the polymer feed pump that has been designated for the corresponding centrifuge.

5) If the centrifuge control panels are not calling for any polymer feed, the polymer feed sequence shall terminate. VCP-7410 shall close the discharge valves for both polymer feed tanks.

6) The polymer feed pumps shall interlock with the LSL for the selected polymer feed tank as run-dry protection. If the LSL signals a low-low level in the selected tank, VCP-7410 shall signal an alarm and automatically stop the polymer feed pumps.

7) The operator shall also have the capability of manually selecting a polymer feed tank using VCP-7410.

d. In manual mode, the polymer feed pumps start, stop, and speed control will use the manual control switches on VCP-7406-1.

e. Polymer feed pumps shall have a hardwired interlock so that a high motor stator indication will automatically stop the associated pump for run-dry protection.

9. (Addendum #1) Upon an area containment leak detection (2 LSH’s in the two containment areas). If high level is detected on either switch, activate the horn and beacon. The following items shall shut off and or close: a. Transfer pump b. Hydration tank outlet valve and mixer c. Batching skid, including blower and auger, etc. d. Rapid fill water valve e. Wetting head water valve f. Emulsion polymer skid

2.18 FINISHES

A. All fabricated steel or ferrous metal surfaces shall be fully prepared with shop applied prime coats in accordance with the requirements of Section 09900, Coating Systems. Stainless steel surfaces shall be insulated from direct contact with ferrous metal.

2.19 SOURCE QUALITY CONTROL

A. Factory Testing: 1. Manufacturer shall provide the option for the Engineer/Owner to witness Factory

Assessment Testing in accordance with Section 01660- Equipment and System Performance and Operational Testing. Travel expenses for up to three personnel shall be paid for by the Contractor, including airfare, car rental, and meals for a minimum of three business days.

2. Inspect control panels for required construction, electrical connection, and intended function via a Software Assessment Test in accordance with Section 17030- Process Instrumentation and Control System Testing.


PART 3–EXECUTION

3.01 INSTALLATION

A. General: The Contractor shall be responsible for the complete installation of the equipment, including all mechanical, electrical, instrumentation, and structural connections, interconnecting piping, utility connections, foundations platforms, conduits, and all other features, accessories, and appurtenances required for the successful installation and operation of the Dry Polymer System. Installation of the equipment shall be in strict accordance with the requirements of the Manufacturer’s written instructions, Shop Drawings, and requirements herein.

B. DAF polymer feed tank retrofit: 1. The Contractor shall provide and install two 4-inch flanges on the top of each of the two

existing DAF polymer feed tanks. Flanges will be used to mount new ultrasonic level transmitters and high level switches.

2. The Contractor shall reuse the existing feed line penetration for the existing DAF feed tanks. The Contractor shall make all necessary retrofits to increase the size of the existing penetration for use with the new feed lines.

3. All modifications to existing FRP tanks shall include provisions to seal modifications to protect exposed fibers.

C. Equipment pads: 1. Contractor shall coordinate the dimensions of the required equipment pads with Vendor

equipment submittals. Contractor shall coordinate the height of equipment pads with the discharge elevation of associated tanks per equipment submittals.

D. Polymer solution flow meters: 1. Two existing 2-inch mag flow meters directly downstream of the existing centrifuge

polymer feed pumps shall be salvaged and reused for new system. 2. Contractor shall re-install existing flow meters as FIT-7412 and FIT-7413 as shown in

the Drawings and shall be responsible for connecting power and control signals as shown in the Drawings.

E. Installation shall be by mechanics/millwrights skilled in this work, in direct employ or under contract to the Contractor. The installation work shall proceed under general supervision of a Manufacturer employed service technician.

F. Installation shall include furnishing the required oil and grease of initial operation. The grades of oil and grease shall be in accordance with the written recommendations of the Manufacturer.

G. Final electrical connections shall be made by qualified electricians in direct employ or under contract to the Contractor. All electrical work shall be performed in compliance with the general requirements of Division 16.

H. The Contractor shall provide instrumentation and control field support personnel as detailed in specification Section 16000- General Requirements for Electrical Work to support execution activities.


I. General installation requirements shall be in accordance with Section 11000- General Requirements for Equipment.

J. Equipment Mounting: 1. Procedure: Section 11002, Rigid Equipment Mounts. 2. Provide a completed Form 11002-A, Section 01999- Reference Forms, for each

equipment installation.

K. Calibration: 1. The dry polymer feed equipment shall be calibrated under the direction of the

Manufacturer’s technician and a signed report shall be submitted to the Engineer. The report shall state whether the equipment has been installed in accordance with the Manufacturer’s printed instructions and that the calibration has been performed on each feed system and found to be in full compliance with the requirements of the contract documents. Certified copies of the tests shall accompany the report.

L. Interface with Other Work 1. The dry polymer batching system will interface with existing DAF polymer equipment,

including two feed tanks. The Manufacturer shall be responsible for integrating DAF equipment so as to provide a complete and functional system that will create activated dry polymer batches and transfer batches to the existing DAF feed tanks with new level controls.

M. Systems Integration 1. The Manufacturer’s control logic development shall include the preparation of control

logic required to implement the control strategies specified in this section. The control logic shall support the specified operator interface functions. The Manufacturer shall provide the programming for all logic within the VCPs. The Manufacturer shall coordinate with Owner on PLC interface between the Vendor’s package system to other systems within the facility, and provide an Excel spreadsheet of the PLC tag data interface to Owner after coordination.

2. The Vendor programming shall adhere to the requirements described in Section 17316- Process Control Software.

3. The Vendor shall allocate up to one week of programmer time to assist the Systems Integrator in linking VCPs to the existing facility network.

3.02 FIELD QUALITY CONTROL

A. In addition to any testing herein, perform all testing for this system consistent with the requirements of Section 01660- Equipment and System Performance and Operational Testing, the applicable codes, and the Manufacturer’s current quality assurance program.

B. The Contractor shall include the necessary oil and grease for initial lubrication and testing of all equipment.

C. After completion of installation, the equipment shall be completely field tested to demonstrate compliance with the performance requirements as specified. Inspection, testing, and certification shall be provided, and testing procedures shall be in accordance with Section 01660- Equipment and System Performance and Operational Testing.


D. Testing procedures shall duplicate as nearly as possible the conditions of operation and any failure mode alarming and recovery and shall be selected to demonstrate that the equipment is operational and free from damage. Each control device, control circuit, or mechanical, electrical, or instrumentation equipment failure mode shall be considered in the testing procedures to demonstrate that the equipment has been properly serviced, aligned, connected, calibrated, and adjusted prior to operation.

E. Component Performance Tests: The testing shall take place while the wastewater plant is operating at stabilized conditions and at such time as acceptable to the Engineer and the Owner. Following the preoperational test phase specified in Section 01660- Equipment and System Performance and Operational Testing, confirm proper operation of each piece of equipment specified in this Section using actual process polymer. 1. Proposed test procedures shall be developed by the System Manufacturer and submitted

to the Engineer for review, comment and approval. Testing shall not begin until the test procedures have been approved by the Engineer.

2. In the event that the dry polymer system does not meet the requirements of the Specifications during the performance test, the representative of the Manufacturer shall make such changes in the equipment and methods of operation as deemed necessary and as approved by the Engineer and pay for all reasonable costs to re-test, including those of the Engineer and Owner. The necessary adjustments shall be made as soon as practical, but within a period not to exceed 30 days. Following the adjustments, make a second test regime similar to the first testing regime. In the event that the dry polymer system still does not achieve specified performance during the second test, then the equipment will be subject to rejection. The dry polymer system Manufacturer shall retain responsibility for the dry polymer system until the acceptance test has been successfully completed. However, after initial startup the Owner shall have the right to use the dry polymer system as needed.

F. System Tests: The testing shall take place while the wastewater plant is operating at stabilized conditions and at such time as acceptable to the Engineer and the Owner. Following the Component Performance Test phase specified in 3.04.F, confirm proper operation of the system using actual process polymer. 1. Operating the feeder unit, wetting head, hydration tank, and transfer pump, operate the

system to achieve the following performance: a. Fill each of the two centrifuge feed tanks and each of the two DAF feed tanks with

0.3% polymer solution to at least 90% of the feed tank capacity, each in 60 minutes or less. Minimum age time shall be 30 minutes.

b. Fill each of the two centrifuge feed tanks and each of the two DAF feed tanks with 0.5% polymer solution to at least 90% of the feed tank capacity, each in 60 minutes or less. Minimum age time shall be 30 minutes.

G. Operational Test: Following the component and system test phases, perform the following tests as part of the operational test phase: 1. After completion of installation, each unit shall be field tested in accordance with Section

01660- Equipment and System Performance and Operational Testing to demonstrate compliance with the performance requirements as specified.


H. Controls Testing: 1. Calibration verification of all furnished instruments and protective devices. 2. Refer to Division 16 and 17 for additional pre-commissioning requirements.

I. Manufacturer Services: 1. Provide a factory-trained representative at the site for the specified quantity and duration

of the following activities. Specified durations do not include travel time to or from the project site. a. Installation Inspections: Assist, supervise, and inspect the Contractor’s activities

during installation of the dry polymer system equipment and appurtenances. Provide a minimum of 12 hours of total inspection during installation.

b. Component Test Phase Inspections: Assist, supervise, and inspect the Contractor’s activities during the component test phase specified in Section 01660- Equipment and System Performance and Operational Testing, and this Section. Provide a minimum of 12 inspection hours.

c. System Test Phase Inspections: Assist, supervise, and inspect the Contractor’s activities during the system test phase specified in Section 01660- Equipment and System Performance and Operational Testing. Provide a minimum of 12 inspection hours.

d. Operational Test Phase Inspections: Assist, supervise, and inspect the Contractor’s activities during the operational test phase specified in Section 01660, Equipment and System Performance and Operational Testing. Provide a minimum of 8 inspection hours.

e. Training Sessions: Procedures Section 01664- Demonstration and Training. Provide a minimum of 4 hours of classroom training on dry polymer system equipment and appurtenances for each training session. Conduct one training session per week on consecutive weeks to accommodate the shift schedules of operation and maintenance staff. Certify completion of training on Form 11000-B, Section 01999- Reference Forms.

2. The periods stated above are minimums only and the Manufacturer is required to be onsite for all of the functions listed above to the extent that is required to complete those functions to the satisfaction of the Owner and the Engineer.

3.03 SYSTEMS START UP

A. Procedures: Section 01660- Equipment and System Performance and Operational Testing.

B. Preoperational (factory) testing; See above

C. Component testing: See above

D. System and Operational testing: Perform the tests in accordance with Section 01660- Equipment and System Performance and Operational Testing.

3.04 CONSTRUCTION SEQUENCING

A. The polymer system is critical to both centrifuge and DAF operations. Demolition, installation, and sequencing shall be sequencing to minimize the total amount of downtime polymer system


operations. The dry polymer system specified in this Section shall be prioritized for critical path construction, with the emulsion polymer system specified in Section 11772 following.

B. Contractor shall coordinate dry polymer system construction with centrifuge construction (Section 11365) so that polymer demand is limited during construction.

C. The Contractor shall provide temporary rental polymer make-down skids which shall be available for operation while the permanent system is unavailable. Rented polymer skids shall be rapid-mix emulsion polymer type. 1. The Contractor shall be responsible for supplying utilities, including power and potable

water. 2. Temporary polymer units shall be housed in the dry polymer storage room. Contractor shall

supply all temporary piping and hoses necessary to connect the temporary units to the designated processes. Units shall be configured such that operators have space to access units and to change out totes as necessary.

3. The Owner shall supply neat polymer totes and operations personnel to operate the temporary units during construction.

4. Temporary polymer units shall include the following features and controls on each unit as a minimum: a. Manual start/stop b. Operator input of desired polymer solution concentration c. Operator input of desired polymer solution feed rate d. Operator input of neat polymer concentration e. Calibration column

5. Contractor shall arrange for rental polymer unit representative to assist with temporary unit installation, start-up, and training. Representative shall be onsite for a minimum of 4 days.

6. Contractor shall supply one temporary polymer unit to feed the centrifuge process. a. Temporary unit shall be suitable for and capable of direct polymer solution feed into the

centrifuge sludge feed lines. b. Unit shall be connected to one centrifuge sludge feed line at a time using the injection

point in the polymer feed room. Coordinate polymer feed with centrifuge construction. Feed shall be configured such that an operator can easily switch which centrifuge sludge feed line is fed by the unit by disconnecting and reconnecting hose union at injection point.

c. Unit shall be sized to deliver activated polymer solution to a centrifuge feed line at a rate of 15 dry pounds of active polymer per hour (calculated as a single centrifuge throughput of 1500 dry lbs/hr, at a polymer dose of 20 lbs of polymer per dry ton of solids). Required minimum flow rate shall be 15 gallons per minute of polymer solution (corresponding to 0.3% active polymer solution).

7. Contactor shall supply one temporary polymer unit to feed the DAF process. a. Temporary unit shall be capable of feeding activated polymer solution to the DAF

polymer feed tanks, T-7328 and T-7329. b. Unit shall be connected to one DAF polymer feed tank at a time. Feed shall be configured

such that an operator can easily switch which tank is fed by moving feed hose. c. Unit shall be sized to deliver activated polymer solution to a DAF polymer feed tank at a

rate of 15 dry lbs of active polymer per hour at a solution flow rate of at least 10 gallons


per minute (corresponds to filling a 600 gallon tank in one hour with 0.3% polymer solution).

**END OF SECTION**

150141 – 2017 Upgrades and Rehabilitation 14611-1 Monorail Hoists James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 14611

MONORAIL AND HOIST

PART 1–GENERAL

1.01 DESCRIPTION

A. SCOPE: 1. This section specifies a monorail system complete with hoist, trolley, associated drive

unit and pendant controls, for installation in the dewatering building polymer room.

B. TYPE: 1. The units shall be underhung, close headroom, single girder monorail. Hoists shall be

of the heavy-duty, electric wire rope type with electric trolley. 2. The trolleys shall be four-wheel type with tracks and appurtenances in accordance with

the drawings and as specified herein. 3. Hoist and trolley motor controller drive types can be single-speed as specified in

paragraph 1.01.D Operating Requirements.

C. EQUIPMENT LIST: 1. Equipment numbers are as follows:

Location Item Equipment No. Dewatering Building Polymer Room

Monorail, hoist and trolley HST7406

D. PERFORMANCE REQUIREMENTS: 1. All equipment provided under this section shall be suitable for Class A-1 (standby)

service as defined by CMAA standards. 2. The monorail cranes shall be furnished with the heavy-duty hoist suspended from its

trolley. 3. Monorail beams, complete with connections to the structural support systems, manual

switches, splices and runway stops, shall be furnished by the crane manufacturer. Monorail beam shall be designed by a Colorado registered civil or structural Engineer in accordance with the hoist manufacturer's recommendations. Load bearing connections shall be provided at each beam or girder and where necessary to limit deflection to less than 1/450 of span.

4. Load carrying parts, except structural members and hoist, shall be designed so that the calculated static stress in the material, based on rated bond, shall not exceed 20 percent of the assumed ultimate strength of the material. Except where more restrictive requirements are specified, structural members shall be designed in accordance with the latest edition of the CMAA specifications. The rated capacity load plus the weight of the bottom block divided by the number of parts of hoisting rope shall not exceed 20 percent of the published breaking strength of the rope.


E. OPERATING CONDITIONS: 1. Operating conditions shall be as follows:

Equipment Number HST7406

1. Hoist Capacity, tons ½

2. Minimum vertical lift, feet 16

3. Max. Headroom (inches)1 24

4. Maximum lifting speed, FPM 16

5. Maximum hoist motor horsepower

0.5

6. Maximum trolly motor horsepower

0.5

7. Beam Size By Manufacturer

8. 360 degree rotating hook (Yes/No) Yes

9. Motorized Hoist (Yes/No) Yes

10. Motorized Trolley (Yes/No) Yes

11. Pendant or remote control Pendant

12. Electrification Festoon cable

13. Atmosphere3 Indoors (NEMA 4X)

Notes: 1. Headroom is distance from bottom of monorail I-beam to bottom of the lifting hook (in stationary position). 2.. Where indicated in the “Atmosphere” row above, all motors and controls enclosures shall meet classification

requirements for the area in which the monorail hoists will be placed and capable of full operation in these environments. In the event that electrical equipment cannot be constructed to fully comply with the requirements of the area classification, supplier shall provide positive lockout of all electrical equipment, including portable transmitter, and signage that the area be verified as non-hazardous before equipment is unlocked and power is applied.

2. Contractor to coordinate hook approach distance, high hook position and overall configuration (horizontally and vertically) to allow removal of equipment without interference or conflicts with proposed piping or other infrastructure/equipment. The Contractor shall examine the drawings for interferences and obstructions that might impose additional limitations upon the equipment.

F. STANDARDS: 1. All equipment furnished under this section shall comply in all respects with the

requirements of OSHA. Unless otherwise noted, the standards of the Crane Manufacturer's Association of America (CMAA) and the Hoist Manufacturer's Institute (HMI) shall prevail.


A. REFERENCES:


1. This section contains references to the following documents. They are a part of this section as specified and modified. Where a referenced document contains references to other standards, those documents are included as references under this section as if referenced directly. In the event of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail.

2. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no bids). If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified by that organization or, if there are no replacement documents, the last version of the document before it was discontinued. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced.

Reference Title

CMAA Crane Manufacturers Association of America ASTM A36/A36M Carbon Structural Steel ASTM A572/A572M High-Strength Low-Alloy Columbium-Vanadium Structural Steel-AASHTO

No. M223 IBC International Building Code

B. UNIT RESPONSIBILITY: 1. The Contractor shall assign unit responsibility as specified in Paragraph 11000-1.02C to

the monorail hoist equipment manufacturer for all equipment specified in this section. A completed, signed, and notarized certificate of Unit Responsibility shall be provided (Form 11000-C, Section 01999).

C. FACTORY TESTING: 1. Factory tests shall be performed by the manufacturer prior to delivery in order to verify

accuracy and performance of the systems as specified. Factory tests need not be witnessed by the Engineer. However, factory tests shall be performed by the manufacturer. The manufacturer shall certify and provide copies of the tests and warranty the equipment's performance specified in this section. All certifications of factory tests shall be submitted to and reviewed by the Engineer before the equipment is shipped.

D. SHIPMENT, PROTECTION AND STORAGE: 1. Equipment shipment, protection and storage shall conform to the requirements specified

in Section 01605. Units shall be packaged in reinforced containers so as to prevent rust or damage during delivery. All connections shall be capped for shipping and while in storage. Each system and all components and mounting hardware shall be delivered at the same time.



A. The equipment furnished under this section will be located indoors at a wastewater treatment plant located in Denver, Colorado, and shall be suitable for the environmental conditions specified in Section 01800.

1.04 SUBMITTALS

A. The contractor shall provide the submittal materials required in Specification Section 11000 in accordance with Section 01300. In addition, the following information shall be provided in accordance with Section 01300: 1. Construction details and materials of construction including monorail beam structural

connection details. 2. Installation requirements, showing clearances required for maintenance purposes.

PART 2–PRODUCTS

2.01 MANUFACTURERS

A. The Owner and Engineer believe the following candidate manufacturers are capable of producing equipment and/or products that will satisfy the requirements of this section. This statement, however, shall not be construed as an endorsement of a particular manufacturer’s products, nor shall it be construed that named manufacturers’ standard equipment or products will comply with the requirements of this section. Candidate manufacturers for enclosed monorail track system include Crane and Hoist of Arizona, Wazee Crane, Yale, Gorbel or equal. Candidate manufacturers for electrical chain hoist include Harrington or equal.

2.02 MATERIALS

A. Materials specified are considered the minimum acceptable for the purposes of durability, strength, and resistance to erosion and corrosion. The Contractor may propose alternative materials for the purpose of providing greater strength or to meet required stress limitations. However, alternative materials must provide at least the same qualities as those specified for the purpose.

Component Material

Runway beam Steel, ASTM A572, grade 50

Trolley, hook Steel, ASTM A572, grade 50

Wheels Steel, ASTM A36

Chain Nickel-plated, Grade 80, DIN chain

2.03 EQUIPMENT

A. MONORAIL BEAM: 1. (Addendum#1) Monorail beam shall be fabricated from a structural steel S beam as

indicated in the drawings. specially fabricated composite beams comprised of top flange, web and hardened steel bottom tee section, continuously welded to the web. The bottom tee shall be shaped to provide a running surface for the end trucks.


B. TROLLEYS: 1. Trolley wheels shall be hardened steel, mounted on permanently lubricated anti-friction

bearings. Trolley shall be fully electrified. Motors shall be specially designed for Class I crane service. Trolley controls shall be the single-speed type with speed indicated under the operating requirements.

C. HOISTS: 1. Hoists shall be chain type. The chain components shall include cushion rubbers, chain

springs, and striker plates. Gear bearings shall be the oil-lubricated anti-friction type, and all bearings shall be designed for a Class M2 (20,000 hour) bearing life. The hoists shall contain an automatic electromechanical type brake designed for long life and positive stopping.

2. A standard limit switch and a special over-travel full current limit switch shall be provided to assure safe operation and positive stopping under all conditions. The limit switch shall automatically disconnect the motor and engage the hoist brake when the hook reaches either it’s upper or lower limit of travel.

3. Each load hook shall be mounted on ball thrust bearings to swivel without twisting the chain. The lifting tackle shall be of the safety type, and the hooks shall be of hardened steel equipped with a safety catch. Sheaves shall be properly guarded and shall be heavy pattern, deep flanged and properly grooved. Sheaves shall be either bronzed bushed or fitted with ball bearings and supported on fixed pins.

D. DRIVE UNITS: 1. Hoist shall be fully electrified. Motors shall be specially designed for Class I crane

service. Hoist controls shall be the single-speed type with speed indicated under the operating requirements.

2. Brakes shall be solenoid actuated. The hoist motor bearings shall be grease lubricated and shall be designed for a Class M3 (50,000 hour) bearing life.

E. ELECTRICAL EQUIPMENT AND CONTROLS: 1. GENERAL: The crane manufacturer shall furnish and mount all electrical equipment on

the crane including motors, control, conduit, and festooning. All wire on the crane shall be furnished by the crane manufacturer, cut to length and installed as far as practical for shipment.

2. POWER SUPPLY: Power supply for crane equipment shall be 460V, 3 phase, 60 Hz. The Contractor shall provide the power feeder with a local disconnect switch. From the local disconnect switch the contractor will provide cable and conduit to the stationary crane terminal box provided by the Manufacturer. Control power transformers shall be provided as necessary by the manufacturer.

3. MOTORS: Motors shall comply with Section 16220 and shall be 1800 rpm maximum, 460 volt, 3 phase, Type 2 with TEFC enclosures.

4. ELECTRIFICATION: Electrification shall be by the festoon cable, as described in the Operating Conditions and connected to the power supply terminal box above.

5. CONTROLLERS: Control shall be magnetic type. All control equipment, including relays, pushbuttons, transformers, and interconnecting wiring shall be provided by the crane supplier. All control equipment shall be housed in enclosures suitable for atmospheres listed in paragraph 14611-1.01E. Enclosure materials shall be in accordance with Section 16000.


6. GENERAL: The hoist and trolley shall be motor driven, single speed, and reversible. Control of all motions shall be from a traveling pushbutton pendant on the hoist. The pushbutton controlling opposite motions shall be mechanically interlocked so that they cannot be depressed simultaneously. An additional emergency stop switch shall be provided on the pendant or remote.

7. OTHER: All controls shall be clearly marked with etched or engraved nameplates. The pendant shall be attached to a retractable cable which will allow it to be raised above head level when the hoist is not in use and which will allow the pendant to be held in the hand during operation from the floor level(s) specified below. Provide a suitable wall bracket for storage of the remote control, where required.

F. EQUIPMENT MOUNTING: 1. Equipment mounting shall conform to the requirements specified in Section 11002.

2.04 MARKINGS AND COATINGS

A. MARKING: 1. All equipment shall have factory-installed stainless steel nameplates with load rating and

weight and any information required by applicable building or other code. 2. Field-coated beams or final-coated beams by manufacturer, shall have the actual (lowest)

load rating of the monorail system painted on in black letter over a white background (e.g. 1 TON). Letters shall be no less than four inches tall and have a 5/8-inch minimum line weight.

B. COATINGS: 1. Unless otherwise specified, each item of equipment shall be shipped to the site of the

Work with the manufacturer's shop applied epoxy prime coating as specified in Section 09900. All prime coats applied by the manufacturer shall be compatible with the intended finish coats as specified. If not, the manufacturer shall notify the Contractor via the submittal information and recommend substitutions. The prime coating shall be applied over clean dry surfaces in accordance with the coating manufacturer's recommendations. Electrical equipment and materials shall be painted by manufacturer as specified in Section 09900.

2.05 SPARE PARTS – NOT USED

2.06 PRODUCT DATA

A. The following product data shall be provided in accordance with Section 01300: 1. Operation and maintenance information as specified in specification Section 01730. 2. Manufacturer's written recommendations for installation. 3. Installation, testing and commissioning certificates in accordance with this section and

specification Sections 01660 and 01999. 4. Training certification form in accordance with this section and specification Section 01999.


PART 3–EXECUTION

3.01 INSTALLATION

A. The equipment shall be installed, checked, adjusted, and tested in accordance with the manufacturer's written instructions. The installation and initial operation of all components shall be certified on Form 11000-A, as specified in Section 01999.

B. The Contractor shall install the complete systems in the general arrangement and where shown on the drawings and as specified. Installation shall be performed by mechanics skilled in work of this kind. The equipment shall be checked, aligned, and approved for start-up by the manufacturer's factory trained representatives. Each system component shall be reviewed and approved by the applicable manufacturer prior to start-up of the complete system. The manufacturer having unit responsibility shall arrange and coordinate such reviews between component manufacturers and the Contractor.

3.02 TESTING

A. The Contractor shall arrange and schedule testing and commissioning with the Engineer. Installation, testing, and commissioning shall be carried out in accordance with specification Section 01660.

B. After completion of installation, the monorail, trolley, and hoist shall be completely tested to ensure compliance with the performance requirements as specified. As a minimum, testing shall be by operating the equipment through a complete lift and lowering cycle and through a complete travel of the bridge and runway beams to determine that the equipment performs smoothly and safely without failure. Such tests shall be carried out with the hoisting equipment loaded at 125 percent of specified capacity. After load testing, the overload limit switch is to be reset at the rated load. Any defects shall be corrected or replaced immediately by the Contractor and at no expense to the Owner. All testing and the costs of all required certification shall be at the Contractor’s expense.

3.03 USE BY CONTRACTOR

A. Contractor may use cranes and hoisting equipment upon prior application and approval of Engineer. Approval will not be unreasonably withheld, but may be revoked if Contractor overloads (or proposes a lift that will exceed rating of) any of the system components and/or operates in a manner unsafe to either personnel or Owner property.

B. Any crane or hoist used by the Contractor shall be repaired, repainted and otherwise refurbished to like-new condition prior to its acceptance. The Contractor assumes all responsibility for operation and maintenance until the crane has been accepted.

**END OF SECTION**



150141 – 2017 Upgrades and Rehabilitation 17000-1 General Requirements for Electrical Work James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 17000

GENERAL REQUIREMENTS FOR INSTRUMENTATION AND CONTROL

PART 1–GENERAL

1.01 DESCRIPTION

A. SCOPE: 1. This section specifies general requirements which are applicable to providing a complete,

functional process control, instrumentation, communication, and signal systems. The requirements of this section are applicable to all work specified in these specifications.

2. Electrical requirements applicable to this work include those specified in Section 16000 for general electrical requirements; Section 16175 for electrical devices; and Section 16176 for control panel devices.

B. DESCRIPTION OF WORK: 1. INSTRUMENTATION AND CONTROL SYSTEM: The work consists of:

Provide new network equipment where shown and specified: 1) MOXA ethernet switches; the switch is to be a managed, fault tolerant switch

with fiber optic connections where shown. Provide a minimum of four spare RJ-45 ports for future use.

2) Fiber optic patch panels shall be Dow Corning fiber optic patch panel (FOPP) model SPH-01P.

Digester cover, install a position switch on the hatch. 1) This will be a digital input to existing control panel, ACP-72. 2) Revise the PLC logic and Digester #2 SCADA graphic to show the hatch and the

Open position. 3) Use a spare DI in this panel for this point. See Appendix for the PLC IO List,

update with the propose DI to use. New Raw Sewage Pumps, VCP-6301,the vendor supplied control panel is supplied

per specification section 11347 and is hardwired to the existing panel ACP-62. 1) See Appendix for the PLC IO List, update with the DI to use as shown on PID. 2) Add the I/O, and necessary cards, as shown on the PID’s. 3) Revise the existing PLC and SCADA programs as shown on the PID’s. 4) Should the PLC fail the VCP-6301 float control circuit shall be enabled.

Provide a new Hydrocyclone Train 1 and Train 2 control panel. This is for the two new hydrocyclone trains and feed pumps VFD motor starters. The motor starters, programmable logic controller, operator interface terminal, etc, shall be in one, local control panel, LCP-8200, provided under this section. The LCP shall include: 1) The control panel shall:

a) NEMA 4X 316 SST painted white enclosure. b) Provide a sun shield with a hinge cover for the operator interface terminal. c) Dedicated 480V section and control sections for electrical safety.

2) The LCP will be networked to the SCADA system.


a) Monitoring and control is to be provided as shown on the PID’s and specified.

b) Provide fiber optic patch panel and ethernet switch. c) Provide a 12” color touch screen, operator interface terminal, Rockwell

Automation Panelview Plus7 or equal. 3) Voltage source 480V 3 phase, 60 Hertz power. Provide surge protection device

for the power line input to the panel, 3 phase 480V, 160KA minimum, Schneider, Phoenix Contact or equal.

4) Control power shall be 120VAC. 5) Provide control power transformers with 25% spare capacity. 6) Provide dedicated 120V, 20 A circuit for convenience outlets:

a) One outlet located on the exterior of the cabinet shall be GFCI, with in-use type cover.

b) One outlet located inside control panel. 7) The VFD’s shall be located in a dedicated 480V section of the enclosure with a

main circuit breaker with flanged handle. The PLC and associated controls shall be located in its own section(s).

8) (Addendum#1) Provide Variable Frequency Drives (VFD) in accordance with Section 11069 for pump equipment. VFD ambient rating shall be rated for 40 50 degrees C and a site elevation of 4700 ft above sea level.

9) The hydrocyclone Selective Wasting Process containing all operating adjustments and controls.

Blower Building, Area 68: 1) Add a lamacoid nameplate with “VCP-6800” to the existing Blower Master

Control Panel. 2) This VCP-6800 PLC program, SCADA program and operator interface terminal

(OIT) shall be revised to control using the existing DO sensors and using the new NH3/NO3 analyzer control variable from VCP-6801. Send the existing DO data over ethernet to VCP-6801 for monitoring.

3) There will be added, two of each, NH3/NO3 sensors, connected to ACP-68 Ethernet switch over a fiber optic network. These redundant units are supplied and installed under this contract (Section 11999) and communicate to VCP-6801 over ethernet.

4) The Blower Master Control Panel will communicate to VCP-6801. VCP-6801 will provide the following data to display on VCP-6800 Blower Master Control Panel: a) The control mode the the system is operating in: AvN, ABAC mode. This is

status only. b) The analyzer values as shown on the PID. c) The PID setpoint (DO) calculated from each controller, there are two. The

setpoint is calculated based on the data received from analyzer 1: AIT-6867 and analyzer 2: AIT-6768. This set point is an input to the existing DO controllers in VCP-6800.

5) Update the VCP-6800: a) Reprogram the VCP-6800 to provide PID based control of the airflow control

valves based on the measured DO as compared to the DO setpoint. The VCP-


8200 is currently programmed to accomplish this control with a step-wise type logic.

b) To the OIT add a graphic screen for this new process with: (1) Ammonia and NOx values (2) Ammonia and NOx High and High-High alarms (3) Add a HS to select the respective NH3/NO3 analyzer DO setpoints,

1/2/AVG (1 = analyzer 1, AIT-6867; 2 = analyzer 2, AIT-6768; AVG = average of the two ), to control the flow control valve PID controller. Provide a deviation alarm (indication only) if there is more than 20% difference between the two analyzers; operations will decide on the corrective action

c) To the OIT add a HS to select the existing DO control mode or the new AvN-ABAC DO control mode. Add a new AvN-ABAC / DO hand switch for this provision. The DO mode is the existing DO control mode.

d) When in the AvN-ABAC mode: (1) The DO setpoint from VCP-6801 is to be used in the updated Blower

Master Control Panel PLC aeration control mode. VCP-6800 shall be programmed to select the DO set point from VCP-6801 or the existing operator entered DO set point; using the new AvN-ABAC / DO hand switch.

(2) Ammonia and NOx alarms and ranges: (a) Ammonia (NH4-N) High Alarm is set at 8, High High Alarm is set at

12. The range is 0-30 mg/l.

(b) NOx High Alarm is set at 12, High High Alarm is set at 20.

(c) Nitrate range is 0-40 mg/l.

(d) Nitrite range is 0-20 mg/l.

(e) The above ranges and setpoints are initial and are subject to change based on actual process conditions. These will be adjusted as needed during startup.

e) When in the AvN-ABAC mode: (1) Provide a hand switch to Enable/Disable the low DO alarms. (2) Provide a hand switch to Enable/Disable the Ammonia and NOx High

and High-High alarms. (3) Display the mode the system is operating in: AvN or ABAC; this status

is from VCP-6801. (4) The minimum air flow shall be limited to 466 SCFM.

f) Over the ethernet network, send to VCP-6801 each of the DO transmitter values for monitoring.

g) SCADA is to monitor and control the following modes: (1) AvN-ABAC or DO control mode selected. (2) Display the control mode the system is operating in: AvN or ABAC

when in the AvN-ABAC control mode.


(3) When in the AvN-ABAC mode, low DO alarms Enabled / Disabled hand switch and status.

(4) When in the AvN-ABAC mode, Ammonia and NOx High and High-High alarms Enabled / Disabled hand switch and status.

(5) Each analyzer value, trends and alarms. 6) The following table represents the VCP-6800 and -6801 limiting parameters for

reference:

Setup and Settings for the Control Loops

Controller Name

Measured/Controlled Variable

Manipulated Variable

Output min bound

Output max bound

Controller type

Controller Parameters

(starting point)

VCP-6801: ABAC

NHx-N= set-point end of aeration zone

(Z8)

DO setpoint [mg DO/L]

0.05 [mg DO/L]

2.0 [mg DO/L] PID

K: 2 Tn: 120 min Tv: 30 min

VCP-6801: AvN

NHx-N/NOx-N = 1 end of aeration zone

(Z8)

DO setpoint [mg

DO/L]

0.05 [mg DO/L]

2.0 [mg DO/L] PID

K: 2 Tn: 120 min Tv: 30 min

VCP-6800:DO Controller

DO in individual zones Airflow 466 [SCFM] 2400

[SCFM] PI N/A

VCP-6800: Airflow Controller

Airflow in individual zones %FCV 20 [%FCV] 80 [%FCV] PI N/A

Existing Area Control Panel ACP-73, and solids building:

1) New centrifuge system is a preselected item by the Owner and is to be furnished and installed under this contract. a) The centrifuge vendor control panels, VCP-7411 and -7412, will be

networked to ACP-73. b) The PLC and SCADA programs shall be updated as shown on the PID’s.

2) Add the I/O, and necessary cards, as shown on the PID’s. 3) On the West side of this panel exterior is the existing fiber optic patch panel,

remove and replace this with a new fiber optic patch panel (FOPP) and reterminate the existing fibers to the new FOPP.

4) At ACP-73 add two new, 120V, circuit breakers for the new LE/LIT-7328 and -7329.

5) Provide a new NEMA 4X, 316SST, local control panel, LCP-7300, for the two DAF Polymer tank mixer controls: a) Each mixer is to include a HOA and run light (green). Power for the run

light is to come from ACP-73. b) The Hand and Auto contacts will be wired back to ACP-73 to connect to the

existing PLC inputs. c) In the Auto mode, the cycle timer is to include operator selectable On time

and Off time. This contact shall be wired to the existing ACP-73 PLC input. This contact shall control the existing Mixer On/Off operation when the HOA is in the Auto mode.


d) The respective mixer shall operate from the cycle timer when the HOA is in the Auto mode. When in the Hand mode the mixer shall be on; when the HOA is in the Off mode the mixer shall be off.

e) The respective mixer shall stop when the tank level is below the low level alarm setpoint from the new ultrasonic level transmitter.

6) Provide a new NEMA 4X, 316 SST, control panel, LCP-7200, for the three existing digested sludge pumps: a) Each sludge pump is to include a HOA and run light (green). Power for the

run light is to come from ACP-73. b) The Hand and Auto contacts will be wired back to ACP-73 to connect to the

existing PLC inputs. c) In the Auto mode, the pump will come on when the centrifuge is started. The

run command comes from respective centrifuge VCP, as well as the pump speed command over the ethenet connection.

d) When in the Hand mode the pump shall start; when the HOA is in the Off mode the pump shall be off.

e) Provide a flow indicator for each sludge pump discharge flow meter. The indicator shall be a 3.5 digit LED indicator, 4-20mA. The 4-20mA signal shall come from the existing PLC output. Power for the flow indicator is to come from ACP-73.

7) Provide a new control panel, LCP-8200, Hydrocyclone Control Panel: a) Supply a UL listed, free standing, stainless steel, NEMA 4X, polyester

powder coated white, forced air ventilation, control panel. Control panel shall be dead front construction with divider between the 480V and the 120V section. Control panel shall house all necessary breakers, VFD’s, contactors, control power transformers, relays, pilot devices, terminal blocks and PLC control equipment for the entire supplied system. Panel supply voltage shall be 3 phase, 480V, 60Hz. Control power to external devices shall include interposing relays as necessary. Panel internal control power shall be 120VAC. Provide all breakers and relays for all instrumentation, motorized valves, and ancillary equipment connected with this system. Provide all necessary output relays and data highway devices for communication to SCADA system. Refer to system P&ID’s.

b) Provide Variable Frequency Drives (VFD) in accordance with Section 11069 for pump driving equipment. VFD ambient rating shall be 50 degrees C, rated for the Pueblo elevation and have input line reactors.

c) Provide a PLC for the Cyclone Selective Wasting Process containing all operating and adjustment controls including main disconnect device, 120-volt control transformer (as-required), indicating lights.

d) Coordinate the controls with the equipment package in the Cyclone Selective Wasting manufacturer’s scope of supply; see section 11185.

e) Voltage source 480V 3 phase, 60 Hertz power. Control power shall be 120VAC. Provide control power transformers with 25% spare capacity.

f) Provide surge protection device for the power line input to the panel. Refer to specification 16445.

g) Controls designed to permit automatic start-up and shut-down, and unattended operation to include:


(1) Cyclone skid operation/monitoring (2) Cyclone Feed pump operation with options to set pump speed manually,

to control pump speed to maintain feed flowrate set by operator, or to adjust speed to achieve a pressure setpoint in response to pressure indicating transmitter external 4-20 ma signal.

(3) Hardwired Interlock with level switch to alarm and shut down operation. (4) Hardwired Interlock with solenoid valve to open the solenoid valve

during any time that there is not process flow in the pipe or the pump is not running.

(5) Software Interlocks with flow and pressure setpoints to alarm and shut down.

(6) Provide contiguous PLC register list for monitoring and control variables to interface with the SCADA system.

h) Control Panels: (1) Main power disconnect switch (pad-lockable), flange type (2) Control power transformer (3) NEMA 4 operator interface terminal, 10”, color touch screen, Ethernet IP

communication, with sun shield to cover the entire unit with a top hinge. (4) Programmable logic controller (PLC) : See Section 17310. (5) Operating and warning lights (30mm) on the panel dead front for the

following (minimum): (a) Power on

(b) Cyclone Skids in Operation, On and Off lights

(c) Malfunction indication, horn and beacon

(d) Acknowledge/Reset pushbutton

(6) Laminated plastic nametags shall be provided for the name of the control panel and all disconnects, switches, lights, and meters.

(7) Spare terminals (control and power voltage) shall be provided to accommodate for remote control operation and to interface with other equipment components.

(8) Forced air ventilation for the panel shall be provided.

Existing area PLC’s located in ACP-62, ACP-69 and ACP-73 are to have the existing Allen Bradley SLC 5/05 model CPU updated to the Control Logix model; and use the existing SLC I/O cards. 1) The SLC 5/05 CPU shall be replaced with a 1747-AENTR card and add a

Control Logix processor. There is room on the existing subpanel for this equipment.

2) Replace the existing Ethernet swith with MOXA, managed, fault tolerant switch to meet the needs of the network as shown; provide a new power supply for this device.


3) Replace the existing UPS, in each APC, with a 500VA unit as specified. Provide a stand with 12” legs for the bottom of the enclosure.

4) Convert the exist program to the RS Logix 5000 platform with comments and coordinate with SCADA.

5) (Addendum#1) The RS Logix 5000 software shall be installed in the new ControLogix processor and fully tested prior to actually shutting down the existing PLC and physically replacing the SLC500.

6) Coordinate with the plant a minimum of two weeks notice as each area will have to be run in the manual mode during the upgrade.

7) Submit a schematic diagram, Bill of Materials and a switch over plan with time intervals for approval. Each ACP upgrade shall be completed in one eight (8) hour day or less.

8) (Addendum#1) Should the upgrade be anticipated to take longer than the 8 hour day for any reason, the Contractor shall satisfactorily reinstall and reinstate the existing SLC500 processessor and associated logic and return the plant to automated operation prior to leaving the project site for the day.

The existing SCADA application software is Rockwell FactoryTalk. The system is to be updated with the new IO and SCADA graphics. The graphics shall match the similar functionality of the existing system to reflect the additional equipment. Update the existing SCADA graphic screens with the status of the entire network to illustrate the network status, and if a problems arises, the network will show where the problem is on this SCADA graphic.

Fiber optic cable, single mode, is to be terminated and tested by the systems integrator. The fiber optic cable is to be supplied and pulled by the electrical contractor, see Division 16.

Supply and install the field instruments as shown and specified. Each existing control panel that is modified, the respective drawings are to be

updated and submitted for review; and then the as-installed drawings shall be added to the operations and maintenance manuals.

2. PROGRAMMING: Programming shall be provided per Section 17315 and 17316.

C. DEFINITIONS: 1. GENERAL: Definitions of terminology related to Instrumentation and Industrial

Electronic Systems used in the specifications shall be as defined in IEEE 100, ISA S51.1, and NEMA ICS 1.

2. TWO-WIRE TRANSMITTER: A transducer which derives operating power supply from the signal transmission circuit and requires no separate power supply connections. A two-wire transmitter produces a 4 to 20 milliampere current regulated signal in a series circuit with a 24-volt direct current driving potential and a maximum circuit resistance of 600 ohms.

3. FOUR-WIRE TRANSMITTER: A transducer which derives operating power from separate power supply connections. A four-wire transmitter produces a 4 to 20 milliampere current regulated signal in a series circuit with a maximum circuit resistance of 600 ohms. Four-wire transmitters typically require 120Vac or 24Vdc input power supply.

4. GALVANIC ISOLATION: Electrical node having no direct current path to another electrical node. Galvanic isolation refers to a device with electrical inputs and/or outputs


which are isolated from ground, the device case, the process fluid, and separate power supply terminals. Inputs and/or outputs may be externally grounded without affecting the characteristics of the devices or providing path for circulation of ground currents.

5. PANEL: An instrument support system which may be a flat surface, a partial enclosure, or a complete enclosure for instruments and other devices used in process control systems including consoles, cabinets and racks. Panels provide mechanical protection, electrical isolation, and protection from dust, dirt, moisture, and chemical contaminants which may be present in the atmosphere.

6. DATA SHEETS: Data sheets shall refer to ISA S20 or ISA TR20.00.01. 7. SIGNAL TYPES: Used in systems specified in Division 17:

LOW-LEVEL ANALOG: Signal with full output level of 100 millivolts or less including thermocouples and resistance temperature detectors.

HIGH-LEVEL ANALOG: Signals with full output level greater than 100 millivolts but less than 30 volts, including 4 20 mA transmission.

DIGITAL CODE: Coded information from the output of an analog to digital converter or digital transmission terminal.

PULSE FREQUENCY: Counting pulses emitted from speed or flow transmitters. MODULATED SIGNALS: Signals from modems or low level audio signals.

Normal signal level: plus 4 dBm to minus 22 dBm. Frequency range is 300 to 10,000 Hertz.

DISCRETE CONTROL OR EVENTS: Dry contact closures and signals monitored by solid state equipment, relays, or control circuits.

LOW VOLTAGE DISCRETE CONTROL OR EVENTS: Dry contact closures and signals monitored by solid state equipment, relays, or control circuits operating at less than 30 volts and 250 milliamperes.

HIGH-LEVEL AUDIO SIGNALS: Audio signals exceeding plus 4 dBm, including loudspeaker circuits.

RADIO FREQUENCY SIGNALS: Continuous wave alternating current signals with fundamental frequency greater than 10 kilohertz.

8. SYSTEMS INTEGRATOR: A firm engaged in the business of detailed control system design and engineering, instrumentation component purchase, system and panel assembly, programming, and implementing the specified process control and industrial automation systems.


A. REFERENCES: 1. This section contains references to the following documents. They are a part of this


2. Unless otherwise specified, references to documents shall mean the documents in effect at the time of Advertisement for Bids or Invitation to Bid (or on the effective date of the Agreement if there were no Bids).

3. If referenced documents have been discontinued by the issuing organization, references to those documents shall mean the replacement documents issued or otherwise identified


by that organization or, if there are no replacement documents, the last version of the document before it was discontinued.

4. Where document dates are given in the following listing, references to those documents shall mean the specific document version associated with that date, regardless of whether the document has been superseded by a version with a later date, discontinued or replaced.

Reference Title

IEEE 100 Standard Dictionary of Electrical and Electronics Terms

ISA S5.4 Instrument Loop Diagrams

ISA S20 Specification Forms for Process Measurement and Control Instrumentation, Primary Elements, and Control Valves

ISA S51.1 Process Instrumentation Terminology

ISA TR20.00.01 Specification Forms for Process Measurement and Control Instruments Part 1: General Considerations

NEMA ICS 1 General Standards for Industrial Control and Systems

B. SYSTEMS INTEGRATOR RESPONSIBILITY: 1. General

The specified control system and instrumentation integration including panel building, instrument calibration, testing, start-up, operational testing, and training shall be performed by a Systems Integrator staffed with qualified personnel, possessing necessary equipment and experience in performing similar installations.

The control system components shall, as far as practical, be of one manufacturer. The components, modules, devices, and control system equipment shall be

recognized industrial quality products. Recognized commercial or office grade products are prohibited.

The overall system performance shall be demonstrated to and accepted by Owner. The application software packages shall be latest versions available, or compatible

with existing software currently in use, as specified.

2. SYSTEMS INTEGRATOR QUALIFICATIONS: The following Systems Integrators are pre-qualified to perform the work specified in

Division 17 without the need to provide Evidence of Experience: 1) AM West Controls 2) Utility Controls and Equipment Company 3) MR Systems, Norcross, GA 4) Revere Controls, Birmingham, AL

Contractor-proposed Systems Integrator shall be evaluated based on submittal of the following Evidence of Experience:

1) Submit evidence of experience in performing three similar successful projects in

the last five years with one project currently in progress or competed within the last two years.


2) Submit project descriptions with contact names, addresses, and telephone numbers from the project Owner, General Contractor, and Principal Design Firm.

3) Submit organization chart and resumes for proposed project personnel. 4) Submit Training and Certification information. Completion of the following

training courses or appropriate portions thereof or possession of the following certifications included with the Systems Integrator’s personnel experience requirements described above: a) Project manager: Control System Engineer (CSE) registration, Professional

Engineer (PE) registration. b) Systems engineer: Control System Engineer (CSE) registration, Professional

Engineer (PE) registration, or completion of the relevant core courses in the Engineering Skills Training program.

c) Programmer: Control System Engineer (CSE) registration, Professional Engineer (PE) registration.

d) Field instrument technician: Certified Control Systems Technician (CCST) registration or completion of the relevant core courses in the Technical Skills Training program.

e) Certified training programs, as offered by ISA. 5) Submit financial data for Systems Integrator division when subsidiary to a parent

corporation. Include two years of financial data. a) Financial Statement. b) Balance Sheet. c) Dun & Bradstreet Report.

3. Pre-Submittal Conference: Schedule a pre-submittal conference with the Owner and Construction Manager

within 30-calendar days after Contract award to discuss the work, equipment, submittal format, and establish the framework for project coordination and communication.

Provide materials 10-days prior to the conference: 1) Instrument Index that lists the devices and instruments specified in Division 17

identify each by tag number, description, function, manufacturer, and model number.

2) Product descriptive literature with a statement that the item is as specified. 3) Proposed equal products with comparative listing of the published specifications

for the specified item and the proposed item. 4) Project schedule with deliverables and milestones. 5) Project Control System Block Diagram, when specified. 6) Sample portion of documented PLC and Operator Interface program, when

specified. 7) Sample control panel schematic diagram proposed for this project, when

specified. Sample can be a copy from a previous project provided that it represents the format being proposed for this project.

8) Sample analog and discrete loop diagrams proposed for this project, when specified. Sample can be a copy from a previous project provided that it represents the format being proposed for this project.


9) A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. A check mark shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each requested deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The Construction Manager shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications.

The pre-submittal conference will not replace the Product and Shop Drawing Submittal review process.

C. PROCESS EQUIPMENT COORDINATION 1. Division 17 specified equipment shall be coordinated for proper operation with

equipment related process equipment specified in other Divisions. 2. Equipment shall be integrated, furnished, and installed in conformance with the drawings,

specifications, and the recommendations of the equipment manufacturer and the related processes equipment manufacturers.

3. Systems Integrator shall obtain manufacturer’s technical information for items of equipment not provided with, but directly connected to, the control system. Provide the necessary coordination and components for correct signal interfaces between specified equipment and the control system.

4. Systems Integrator shall coordinate with project subcontractors and equipment suppliers. 5. Systems Integrator shall provide installation supervision for the duration of the project. 6. Conflicts between the plans, specifications, manufacturer/vendor drawings and

installation instructions, etc., shall be presented to the Construction Manager for resolution before proceeding.

D. FACTORY ACCEPTANCE TEST (FAT): 1. FAT are required only if specifically called for a given control panel.


A. GENERAL: 1. Specified data communication and process control equipment shall suitable for operation

in indoor locations and in outdoor locations. Ambient conditions are specified in Section 01800.

B. CORROSIVE LOCATIONS: 1. Corrosive locations shall be as specified in Division 16.

C. HAZARDOUS (CLASSIFIED) AREAS: 1. Hazardous areas shall be identified on the electrical drawings.

D. SEISMIC:


1. Equipment and supports shall be braced per Section 01900.

1.04 FUNCTIONAL REQUIREMENTS

A. GENERAL: 1. The instrumentation and control system functions are shown on the drawings and

specified in subsequent sections of Division 17. The Systems Integrator drawings and integration practices shall be as defined in IEEE 100, ISA S51.1, and NEMA ICS 1.

B. SUBMITTAL DRAWINGS: 1. GENERAL: The drawings included in the project manual are functional in nature and do

not show exact locations of equipment or interconnections between equipment. The Contractor’s Systems Integrator shall prepare detailed installation drawings as specified below.

Drawings prepared in AutoCAD version 2017 with borders and title blocks identifying the project, system, revisions to the drawing, and type of drawing. Each revision of a drawing shall include the date and description of the revisions. Drawing prints shall be 11” x 17” with a minimum lettering size of 1/8”.

Diagrams shall carry a uniform and coordinated set of wire numbers and terminal block numbers in compliance with panel wiring, Section 17110, to permit cross-referencing between contract documents and the drawings prepared by the Contractor.

2. CONNECTION DIAGRAMS: Show components of a control panel in an arrangement similar to the actual layout of the panel including internal wiring between devices within the panel. Show terminal blocks used for internal wiring or field wiring, identified as such. Indicate insulation color code, signal polarities, and wire numbers and terminal block numbers.

3. INTERCONNECTION DIAGRAMS: Show panels, panel devices, and field devices with wire numbers, cable numbers, raceway numbers, terminal box numbers, terminal block numbers, panel numbers, and field device tag numbers.

4. ELEMENTARY OR SCHEMATIC DIAGRAM: Shows, by means of graphic symbols, the electrical connections and functions of a specific circuit arrangement. Provide schematics for internal panel power distribution, lighting, and any panel HVAC.

5. ARRANGEMENT, LAYOUT, OR OUTLINE DRAWINGS: Show the dimensioned external and interior control panel views with components and Bill of Material. Provide panel heat load calculations, and indicate cooling or ventilation provisions as required.

6. NETWORK BLOCK DIAGRAM: A network block diagram is a diagram of the overall SCADA system, with annotated boxes to show the primary network components (controllers, hubs, switches, computers, displays), and annotated interconnecting lines that show the system communication media and communication protocols.

7. LOOP DIAGRAMS: Provide loop diagrams for analog and discrete loops interconnected into the control system circuits:

Prepare per ISA S5.4 – Loop Diagrams showing the process, field instrument, control panel (front and behind), software functions and SCADA.

Show device element wiring of the system. Show circuits for hardwired device interlocks. Show circuit cable and wire cable numbers, signal polarities, and terminal block

numbers.


1.05 SUBMITTALS

A. The following information shall be provided in accordance with and Section 01300: 1. A copy of this specification section, with addendum updates included, and all referenced

and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. A check mark shall denote full compliance with a paragraph as a whole.

If deviations from the specifications are indicated, and therefore requested by the Contractor, each requested deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation.

The Construction Manager shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the Contractor with the specifications.

Failure to include a copy of the marked-up specification sections, along with justification for requested deviations from the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.

2. Detailed product literature, showing product specifications and model number breakdown. Mark to denote features and options included. Include only the applicable pages.

3. Manufacturer’s installation manual excerpts, as to be used for this project: Installation details/drawings. Electrical connection diagrams Calibration procedures.

4. Drawings and diagrams specified in paragraph 17000-1.04 B. 5. Nameplate list with material, tag number and description as specified herein. 6. Systems Integrator Evidence of Experience per paragraph 17000-1.02 B 3. 7. Data Sheets in accordance with ISA 20 for each instrument. Identical instruments may

be submitted with one common ISA Data Sheet and accompanying tag list.

B. Review the submittal requirements specified in other Division 17 Sections.

PART 2–PRODUCTS

2.01 GENERAL

A. MATERIALS AND QUALITY: 1. Equipment material shall be new, free from defects, and industrial-grade, as specified.

Each type of instrument, instrument accessory, and device used throughout the work shall be manufactured by one firm, where possible.

2. Electronic equipment shall be of solid-state construction with printed or etched circuit boards of glass epoxy of sufficient thickness to prevent warping.

3. Printed circuit boards in field mounted equipment shall be coated with 2 mils of conformal coating in compliance with MILSPEC MIL-I-46058C.


B. ENCLOSURES: 1. Table A specifies the instrument and control panel enclosure material and minimum

NEMA rating for the location and application.

Table A Location Enclosure Material and NEMA Rating

Indoor: Architecturally Finished Area NEMA 12: mild steel

Indoor: Electrical Room NEMA 12: mild steel

Indoor: Process Areas NEMA 4X: 316 Stainless Steel

Indoor: Corrosive Area NEMA 4X: 316 Stainless Steel

Outdoor: Corrosive Area NEMA 4X: 316 Stainless Steel

Outdoor: Non-Corrosive Areas NEMA 4X: 316 Stainless Steel

Corrosive Area (Hypochlorite) NEMA 4X: Non-metallic

Hazardous Area: NEMA 7: Galvanized Malleable Iron or Aluminum or NEMA 4X and UL listed or FM Approved for the Hazardous Area.

Hazardous and Corrosive Area NEMA 7: Iron or Aluminum with factory applied corrosion resistant coating or NEMA 4X and UL listed or FM Approved for the Hazardous Area.

2.02 NAMEPLATES

A. Nameplates shall be provided for all field mounted instrument, analyzer, or equipment specified in Division 17. Nameplate lettering shall include the equipment or instrument loop title and the instrument or equipment tag number, where nameplate engraving is not specified or shown. Nameplates shall be machine engraved white phenolic with black lettering, or stamped stainless steel, with 5/32-inch high lettering, as minimum, unless otherwise specified or shown. Nameplate wording may be changed without additional cost or time, if changes are made prior to commencement of engraving.

B. Nameplates shall be attached to support hardware with a minimum of two self-tapping type 316 stainless steel screws in a readily visible location so the nameplate will remain to identify the service when the device is removed. Field instrument nameplates shall be attached with braided stainless steel straps where not stand mounted.

2.03 PRODUCT DATA

A. The following Product Data shall be provided in accordance with Section 01300. 1. Record drawings specified by paragraph 17000-1.04 B and the schedules included in

Division 17 shall be provided in accordance with Section 01720 in the latest AutoCAD format and PDF format on CD.

2. Provide record drawing prints of all drawings following project start-up, but prior to acceptance of the work showing the final constructed state of the instrumentation and control systems.

3. Operating and maintenance information shall be provided in accordance with Section 01730. Include the following in each Operation and Maintenance manual:

Final reviewed Submittals, including revised as-built record drawings.


Manufacturer’s operation and maintenance instructions, edited for this project. Written record of menu configuration, jumpers, switch settings, and other

configurable parameters for each instrument.

PART 3–EXECUTION

3.01 INSTALLATION

A. GENERAL: 1. Equipment shall be installed in locations that are accessible for operation and

maintenance services. Equipment not accessible shall be reinstalled at no cost to the Owner.

2. Installation, calibration, settings, and testing procedures are specified in Section 17000, Section 17200 – Instrument Index Part 3 Execution, and subsequent sections of Division 17

B. FIELD EQUIPMENT: 1. Equipment shall be provided with ports and adjustable items accessible for in-place

testing and calibration. Install equipment between 48 inches and 60 inches above the floor or permanent work platform. Equipment shall be mounted to avoid shock or vibration that may impair operation. Equipment shall be mounted for unobstructed access and walkways. Equipment support systems shall not be attached to handrails, process piping or mechanical equipment.

2. Instruments and cabinets supported by concrete walls shall be spaced 5/8 inch by framing channel between instrument or cabinet and wall. Block wall shall have additional installation supports, as required, to avoid damage to the wall. Equipment supports shall be hot-dip galvanized after fabrication or shall be 316L stainless steel, as shown or specified.

3. Support systems including panels shall be designed in accordance with Section 01900 to prevent deformation greater than 1/8 inch in any direction under the attached equipment load and under an external load of 200 pounds.

4. In wet or outdoor areas, conduit penetrations into instrument housing shall be made through the bottom (preferred) or side of enclosures to minimize water entry from around or from inside of conduits. Provide conduit hubs for connections and waterproof mastic for moisture sealant.

5. Nameplates shall be provided for all field mounted equipment. Nameplates shall be attached to support hardware with a minimum of two self-tapping Type 316 stainless steel screws in a readily visible location, but such that if the field device is changed out, the nameplate will remain to identify the service.

C. ELECTRICAL POWER CONNECTIONS: 1. Equipment electric power wiring shall comply with Division 16. Power disconnect

switches shall be provided within sight of equipment and labeled to indicate the specific equipment served and the power source location. "Within sight of" is defined as having an unobstructed view from the equipment served and within 50 feet of the equipment served.

2. Equipment power disconnect switches shall be mounted between 36 inches and 72 inches above the floor or permanent work platform. Where equipment location requirements


cannot be met by a single disconnect switch, provide two disconnect switches: one at the equipment and one at the work platform.

3. Provide a surge arrestor on each 120-volt AC disconnect switch serving equipment located outdoors. Surge arrestor shall be Telematic, LP Series or equal.

D. SIGNAL CONNECTIONS: 1. Equipment electric signal connections shall be made on terminal blocks or by locking

plug and receptacle assemblies. Flexible cable, receptacle and plug assemblies shall be used where shown or specified.

2. Jacketed flexible conduit shall be used between equipment and rigid raceway systems. Flexible cable assemblies may be used where plug and receptacle assemblies are provided and the installation is not subject to mechanical damage in normal use. The length of flexible conduit or cord assemblies shall not exceed 2 feet except where sufficient length is required to allow withdrawal of instruments for maintenance or calibration without disconnection of conduit or cord assemblies.

3.02 FIELD TESTS AND INSPECTIONS

A. DELIVERY INSPECTION: 1. The Contractor shall notify the Owner's Representative upon arrival of any material or

equipment to be incorporated into the work. The Contractor shall remove protective covers or otherwise provide access in order that the Owner's Representative may inspect such items.

B. INSPECTION AND INSTALLED TESTS: 1. Refer to Section 17030 – Process Instrumentation and Control System Testing.

**END OF SECTION**

150141 – 2017 Upgrades and Rehabilitation 17200-1 Instrument Index James R. DiIorio Water Reclamation Facility Construction Bid Set

SECTION 17200

INSTRUMENT INDEX

PART 1–GENERAL

1.01 DESCRIPTION

SCOPE: 1. This section specifies the Instrument Index and general requirements applicable to

process instrumentation and analyzer systems consisting of process sensors, process indicators, signal conditioning module, control and monitoring devices, transmitters, and accessories.

2. The Contractor shall provide, calibrate, and test the complete process instrumentation and analyzer systems and place in operation and test the system. Testing includes tuning loops and making final adjustments to instruments and analyzers during facility start-up.

3. The Contactor shall provide the services of certified instrument technicians for testing and adjustment activities as specified in Section 17000.

4. The Contractor shall examine the mechanical drawings and specifications to determine actual locations, sizes, materials and ratings of process connections. Process taps shall be indicated on pipe shop drawings as specified in paragraph 15050-2.04.

EQUIPMENT FURNISHED UNDER OTHER CONTRACTS: none.

1.02 REFERENCES

Refer to Section 17000 – General Requirements for Instrumentation and Control.

Refer to Section 17030 – Process Instrumentation and Control System Testing.

1.03 SUBMITTALS

Refer to Sections 17000 and 17030.

PART 2–PRODUCTS

2.01 INSTRUMENT INDEX

The Instrument Index, paragraph 17200-3.03, lists instruments and analyzers required for the project. Instrument functions specified on this list shall be provided by the Contractor.

Additional instrumentation devices such as process taps, seals, and other items required to complete the instrument loops due to characteristics of the equipment selected by the Contractor and not specified in the instrument index or on the contract drawings shall be provided at no additional cost to provide a complete working system.


PART 3–EXECUTION

3.01 GENERAL REQUIREMENTS

Materials, equipment, and installation shall be tested and inspected per Sections 17000, 17030, and this section.

Provide buffer solutions and reference fluids for analytical equipment test procedures.

3.02 INSTALLED EQUIPMENT - TESTS AND INSPECTION

Refer to Section 17030 – Process Instrumentation and Control System Testing.

3.03 INSTRUMENT INDEX

The following is an index of the instrumentation equipment, analyzers, and devices.

DESCRIPTION OF HEADINGS: 1. TAG NUMBER: Tag Number appears as a heading (PREFIX and NUMBER) and

consists of a two, three or four letter prefix indicating the instrument function followed by a number identifying the process loop with which the instrument is associated. Tag Number provides an identification of the instrument, analyzer, or device.

2. DESCRIPTION: Provides the functional description of the instrument, analyzer, or device.

3. P&ID NUMBER: Lists the Process and Instrumentation Diagram on which the instrument, analyzer, or device appears.]

4. SPECIFICATION: Provides the specification reference and “INSTRUSPEC” designation for the instrument, analyzer, or device. SIZE: Provides the application data relative to sizing the instrument; flow tube diameter, probe length, associated pipe sizes, etc.

5. RANGE: Provides the calibrated instrument range for each application. 6. SETPOINT: Provides the calibrated switch setpoint. 7. COMMENTS: Provides the features, interlocks, and information applicable to the

instrument, analyzer, or device.

TAG NO. DESCRIPTION SPEC RANGE / SETPOINT SIZE COMMENTS

LSHH-6301 FLOAT SWITCH 17216-LFS X FT AFF –Determined during startup

NA Intrinsic Safety Barrier Required

LSH-6301 FLOAT SWITCH 17216-LFS X FT AFF – Determined during startup




LSL-6301 FLOAT SWITCH 17216-LFS X FT AFF – Determined during startup


LSLL-6301 FLOAT SWITCH 17216-LFS X FT AFF – Determined during startup


AE/AIT-6867A/6867/6867B

NH4/NO3; NO3/NO2 ANALYZER

11999 NH4: 0-30 NO3: 0-40 NO2: 0-20

NA

AE/AIT-6868A/6868/6868B

NH4/NO3; NO3/NO2 ANALYZER

11999 NH4: 0-30 NO3: 0-40 NO2: 0-20

NA

ZSC-7204 LIMIT SWITCH 11556 NA NA PROVIDED BY VENDOR

FE/FIT-7411 FLOW ELEMENT/ TRANSMITTER NA 0-300 GPM 6” Existing

VE/VT-7411-1 VIBRATION TRANSDUCER NA NA PROVIDED BY

VENDOR

FE/FIT-7412 FLOW ELEMENT/ TRANSMITTER NA 0-300 GPM 6” Existing

VE/VT-7412-1 VIBRATION TRANSDUCER NA NA PROVIDED BY

VENDOR

FI-7406-1 VARIABLE AREA FLOW METER 17211-FVA

PROVIDED BY VENDOR

FSL-7406-1 FLOW SWITCH 17216-FTS PROVIDED BY VENDOR

FI-7406-2 VARIABLE AREA FLOW METER 17211-FVA

PROVIDED BY VENDOR

FSL-7406-2 FLOW SWITCH 17216-FTS PROVIDED BY VENDOR

LIT-7406-1 LEVEL TRANSMITTER 17212 0-13 FT NA

PROVIDED BY VENDOR

LSL-7406 FLOAT SWITCH 17216-LFS 12 FT PROVIDED BY VENDOR

PI-7406 PRESSURE GAUGE 0-60 PSI

PROVIDED BY VENDOR



PSH-7406 PRESSURE SWITCH 17216-PS 0-50 PSI

PROVIDED BY VENDOR

LIT-7328 LEVEL TRANSMITTER 17212-LUT 0-7 FT PROVIDED BY

VENDOR

LIT-7329 LEVEL TRANSMITTER 17212-LUT 0-7 FT PROVIDED BY

VENDOR

LE/LIT-7401 LEVEL TRANSMITTER 17212-LUT 0-13 FT

PROVIDED BY VENDOR

LSH-7401 FLOAT SWITCH 17216-LFS 12 FT PROVIDED BY VENDOR

LE/LIT-7402 LEVEL TRANSMITTER 17212-LUT 0-13 FT

PROVIDED BY VENDOR

LSH-7402 FLOAT SWITCH 17216-LFS 12 FT PROVIDED BY VENDOR

LSH-7430 LEVEL SWITCH 17216-LCS 1” AFF NA

FI-7412 VARIABLE AREA FLOW METER 17211-FVA

PROVIDED BY VENDOR

FI-7413 VARIABLE AREA FLOW METER 17211-FVA

PROVIDED BY VENDOR


PROVIDED BY VENDOR

PSH-7403 PRESSURE SWITCH 17216-PS 50 PSI

PROVIDED BY VENDOR


PROVIDED BY VENDOR


PROVIDED BY VENDOR


PROVIDED BY VENDOR


PROVIDED BY VENDOR



LSH-7440 LEVEL SWITCH 17216-LCS 1” AFF NA

PI-8211 PRESSURE INDICATOR 17211-PG 0-60 PSI

FE/FIT-8211-1 FLOW ELEMENT/ TRANSMITTER 17212-FM 0-200 GPM 4”

PIT-8211 PRESSURE INDICATOR/ TRANSMITTER

17212-PGT 0-60 PSIG PROVIDED BY VENDOR

PI-8211-1 PRESSURE INDICATOR 17211-PG 0-60 PSIG

PROVIDED BY VENDOR

PI-8211-2 PRESSURE INDICATOR 17211-PG 0-60 PSI

PROVIDED BY VENDOR


PROVIDED BY VENDOR


PROVIDED BY VENDOR


LSH-8213 FLOAT SWITCH 17216-LFS 6 FT AFF

PI-8212 PRESSURE INDICATOR 17211-PG 0-60 PSI


PIT-8212 PRESSURE INDICATOR/ TRANSMITTER

17212-PGT 0-60 PSI PROVIDED BY VENDOR


PROVIDED BY VENDOR


PROVIDED BY VENDOR


PROVIDED BY VENDOR




PROVIDED BY VENDOR


ADDENDUM#1:

LE/LSH-7430 CONDUCTANCE LEVEL SWITCH 17216-LCS 1” AFF N/A

PROVIDED BY VENDOR

LE/LSH-7440 CONDUCTANCE LEVEL SWITCH 17216-LCS 1” AFF N/A

PROVIDED BY VENDOR

UA-7440 ALARM HORN/BEACON

16175-2.08, 2.09 N/A N/A

PROVIDED BY VENDOR

**END OF SECTION**

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